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Lexmark C935 Series, Service Manual

The Lexmark C935 Series is a high-performance color laser printer designed for businesses. To ensure smooth operation and maintenance, it is essential to have the Service Manual on hand. You can download the manual for free from our website and keep your printer running at its best.

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5057-XXX

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Notices and safety information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  xvii

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   xvii
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  xxiii

Preface  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

Change history

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-xxvi

Navigation buttons

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-xxvi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   xxvii

General information

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  

1-1

Printer technology  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Processor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Memory  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Acoustics  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Connectivity  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Size and weight – without finisher  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Printer overview

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-2

Basic model  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-2
Configured model   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-3

Printer theory

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-4

Media transport  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-4

Media transport path  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-4

SFP paper path rolls  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-5

SFP sensors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-6

Functions of main components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-6

Media tray assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-6
Rear media guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-7
End guide   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-7
Bottom plate   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-7

Media tray assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-7

Detection of media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-7
Media feed unit assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-7
Media feed/lift motor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-8
Switch (media size)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-8
Sensor (media out)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-8
Sensor (media level)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-8
Sensor (feed-out)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-8

Multi-purpose feeder (MPF)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9

MPF feed roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9
MPF pick solenoid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9
Sensor (MPF media out)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9
Sensor (MPF media width)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9

Media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9
Registration   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-10

Sensor (registration)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-10
Sensor (transparency detect)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-10
Registration clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-10
Media transport roll assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-10
Registration roll assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-10

Transfer   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-11

Transfer belt drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-11
Transfer belt cleaning assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Transfer belt unit assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-12
Transfer belt steering motor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-12
2nd transfer roll assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-12
2nd transfer roll retract motor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-12
Sensor (2nd transfer roll HP)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-13

Summary of Contents for C935 Series

Page 1: ...le 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 co...

Page 2: ...t believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all...

Page 3: ...7 End guide 1 7 Bottom plate 1 7 Media tray assembly 1 7 Detection of media size 1 7 Media feed unit assembly 1 7 Media feed lift motor 1 8 Switch media size 1 8 Sensor media out 1 8 Sensor media lev...

Page 4: ...1 22 Switch printer front door interlock and switch printer left door interlock 1 22 Switch printer left lower door interlock 1 22 Fuser cooling fan 1 23 AC drive card assembly 1 23 5V LVPS card asse...

Page 5: ...M theory 1 42 Media transport 1 43 Media transport path 1 43 Media transport path 1 44 Functions of main components 1 44 Media tray assembly 1 44 Rear media guide 1 44 Bottom plate 1 45 Tray 2 3 4 med...

Page 6: ...2 27 201 00 Sensor fuser exit late jam 2 28 202 00 Sensor fuser exit lag jam 2 30 230 00 Sensor duplex wait late jam duplex media feed 2 31 231 00 Sensor registration late jam duplex feed 2 33 231 01...

Page 7: ...rking device Xerographics error 2 95 905 03 Marking device other1 error 2 95 905 04 Marking device paper handling error 2 95 905 05 Marking device other2 error 2 95 907 00 Printhead polygon mirror mot...

Page 8: ...sembly 2 125 980 01 HVPS controller communication error 2 125 980 02 Communication error between printer and RIP card assembly 2 126 980 03 Communication error with finisher controller card assembly 2...

Page 9: ...RINT TESTS 3 6 Input Source Print Test 3 7 Print Quality Test Pages 3 7 HARDWARE TESTS 3 7 Panel Test 3 7 Button Test 3 7 DRAM Test 3 8 CACHE Test 3 8 DUPLEX TESTS 3 8 Quick Test 3 8 Sensor Test duple...

Page 10: ...Removal procedures 4 2 Before starting service work 4 2 Printer front door assembly removal 4 3 Right cover assembly removal 4 4 Top cover assembly removal 4 4 Rear cover assembly removal 4 5 Rear lef...

Page 11: ...embly removal 4 61 Transfer belt lift latch assembly removal 4 63 Left transfer belt lift assembly removal 4 64 Transfer belt lift handle assembly removal 4 70 Transfer belt steering motor removal 4 7...

Page 12: ...removal 4 123 2000 sheet dual input TTM rear cover removal 4 124 2000 sheet dual input TTM caster removal 4 124 2000 sheet dual input TTM tray support roll removal 4 125 2000 sheet dual input TTM TTM...

Page 13: ...4 174 3X 500 sheet drawer 3TM media feed lift motor removal 4 175 3X 500 sheet drawer 3TM one way clutch gear assembly removal 4 176 3X 500 sheet drawer 3TM media out actuator removal 4 177 3X 500 sh...

Page 14: ...n guide 6 1 Scheduled maintenance 6 2 Parts catalog 7 1 How to use this parts catalog 7 1 Assembly 1 Covers 1 7 2 Assembly 2 Covers 2 7 3 Assembly 3 Covers 3 7 5 Assembly 4 PC cartridge and developer...

Page 15: ...Assembly 38 3TM covers 7 47 Assembly 39 3TM feed unit assembly 7 49 Assembly 40 3TM media feed unit 7 51 Assembly 41 3TM left door 7 53 Assembly 42 3TM drive and electrical 7 55 Assembly 43 TTM cover...

Page 16: ...xvi Printer Service Manual 5057 XXX Go Back Previous Next...

Page 17: ...n Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse I bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis c...

Page 18: ...de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possibl...

Page 19: ...kitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skr...

Page 20: ...requisits d IEC 60825 1 Els productes l ser de classe I no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la...

Page 21: ...Notices and safety information xxi 5057 XXX Go Back Previous Next...

Page 22: ...xxii Printer Service Manual 5057 XXX Go Back Previous Next...

Page 23: ...gr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques l...

Page 24: ...s La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el...

Page 25: ...d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de...

Page 26: ...nts on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs...

Page 27: ...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 ar...

Page 28: ...xxviii Printer Service Manual 5057 XXX Go Back Previous Next...

Page 29: ...rements were made in accordance with ISO 7779 and reported in conformance with ISO 9296 Environment Connectivity Standard USB and internet Optional parallel and serial Size and weight without finisher...

Page 30: ...ectrical or cabling connections such as the power cord or options and features during a lightning storm Basic model The following illustration shows a printer with its base features Duplex unit Multip...

Page 31: ...illustration shows a fully configured printer Items denoted with an asterisk are options Finisher Bridge unit Used in conjunction with finisher Duplex unit Multipurpose feeder MPF Tray 1 and tray 2 50...

Page 32: ...ed unit ASM Media feed unit ASM Pick roll Pick roll Separation roll Separation roll Feed roll Media transport roll ASM Tray 1 Tray 2 Feed roll Registration roll ASM 2nd Transfer roll ASM Transfer belt...

Page 33: ...Upper media transport roll assembly Buffer roll assembly Lower media exit roll assembly Booklet media transport roll assembly Booklet media entrance roll assembly Booklet media exit roll assembly Book...

Page 34: ...tration Sensor bridge unit media entrance Sensor bridge unit media exit Sensor standard bin media full Tray 2 1TM optional Sensor tray 2 feed out Sensor bridge unit media bin exit Tray 2 Tray 3 Tray 4...

Page 35: ...mbly is transmitted to the switch media size by moving these guides The media size is detected by the on off information of these switches Media feed unit assembly Since tray 1 and tray 2 are function...

Page 36: ...the sensor media out The sensor light is transmitted When the sensing area is blocked media is present the signal is off Sensor media level This sensor detects by the actuator position whether media...

Page 37: ...lls Sensor MPF media out The sensor MPF media out detects whether media is present on the MPF Sensor MPF media width The MPF side guides detects the width length in the main scanning direction of medi...

Page 38: ...sport roll assembly The media transport roll assembly feeds paper from tray 2 tray 3 and tray 4 toward the registration roll assembly Registration roll assembly Folio 8 5 inches 13 inches Statement 5...

Page 39: ...y This motor is used to rotate the transfer belt Transfer belt cleaning assembly This assembly is used to remove residual toner images from the transfer belt after 2nd transfer and before the next pri...

Page 40: ...urface and CMY drums Transfer belt steering motor This motor is used to ensure that the transfer belt is properly tracking If the transfer belt starts to track off center then the transfer belt steeri...

Page 41: ...reaches the polygon mirror as it passes through multiple lenses mirrors and windows The laser beam then arrives at the drum surface 3 SOS card assembly when a laser beam hits the SOS sensor on the SO...

Page 42: ...1 14 Printer Service Manual 5057 XXX Go Back Previous Next Conceptual diagram of an image created by scanning Printhead...

Page 43: ...General information 1 15 5057 XXX Go Back Previous Next Y Laser Path Polygon Mirror Y drum Sensor Y start of scan M Laser Path Polygon Mirror M drum Sensor M start of scan...

Page 44: ...irty the shutter stays closed except when laser beams are written onto the drums The printhead shutter motor assembly is used to prevent contamination from obstructing the printhead slit glasses The p...

Page 45: ...roll is a hollow metal tube with a coated surface This tube is heated by the inner heater lamp The heat is applied to the media passing between the heat roll and pressure roll fusing the toner on the...

Page 46: ...perature the thermostat cuts off the circuits of the main heater lamp and sub heater lamp Front thermistor The front thermistor monitors the surface temperature of the media feed portion of the heat r...

Page 47: ...ex diverter gate The duplex diverter gate switches the media transport path When the duplex diverter gate is lifted media is fed to the standard bin When it is lowered media is fed to the duplex Drive...

Page 48: ...ives the MPF unit assembly and media transport roll CMYK PC cartridge drive motor assembly The CMYK PC cartridge drive motor assembly uses dual DC brushless motors that drive the four drums in the fou...

Page 49: ...t assemblies K developer clutch This clutch is used to engage the K developer unit assembly and is driven by the K developer transfer drive motor assembly CMYK toner add motor assembly K developer clu...

Page 50: ...g on off the switch power supplies cuts off the main power of the printer Finisher AC output Supplies power to the finisher from the AC drive card assembly Switch printer front door interlock and swit...

Page 51: ...its 5 V for laser diodes from AC power 24V LVPS card assembly The LVPS card assembly generates 24 V for motors clutches from AC power CMYK transfer roll HVPS card assembly The CMYK transfer roll HVPS...

Page 52: ...peration based on the communication with the RIP card assembly and on sensor switch information It also controls many of the drive motors clutches and solenoids RIP card assembly The RIP card assembly...

Page 53: ...W4 S W5 No media tray assembly Off Off Off Off Off 5 5 X 8 5 SEF A5 SEF Off Off On Off Off B5 SEF Off Off On On On 8 5 X 13 SEF Off On Off On Off 8 5 X 14 SEF Off On Off On On A4 SEF Off On On Off Off...

Page 54: ...r a preset time period has passed from power on If a failure occurs the heater lamps are turned off the fuser ready is turned off and then the fuser temperature control is stopped Main sub heater lamp...

Page 55: ...Y K toner C toner M toner Y toner 2nd transfer roll assembly Printhead Transfer belt Fuser Cleaning roll Transfer belt cleaning assembly Cleaning blade Photo conductor drum Charge roll Sensor ATC Eras...

Page 56: ...harge The charge roll is a conductive roll that is positioned slightly above the surface of the drum The HVPS supplies the charge roll with two voltages a negative DC charge voltage and an AC discharg...

Page 57: ...here to the Magnetic Roll The Metering Blade spreads the toner into a very thin layer on the Magnetic Roll Friction between the Magnetic Roll and the CM Blade generates a small electrical charge that...

Page 58: ...e drum surface The image is called a developed image Transfer As the paper travels between the 2nd transfer Roll and the transfer belt surface the Transfer Roll applies a positive charge to the back o...

Page 59: ...ing Blade removes any toner that remains on the drum after the transfer process The toner that the Cleaning Blade removes is collected inside the sealed PC Cartridge and reused Discharge At both the s...

Page 60: ...sensor that detects a pre placed toner patch and image on the transfer belt and outputs pulses when the central line of the patch image aligns with the central line of the detector The sensor outputs...

Page 61: ...General information 1 33 5057 XXX Go Back Previous Next TTM theory...

Page 62: ...ow Pick roll Pick roll Separation roll Separation roll Feed roll Transfer belt 2nd transfer roll assembly Heat roll Pressure roll Fuser unit ASM Standard media exit roll assembly Duplex media transpor...

Page 63: ...Registration roll assembly Bridge unit assembly included with finisher Standard media exit roll assembly Fuser exit roll assembly Duplex media transport roll assembly Fuser Finisher optional Booklet...

Page 64: ...ly to the media lift shaft assembly through the tray lift gear assembly 3 The bottom plate is lifted up via the rear tray cables front right cable and front left cable by the rotation of the tray lift...

Page 65: ...General information 1 37 5057 XXX Go Back Previous Next Tray 3 or 4 media tray assembly Rear lift cables Rear media guide Bottom plate F R lift cable F L lift cable...

Page 66: ...ng the bottom plate it rotates in reverse to drive the tray module gears to turn the lift up shaft Switch media size This switch media size sets the size of media supplied from each media tray assembl...

Page 67: ...detects media fed from trays 2 3 or 4 Sensor tray 3 feed out The sensor tray 3 feed out detects media fed from the tray 3 or tray 4 Sensor tray 4 feed out The sensor tray 4 feed out detects media fed...

Page 68: ...left door assembly TTM controller card assembly The TTM controller card assembly which contains a CPU controls media feed in the tandem tray module upon receiving a command from the upper printer engi...

Page 69: ...states of the switches on the switch TTM media size corresponding to the media sizes of the media tray assembly Note The switches TTM media size are denoted by S W1 and S W3 respectively from the lef...

Page 70: ...1 42 Printer Service Manual 5057 XXX Go Back Previous Next 3TM theory...

Page 71: ...ck roll Pick roll Separation roll Separation roll Feed roll Transfer belt 2nd transfer roll assembly Heat roll Pressure roll Fuser unit ASM Standard media exit roll assembly Duplex media transportroll...

Page 72: ...ray 1 Registration roll assembly Bridge unit assembly included with finisher Standard media exit roll assembly Fuser exit roll assembly Duplex media transport roll assembly Fuser Finisher optional Boo...

Page 73: ...blies to feed media When the pick roll picks up sheets of media and the remaining media decreases the media level actuator of the sensor media level lowers accordingly Media feed lift motor The media...

Page 74: ...at the media has been lifted Main components Switch tray module left door interlock The switch tray module left door interlock detects open close of the tray module left door assembly Sensor tray 2 fe...

Page 75: ...ray 3 or tray 4 to the printer Tray module drive motor This motor is used to drive the media transport mechanism in the tray module 3TM controller card assembly The 3TM controller card assembly which...

Page 76: ...off states of the switches on the switch media size corresponding to the media sizes of the media tray assembly Note The switches media size are denoted by S W1 and S W3 respectively from the left sid...

Page 77: ...General information 1 49 5057 XXX Go Back Previous Next 1TM theory...

Page 78: ...ick roll Pick roll Separation roll Separation roll Feed roll Transfer belt 2nd transfer roll assembly Heat roll Pressure roll Fuser unit ASM Standard media exit roll assembly Duplex media transportrol...

Page 79: ...istration roll assembly Bridge unit assembly included with finisher Standard media exit roll assembly Fuser exit roll assembly Duplex media transport roll assembly Fuser Finisher optional Booklet make...

Page 80: ...ying media from the media tray assembly to the printer The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll assemblies to feed media When t...

Page 81: ...dia out actuator that has stayed in the sensor media out sensing area leaves there Thus the light of the sensor is transmitted When the sensing area is blocked media is present the signal turns off Se...

Page 82: ...y The tray module transport roll assembly feeds media from the tray 2 Tray module drive motor This motor is used to drive the media transport mechanism in the tray module 1TM controller card assembly...

Page 83: ...ff states of the switches on the switch media size corresponding to the media sizes of the media tray assembly Note The switches media size are denoted by S W1 and S W3 respectively from the left side...

Page 84: ...1 56 Printer Service Manual 5057 XXX Go Back Previous Next Duplex...

Page 85: ...interlock detects open close of the left door Sensor duplex wait The sensor duplex wait detects whether media is remaining in the duplex Duplex media transport roll assembly The two duplex media trans...

Page 86: ...sensor switch information Duplex drive motor The duplex drive motor transmits driving force to the two duplex media transport roll assemblies and the duplex media center transport roll assembly middle...

Page 87: ...magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade Needle nose pliers Diagonal side cutters Spring hook Analog or digital multi meter Parallel wrap plug 1319128 Twina...

Page 88: ...HCF High Capacity Feeder HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LD Laser Diode LED Light Emitting Diode LEF Long Edge F...

Page 89: ...n 1 61 5057 XXX Go Back Previous Next SRAM Static Random Access Memory TTM Tandem Tray Module TVOC Total Volatile Organic Compound UPR Used Parts Return V Volts V ac Volts alternating current V dc Vol...

Page 90: ...1 62 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 91: ...General information 1 63 5057 XXX Go Back Previous Next...

Page 92: ...1 64 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 93: ...xt level support for assistance CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable electronic board or assembly CAUTION If the printer is kept on never...

Page 94: ...e gas is generated The printer is not installed in direct sun The printer is installed on a level and stable surface Media meets specifications and is installed properly Customer maintenance parts hav...

Page 95: ...gistration Go to 201 00 Sensor fuser exit late jam on page 2 28 202 00 Paper jam Sensor fuser exit lag jam The media reached the sensor fuser exit but did not clear it within the specified time Go to...

Page 96: ...nes refer to Options Service Manual 244 00 Paper jam Sensor tray 4 feed out late jam The media is late reaching the sensor tray 4 feed out within the specified time after the tray 4 media feed lift mo...

Page 97: ...the Finisher Service Manual 282 01 Paper jam Sensor finisher media entrance static jam Paper remains on the sensor finisher media entrance Refer to the Finisher Service Manual 283 00 Paper jam Sensor...

Page 98: ...ance late jam The media is late reaching the sensor booklet media entrance within the specified time after reaching the sensor bridge unit media exit Refer to the Finisher Service Manual 289 01 Paper...

Page 99: ...atch error on page 2 53 34 Check tray 3 guides Tray 3 media size mismatch error The media tray assembly 3 side guide or end guide is not properly set Go to Tray 3 media size mismatch error on page 2 5...

Page 100: ...Color PC cartridge not detected on page 2 141 849 00 Service hard drive Hard drive configuration ID mismatch The device does not have a hard drive installed even though its configuration ID indicates...

Page 101: ...to 902 01 General upper engine error fuse 2 on page 2 64 902 02 Service engine error General upper engine card error Fuse 3 An error has occurred in the upper engine card assembly Go to 902 02 General...

Page 102: ...re than three times it must be reset inside diagnostic mode before troubleshooting can begin or the machine can operate Go to 904 00 Sensor transfer belt HP late error on page 2 74 904 01 Service tran...

Page 103: ...arking device video error on page 2 94 905 02 Service engine error Marking device Xerographic error Internal processing error occurred in printer engine Go to 905 02 Marking device Xerographics error...

Page 104: ...rror on page 2 99 911 01 Service engine error Transfer belt drive motor cooling fan error When the transfer belt drive motor cooling fan was operating fan lock was detected for more than 30 seconds Go...

Page 105: ...ser temperature did not reach the ready temperature in the specified time Go to 920 06 Sub lamp warm up failure on page 2 104 920 07 Service fuser error Sub lamp on time error The Sub lamp was turned...

Page 106: ...to 925 03 Sensor K ATC on page 2 110 930 00 Black toner RFID communication failure Communication error with the K sensor RFID toner cartridge has occurred Go to 930 00 Black toner RFID communication f...

Page 107: ...943 00 Switch media size size sensing error tray 3 on page 2 116 943 01 Service tray 3 failure Sensor media level late error tray 3 The sensing area of the sensor media level in the media tray 3 is n...

Page 108: ...ates a mismatch between the RIP card assembly and the interconnect card assembly Warning In the event of replacement of any one of the following components RIP card assembly Interconnect card assembly...

Page 109: ...assembly cooling fan failure on page 2 124 956 03 Service system board RIP card assembly FPGA failure The RIP card assembly has failed Go to Go to 956 03 RIP card assembly FPGA failure on page 2 124...

Page 110: ...emains interrupted within the specified time after the rear tamper starts moving from the home position Refer to the Finisher Service Manual 984 00 Service finisher error Sensor punch unit HP late err...

Page 111: ...ler unit motor starts moving to the home position Refer to the Finisher Service Manual 990 00 Service finisher error Sensor stapler carriage HP late error The sensing area of the sensor stapler carria...

Page 112: ...not detect any media when the booklet stapler motor was activated Refer to the Finisher Service Manual 991 08 Service finisher error Sensor booklet knife HP late error The sensing area of the sensor b...

Page 113: ...embly open The printer lower left door assembly is open Go to Printer left lower door assembly open on page 2 136 Close door D 1TM 3TM or TTM left door assembly open The 1TM 3TM or TTM tray left door...

Page 114: ...to the Finisher Service Manual Remove paper from bin 2 Stacker media bin full mix size The stacker media bin has reached maximum capacity mix size Refer to the Finisher Service Manual Remove paper fro...

Page 115: ...e sensing area of the above sensor is interrupted or blocked Go to step 5 Go to step 4 4 Check the sensor registration for proper connection Is the above component properly connected Replace the senso...

Page 116: ...o K developer transport drive motor assembly removal on page 4 106 Replace the connection 9 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower prin...

Page 117: ...the fuser area to cool before proceeding Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 8 Go to step 7 7 Check the s...

Page 118: ...motor assembly removal on page 4 106 Replace the connection 12 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly rem...

Page 119: ...s wear and damage Go to step 4 Replace the 2nd transfer roll assembly Go to 2nd transfer roll assembly removal on page 4 35 4 Check the sensor media on belt for proper operation 1 Enter the Diagnostic...

Page 120: ...the sensor fuser exit for proper operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Fuser exit Caution The area around the actuator is very hot Allow the fu...

Page 121: ...egistration clutch for proper connection Is the registration clutch properly connected Replace the registration clutch Go to Registration clutch removal on page 4 37 Replace the connection 10 Check th...

Page 122: ...ime the sensing area of the above sensor is interrupted or blocked Go to step 4 Go to step 3 3 Check the sensor fuser exit for proper connection Is the above component properly connected Replace the s...

Page 123: ...sport drive motor assembly removal on page 4 106 Replace the connection 8 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card as...

Page 124: ...o step 7 Go to step 6 6 Check the duplex diverter gate solenoid for proper connection Is the above component properly connected Replace duplex media inverter assembly Go to Duplex media inverter assem...

Page 125: ...nverter assembly Go to Duplex media inverter assemblyremoval on page 4 9 Replace the connection 11 Perform a 2 sided print test Does the error remain Replace the duplex controller card assembly Go to...

Page 126: ...iagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly Go to step 7 Go to step 6 6 Check the duplex diverter...

Page 127: ...inverter assembly Go to Duplex media inverter assemblyremoval on page 4 9 Replace the connection 11 Perform a 2 sided print test Does the error remain Replace the duplex controller card assembly Go t...

Page 128: ...agnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly Go to step 7 Go to step 6 6 Check the duplex diverter g...

Page 129: ...he duplex media inverter assembly Go to Duplex media inverter assembly removal on page 4 9 Replace the connection 11 Perform a 2 sided print test Does the error remain Replace the duplex controller ca...

Page 130: ...Select Tray 1 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 7 Go to step 6 6 Check the sensor tra...

Page 131: ...above components free of excess wear and contamination Go to step 4 Clean or replace the feed roll separating roll or pick roll Go to Feed roll removal on page 4 115 Separation roll removal on page 4...

Page 132: ...a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 93 Problem solved Step Check Yes No 1 Check the media con...

Page 133: ...tches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select MPF transport drive motor Does the above component operate properly Go to step 9 Skip to st...

Page 134: ...the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 7 Go to step 6 6 Check the sensor tray 3 feed out for proper connection Is the above com...

Page 135: ...card assembly Go to Lower printer engine card assemblyremoval on page 4 93 Problem solved Step Check Yes No 1 Check the media condition Is the media in the tray crumpled or damaged Replace the damaged...

Page 136: ...lace the connection 7 Check the tray module drive motor for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostic...

Page 137: ...embly Go to Lower printer engine card assemblyremoval on page 4 93 Problem solved Step Check Yes No 1 Check the media condition Is the media in the tray crumpled or damaged Replace the damaged media w...

Page 138: ...lect Printer motor tests 4 Select Tray 4 media feed lift motor Does the above component operate properly Go to step 9 Skip to step 8 8 Check the media feed lift motor for proper connection Is the abov...

Page 139: ...card assembly Go to Lower printer engine card assemblyremoval on page 4 93 Problem solved Step Check Yes No 1 Check the media condition Is the media in the tray crumpled or damaged Replace the damaged...

Page 140: ...lace the connection 7 Check the tray module drive motor for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostic...

Page 141: ...a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assemblyremoval on page 4 93 Problem solved Step Check Yes No 1 Check the media cond...

Page 142: ...orming motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select MPF pick solenoid Does the ab...

Page 143: ...ent properly installed Go to step 3 Reinstall the black toner cartridge 2 Replace the black toner cartridge Does the error continue Got to step 3 Problem solved 3 Check the sensor RFID toner cartridge...

Page 144: ...remain when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved 5 Perform a POR Does the error remai...

Page 145: ...oes the error remain when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved 6 Perform a POR Does th...

Page 146: ...ly side guide 2 Check the media tray assembly 3 end guide Is the above component set properly Go to step 3 Properly set the media tray assembly end guide 3 Check the media tray assembly for damage Is...

Page 147: ...cted Replace the switch media size Replace the connection 5 Perform a POR Does the error remain when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engin...

Page 148: ...he connection 5 Perform a POR Does the error remain when the power is turned off on Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 93 Problem...

Page 149: ...he connection 5 Perform a POR Does the error remain when the power is turned off on Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 93 Problem...

Page 150: ...he connection 5 Perform a POR Does the error remain when the power is turned off on Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 93 Problem...

Page 151: ...ct removal on page 4 38 Replace the connection 5 Perform a POR Does the error remain when the power is turned off on Replace the lower printer engine card assembly Go to Lower printer engine card asse...

Page 152: ...e connections connected properly Replace the hard drive Go to Hard drive removal on page 4 87 Replace the connections 2 Perform a POR Does the error remain when the power is turned off on again Replac...

Page 153: ...r a print job Does the 900 xx error reoccur Go to step 31 Go to step 10 10 Is the device a Multi Function Printer Go to step 11 Go to step 13 11 Run a copy job Does the 900 xx error reoccur Go to step...

Page 154: ...Are there any more ISP options to install Go to step 27 Problem resolved 27 Install the next ISP option Restart the device Does the 900 xx error reoccur Go to step 29 Go to step 28 28 Run a job to tes...

Page 155: ...Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print t...

Page 156: ...S cooling fan cables and any associated cables for damage Are the above components free from crimps and damage Go to step 7 Repair or replace the appropriate cable assemblies or replace the 24V LVPS c...

Page 157: ...per printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go...

Page 158: ...mains go to step 2 2 Check the duplex drive motor assembly cables and any associated cables for damage Are the above components free from crimps and damage Go to step 3 Repair or replace the appropria...

Page 159: ...s or laser diode power card assembly Go to Laser diode power card assembly removal on page 4 95 4 Replace the transfer belt unit assembly Go to Does the error occur when the power is turned off on Rep...

Page 160: ...or replace the appropriate cable assemblies or replace the transfer belt steering motor assembly Go to Transfer belt steering motor removal on page 4 76 3 Check the printhead shutter motor assembly c...

Page 161: ...rd assembly removal on page 4 93 Problem solved Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains g...

Page 162: ...cables and any associated cables for damage Are the above components free from crimps and damage Go to step 7 Repair or replace the appropriate cable assemblies or replace the duplex media inverter a...

Page 163: ...n performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Tests 4 Select K developer transport...

Page 164: ...tor Tests 4 Select K PC cartridge drive motor Does the above component operate properly Go to step 4 Go to step 3 3 Check the CMYK PC cartridge drive motor assembly for proper connection Is the above...

Page 165: ...Go to CMYK PC cartridge drive motor assembly removal on page 4 101 Replace the connection 4 Perform a POR Does the error occur when the power is turned off on Replace the lower printer engine card ass...

Page 166: ...t fail HP Is the transfer belt torn damaged or missing Replace the transfer belt If the problem persists go to the next step Go to step 3 2 Perform a POR Does the error occur when the power is turned...

Page 167: ...tall the PC cartridge units correctly See PC cartridge unit removal on page 4 43 If the problem persists go to the next step 7 Do the PC units easily slide in and out of the machine Go to the next ste...

Page 168: ...belt lever is lowered the transfer belt steering mechanism lock might break and remain inside the machine in the area as showing in the following image A The following images show the transfer belt s...

Page 169: ...ee Transfer belt cleaning assembly removal on page 4 17 Check for damage The most likely damage B C Is shown in the following images Undamaged Damaged Is the transfer belt cleaning assembly damaged Re...

Page 170: ...ck Yes No 1 Reset the transfer belt HP failure lock out condition 1 Enter the Diagnostics Menu 2 Touch Trans belt fail HP 3 Touch Trans belt fail HP Does the transfer belt appear damaged or torn in ha...

Page 171: ...on page 4 228 Does the problem persist Go to the next step The problem is resolved 6 Check the transfer belt steering motor assembly for proper operation Caution When performing motor tests ensure tha...

Page 172: ...Correct Go to the next step Remove and reinstall the PC cartridge units correctly See PC cartridge unit removal on page 4 43 8 Do the PC units easily slide in and out of the machine Go to the next ste...

Page 173: ...ed before the transfer belt lever is lowered the transfer belt steering mechanism lock might break and remain inside the machine in the area as showing in the following image A The following images sh...

Page 174: ...elt cleaning assembly See Transfer belt cleaning assembly removal on page 4 17 Check for damage The most likely damage B C Is shown in the following images Undamaged Damaged Is the transfer belt clean...

Page 175: ...s the above component properly connected Replace the transfer belt steering motor Go to Transfer belt steering motor removal on page 4 76 Replace the connection Step Check Yes No 1 Reset the transfer...

Page 176: ...belt lift mechanism is functioning properly See Transfer belt lift mechanism adjustment on page 4 228 Does the error remain Go to the next step The problem is resolved 3 Are the PC cartridge units co...

Page 177: ...erase lamp assembly removal on page 4 76 5 Check that the transfer belt steering mechanism lock packaging was fully removed If not removed before the transfer belt lever is lowered the transfer belt...

Page 178: ...ort Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 2 Check to ensure that the trans...

Page 179: ...connection 7 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 93 If the problem persists go to the...

Page 180: ...roll retract motor Does the above component operate properly Go to step 6 Skip to step 5 5 Check the 2nd transfer roll retract motor for proper connection Is the above component properly connected Rep...

Page 181: ...ift mechanism is functioning properly See Transfer belt lift mechanism adjustment on page 4 228 Does the error remain The problem is resolved Contact the next level of support 4 Are the PC cartridge u...

Page 182: ...not removed before the transfer belt lever is lowered the transfer belt steering mechanism lock might break and remain inside the machine in the area as showing in the following image A The following...

Page 183: ...ccur when the power is turned off on Go to step 3 Perform several print tests If the problem remains go to step 3 3 Did the error occur following a developer unit replacement Verify the developers are...

Page 184: ...Correct Go to the next step Remove and reinstall the PC cartridge units correctly See PC cartridge unit removal on page 4 43 6 Do the PC units easily slide in and out of the machine Go to the next ste...

Page 185: ...ing images show the transfer belt steering mechanism lock Are there any remnants from the packaging Remove any packaging remnants Contact the next level of support 8 Replace the transfer belt unit ass...

Page 186: ...2 Perform several print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the printer engine card assem...

Page 187: ...Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem...

Page 188: ...bly removal on page 4 104 Problem solved Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to st...

Page 189: ...r occur when the power is turned off on again Go to step 3 Problem solved 3 Perform a POR Does the error occur when the power is turned off on Replace the printhead assembly Go to Printhead assembly r...

Page 190: ...o 1 Reinstall the waste toner cartridge Does the error remain Replace the waste toner cartridge Go to step 2 Problem solved 2 Check the sensor waste toner full for proper operation 1 Enter the Diagnos...

Page 191: ...power is turned off on Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 93 Problem solved Step Check Yes No 1 Perform a POR Does the error occu...

Page 192: ...ESTS 3 Select Fuser cooling fan Does the above component operate properly Go to step 4 Go to step 3 3 Check the fuser cooling fan for proper connection Is the above component properly connected Replac...

Page 193: ...embly properly 4 Check the fuser unit assembly for proper connection Is the above component properly connected Go to step 5 Repair the connection 5 Perform a print test Does the error continue Replace...

Page 194: ...here a media jam in the fuser unit assembly Remove the media Go to step 3 3 Check the fuser unit assembly for proper installation Is the fuser unit assembly installed properly Go to step 4 Install the...

Page 195: ...d for the machine Go to step 2 Install the appropriate voltage fuser unit assembly 2 Check the fuser unit assembly for a media jam Is there a media jam in the fuser unit assembly Remove the media Go t...

Page 196: ...Fuser unit assembly removal on page 4 15 Go to step 5 Problem solved 5 Perform a POR Does the error occur when the power is turned off on Replace the AC drive card bracket assembly Go to AC drive card...

Page 197: ...ection 4 Perform a print test Does the error continue Replace the fuser unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 5 Problem solved 5 Perform a POR Does the error occur wh...

Page 198: ...drum 2 Install the M PC drum in one of the other three PC locations Ensure that all PC drum slots contain a PC drum Perform a POR Does the error remain or follow the problematic cartridge Replace the...

Page 199: ...plate assembly Go to Developer interlock plate assembly removal on page 4 48 5 Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assembly Go to G...

Page 200: ...s the error continue Go to step 2 Problem solved 2 Check the sensor Y ATC for proper connection Is the above component properly connected Replace the Y developer unit assembly Go to Developer unit ass...

Page 201: ...0 Problem solved Step Check Yes No 1 Reset the C ATC failure lock out condition 1 Enter diagnostic mode 2 Touch ATC sensor failure clear 3 Touch C channel 925 02 Perform a very large print test Does t...

Page 202: ...e connection 3 Perform a very large print test Does the error continue Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step...

Page 203: ...off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check Yes No 1 Check the M toner cartridge Is the M toner cartr...

Page 204: ...Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Problem solved 2 Check the MPF feed unit assembly Is the above component properly connected Replace the...

Page 205: ...rm a POR Does the error continue when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check...

Page 206: ...lift motor Go to Media feed lift motor removal on page 4 120 Replace the connection 6 Perform a POR Does the error continue when the power is turned off on Replace the upper printer engine card assemb...

Page 207: ...n 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 2 5 Select Media level Does the display on the operator panel change every time the media tray is opened and...

Page 208: ...echanisms on the back and the bottom of the media tray damaged Replace the media tray assembly Go to step 3 3 Check the tray 3 switch media size for proper operation 1 Enter the Diagnostics Menu 2 Sel...

Page 209: ...Go to step 4 Go to step 3 3 Check the sensor media level tray 3 for proper connection Is the above component properly connected Replace the sensor media level Go to Sensor media level removal on page...

Page 210: ...INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 4 5 Select Tray 4 present Does the display on the operator panel change every time the media tray is opened and closed Go to step 5 Go to step 4 4...

Page 211: ...emoval on page 4 24 Replace the connection 4 Check the media feed lift motor tray 4 for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overr...

Page 212: ...ginal interconnect card assembly Does the error remain Go to step 5 Problem solved 4 Replace the current operator panel with the original panel Does the error remain Go to step 6 Problem solved 5 If p...

Page 213: ...inal interconnect card assembly with a new and not previously installed interconnect card assembly Does the error remain Contact the next level of support Problem solved 6 If problem remains replace t...

Page 214: ...page 4 86 Problem solved Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 2 Turn the...

Page 215: ...tep Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds...

Page 216: ...card cooling fan and heatsink correctly Step Check Yes No 1 Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to ste...

Page 217: ...eet drawer 3TM 3TM controller card assembly removal on page 4 189 or 2000 sheet dual input TTM TTM controller card assembly removal on page 4 163 Go to step 3 Problem solved 3 Perform a POR Does the e...

Page 218: ...2 Perform a POR Does the error continue when the power is turned off on Replace the RIP card assembly Go to RIP card assembly removal on page 4 86 Go to step 3 Problem solved 3 Perform a POR Does the...

Page 219: ...4 207 3X 500 sheet drawer 3TM 3TM left door assembly removal on page 4 187 or 2000 sheet dual input TTM left door assembly removal on page 4 158 2 Check the switch tray module left door interlock for...

Page 220: ...blyremoval on page 4 90 Problem solved Step Check Yes No 1 Check the duplex left door for proper operation Does the above component open and close properly Go to step 2 Replace the duplex unit assembl...

Page 221: ...ia tray guide and media tray end guide of tray 1 or tray 2 set correctly Go to step 3 Set the guides properly 3 Check the switch media size for proper installation Pull out the media tray to visually...

Page 222: ...val on page 4 140 4 Check the switch TTM media size for proper connection Check tray 3 and tray 4 Are the above sensors connected properly Replace the appropriate switch TTM media size Go to 2000 shee...

Page 223: ...1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 1 5 Select Media out 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray...

Page 224: ...e the connection 4 Perform a POR Does the error continue when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Pr...

Page 225: ...or continue Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check Yes No 1 Check the printer front door for proper oper...

Page 226: ...as shown in the graphic below free of damage Go to step 2 Replace the printer left door closed actuator 40X4098 2 Check the printer left door for proper operation Does the above component open and cl...

Page 227: ...he printer right cover assembly Go to Printer left door damper removal on page 4 29 2 Check the switch transfer belt access door interlock for operation 1 Enter the Diagnostics Menu 2 Select BASE SENS...

Page 228: ...the display on the operator panel change every time the actuator on the above switch is operated Go to step 4 Go to step 3 3 Check the switch printer left lower door interlock connection Is the above...

Page 229: ...r move up and down normally Go to step 2 Reinstall the standard media bin full actuator 2 Check the sensor standard bin full exit 1 for operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST...

Page 230: ...ine card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check Yes No 1 Checking the toner cartridge for correct installation Open the printer front door ass...

Page 231: ...properly connected Replace the sensor waste toner cartridge full Go to Sensor waste toner cartridge full removal on page 4 40 Replace the connection 4 Perform a POR Does the error remain when the powe...

Page 232: ...ion 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Exit level 4 Select Standard bin full 1 Does the display on the operator panel change every time the sensing area of the above senso...

Page 233: ...ber and installed properly Go to step 2 Reinstall the appropriate PC cartridge Go to PC cartridge unit removal on page 4 43 2 Replace the appropriate PC cartridge Does the error remain Go to step 3 Pr...

Page 234: ...card assembly Go to Upper printer engine card assembly removal on page 4 90 Problem solved Step Check Yes No 1 Check the CMY PC cartridges Is the above component properly installed Go to step 2 Reinst...

Page 235: ...m solved 3 Perform a POR Does the error remain when the power is turned off on again Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Proble...

Page 236: ...YK toner add motor assembly connection Is the above component properly connected Replace the CMYK toner add motor assembly Go to CMYK toner add motor assembly removal on page 4 103 Replace the connect...

Page 237: ...ents of three seconds or less or toner spill will occur 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select C M Y or K toner add motor Does the above component opera...

Page 238: ...al stripes Vertical stripes process direction on page 2 156 Horizontal stripes Horizontal stripes side to side direction on page 2 158 Partial lack Partial lack on page 2 160 Spots Spots on page 2 162...

Page 239: ...transfer roll assembly free of excess wear and contamination Go to step 4 Replace the 2nd transfer roll assembly Go to 2nd transfer roll assembly removal on page 4 35 4 Check the four PC cartridges fo...

Page 240: ...HVPS card assembly removal on page 4 112 Perform a print test Does the problem remain Go to step 8 Problem solved 8 Check the printhead assembly Replace the printhead assembly Go to Printhead assembly...

Page 241: ...nstallation Check the PC cartridge connections Are the PC cartridge connections free of excess wear and contamination Go to step 4 Correct and clean contaminated pins or replace the appropriate PC car...

Page 242: ...transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 112 Perform a print test Does the problem remain Go to step 10 Problem solved 10 Replace the printhe...

Page 243: ...ge or connector 2 Check the charge roll HVPS card assembly connections Is the above component properly connected Go to step 3 Replace the connection 3 Replace the charge roll HVPS card assembly Go to...

Page 244: ...printhead assembly window 4 Check the four PC cartridges for proper installation Check the PC cartridge connections Are the PC cartridge connections free of excess wear and contamination Go to step 5...

Page 245: ...ssembly Go to Upper printer engine card assembly removal on page 4 90 Perform a print test Does the problem remain Go to step 9 Problem solved 9 Check the printhead assembly for connection Is the abov...

Page 246: ...transfer roll assembly free of excess wear and contamination Go to step 5 Replace the 2nd transfer roll assembly Go to 2nd transfer roll assembly removal on page 4 35 5 Replace the transfer belt unit...

Page 247: ...104 Does the error continue Go to step 9 Problem solved 9 Check the upper printer engine card assembly Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal o...

Page 248: ...o 2nd transfer roll assembly removal on page 4 35 4 Check the four PC cartridges for proper installation Check the PC cartridge connections Are the PC cartridge connections free of excess wear and con...

Page 249: ...r engine card assembly Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Perform a print test Does the error continue Problem solved Replace...

Page 250: ...lean contaminated pins or replace the appropriate PC cartridge or connector 4 Check the 2nd transfer roll assembly for contamination and wear Is the 2nd transfer roll assembly free of excess wear and...

Page 251: ...ssembly removal on page 4 112 Perform a print test Does the problem remain Go to step 8 Problem solved 8 Check the upper printer engine card assembly Replace the upper printer engine card assembly Go...

Page 252: ...assembly free of contamination Go to step 4 Remove debris or clean the printhead assembly window 4 Check the 2nd transfer roll assembly for contamination and wear Is the 2nd transfer roll assembly fr...

Page 253: ...104 Does the error continue Go to step 9 Problem solved 9 Check the upper printer engine card assembly Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal o...

Page 254: ...cartridge or connector 4 Check the 2nd transfer roll assembly for contamination and wear Is the 2nd transfer roll assembly free of excess wear and contamination Go to step 5 Replace the 2nd transfer...

Page 255: ...rror continue Replace the RIP card assembly Go to RIP card assembly removal on page 4 86 Problem solved Step Check Yes No 1 Check the media condition Load new dry recommended media Re print the defect...

Page 256: ...r engine card assembly Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 90 Perform a print test Does the error continue Replace the RIP card as...

Page 257: ...ppropriate PC cartridge or connector 4 Check the 2nd transfer roll assembly for contamination and wear Is the 2nd transfer roll assembly free of excess wear and contamination Go to step 5 Replace the...

Page 258: ...104 Does the error continue Go to step 8 Problem solved 8 Check the upper printer engine card assembly Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal o...

Page 259: ...ay assembly into the printer 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 assem...

Page 260: ...7 Replace registration transport roll assembly Go to Registration transport roll assembly removal on page 4 36 7 Check the upper printer engine card assembly Replace the upper printer engine card ass...

Page 261: ...tep 3 Problem solved 3 Check the media condition Load new dry recommended media Re print the defective image Does the error continue Go to step 4 Problem solved 4 Check the 2nd transfer roll assembly...

Page 262: ...move the fuser unit assembly CAUTION Allow the fuser unit assembly to cool down Is there contamination or cracks on the heat roll and or pressure roll Replace the fuser unit assembly Go to Fuser unit...

Page 263: ...he fuser unit assembly to cool down Is there contamination or cracks on the heat roll and or pressure roll Replace the fuser unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 4 4...

Page 264: ...Color registration RegCon on page 4 214 Does the error remain Go to step 4 Problem solved 4 Replace the printhead Go to Printhead assembly removal on page 4 104 Go to step 5 Problem solved 5 Re adjust...

Page 265: ...ce the transfer belt unit assembly Go to Transfer belt unit assembly removal on page 4 16 Does the problem remain Go to step 3 Problem solved 3 Check the upper printer engine card assembly Replace the...

Page 266: ...veloper carrier removal and replacement on page 4 57 Does the problem remain Go to step 3 Problem solved 3 Replace the printhead Go to Printhead assembly removal on page 4 104 Does the problem remain...

Page 267: ...age Estimator Setup Menu Printer Language Printer Usage Power Saver Resource Save Download Target Print Timeout Auto Continue Wait Timeout Jam Recovery Page Protect Display Language Alarm Control Hole...

Page 268: ...2 176 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 269: ...elease the buttons after 10 seconds The Diagnostics Menu group consists of menus settings and operations that are used to diagnose various printer problems Note While the Diagnostics Menu Group is act...

Page 270: ...Sub paddle solenoid Media eject clutch Media eject clamp motor Media eject motor Fin Buffer solenoid Punch carriage shift motor Punch unit motor Front tamper motor Rear tamper motor Stapler carriage m...

Page 271: ...tch Duplex diverter gate solenoid Transfer belt drive motor C toner add motor M toner add motor Y toner add motor K toner add motor CMY developer drive motor K developer clutch Fuser cooling fan Image...

Page 272: ...Tests Finisher on page 3 12 Sensor Tests See Sensor Test Finisher on page 3 12 BASE SENSOR TESTS See BASE SENSOR TEST on page 3 14 Cover and Door Devices Exit Level Media Path Transfer Belt PRINTER S...

Page 273: ...r Config See Finisher Config on page 3 23 Exit Diagnostics Menu See Exiting Diagnostics on page 3 23 The following Finisher Motor Tests are available Motor entrance paddle Stacker bin lift motor Motor...

Page 274: ...rns to the Input Source screen The following Printer Motor Tests are available Transfer belt steering motor Y toner add motor CMY PC cartridge drive motor K toner add motor K PC cartridge drive motor...

Page 275: ...lled in Tray 1 to print this report Once started printing cannot be canceled and all key presses are ignored until printing completes The test pages are always simplexed regardless of the value of the...

Page 276: ...ect CACHE Test CACHE Test Testing appears on the LCD and then Resetting the Printer appears The printer automatically performs a POR The following type of message appears P represents the number of ti...

Page 277: ...put sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path 1 Select DUPLEX TESTS from the Diagnostics Menu 2 Select Sensor Test 3 Select Duplex...

Page 278: ...ate Open or Closed After selecting a specific sensor you can manually toggle the sensor between its two values Open or Closed The LCD displays Open when the sensor is open and Closed when the sensor i...

Page 279: ...us until Stop is pressed If a test is canceled All Bin Test Canceled appears on the LCD and feeds any remaining media in the paper path to the appropriate output destination Sensor Test output bin Thi...

Page 280: ...test the display returns to the Hole Punch Test screen Feed Tests Finisher This test is used to verify that media can be fed to a finisher output bin This test feeds one sheet of media from the printe...

Page 281: ...evel2 Stacker bin upper limit Stacker bin no media Stacker bin level encod Sensor Name Bridge unit media entrance Bridge unit media exit Finisher media entrance Bridge unit media bin exit Buffer path...

Page 282: ...ansfer Belt After you select a category of sensors the panel displays the name of the selected category in the header row and each sensor in that category You must select a specific sensor from this l...

Page 283: ...ately displays the sensor s status then the sensor must be malfunctioning Press Stop to cancel the test Door E printer front Door J transfer belt access Sensor Name C PC cartridge present M PC cartrid...

Page 284: ...ngs are used by Engine code ECs to fix field problems Warning Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cann...

Page 285: ...Backspace key to erase any of the existing characters Then enter the correct ID using the number and letter keys that appear on the screen Note To exit the Configuration ID screen and return to the PR...

Page 286: ...a printed Event Log As the Event Log report prints Printing EVENT LOG appears on the LCD Clear the Event Log To clear the Event Log 1 Select Event Log from the Diagnostics Menu 2 Select Clear Log Yes...

Page 287: ...the LCD When testing is complete the LCD returns to Fuser Temp Fail Clear ATC SENSOR FAILURE CLEAR To perform the ATC Sensor Failure Clear Test 1 Select ATC SENSOR FAILURE CLEAR from the Diagnostics M...

Page 288: ...ENGINE ADJUST settings 1 Select ENGINE ADJUST from the Diagnostics Menu The following tests appear on the LCD Select the following Then select Appears on the LCD PH Adjust Media tray registration Adj...

Page 289: ...n LCD Adj side reg tray 2 Registration values appear on the LCD If required reset the values and Select to submit the changes Adj Side Reg Tr3 appears on LCD Adj side reg tray 3 Registration values ap...

Page 290: ...and Select to submit the changes SNR Output Ref TC M Registration values appear on the LCD If required reset the values and Select to submit the changes SNR Output Ref TC C Registration values appear...

Page 291: ...Booklet Fold Adjust Test 1 Select Booklet Fold Adjust from the Diagnostics Menu The following tests appear on the LCD Finisher Config To perform Finisher Config Select Finisher Config from the Diagnos...

Page 292: ...ter Press Back to return to the Configuration Menu Maintenance Counter Value See Maintenance Counter Value on page 3 24 Reset Maintenance Counter See Reset Maintenance Counter on page 3 25 Black Only...

Page 293: ...ostics version of the Print Quality Pages report The limited Configuration and the full Diagnostics printed versions of this report display the same panel messages when they print and follow the same...

Page 294: ...trays but not to the MP Feeder The MP Feeder can support these paper sizes regardless of the value of this setting Panel Menus Selections are to Disable or Enable default operator panel menus To chang...

Page 295: ...bled appears in the Power Saver menu and Power Saver can be turned off If On is set in the Energy Conserve menu the Power Saver feature cannot be disabled To change this setting 1 Select Energy Conser...

Page 296: ...he value or to decrease the value 3 Press to save the change This setting affects the PostScript PCL PDF and XL emulators This function is not supported when the device generates output at 600 dpi res...

Page 297: ...ssage This setting allows you to disable any Tray Low warnings that the printer may register Selecting Disabled turns off the tray low prompts The default is Enabled To change this setting 1 Select Re...

Page 298: ...transfer roll 83 05 mm Registration roll 62 61 mm Developer magnetic roll 33 76 mm Developer auger roll 43 89 mm Fuser hot roll 85 15 mm Charge roll 43 98 mm PC drum 94 25 mm Transfer belt 949 00 mm...

Page 299: ...ic electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place...

Page 300: ...embly to avoid pinching wires obstructing the paper path or restricting mechanical movement Note A wide variety of screws are used make note of their positions during service CAUTION Remove the power...

Page 301: ...ront door assembly 2 Press the tab and rotate the two flexible supports A 90 and pull from the machine 3 Remove the two flexible supports A 4 Remove the two screws securing the two brackets B to the p...

Page 302: ...mbly B down and pull out 4 Remove the right cover assembly B Top cover assembly removal 1 Open the printer front door assembly 2 Remove the rear cover assembly See Rear cover assembly removal on page...

Page 303: ...val Note Remove the blind cover A if the printer is equipped with a 1TM 3TM or a TTM 1 Remove all connectors and power cords from the rear of the machine 2 Remove the four screws securing the rear cov...

Page 304: ...Rear left middle cover removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Open the printer left door assembly 3 Remove the screw securing the rear left middle cove...

Page 305: ...that the rear left middle cover is removed before removing the rear left upper cover or damage will occur 2 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 3 Remove o...

Page 306: ...pin B from the machine 6 Remove the hinge pin B 7 Remove the printer left lower door assembly A MPF feed unit assembly removal 1 Remove the rear cover assembly See Rear cover assembly removal on page...

Page 307: ...left cover A up and pull out 4 Remove the front left cover A Duplex media inverter assembly removal 1 Open the printer left door assembly 2 Remove the E clip securing the fuser exit roll assembly A t...

Page 308: ...the two screws securing the duplex unit assembly A to the printer left door assembly B 2 Gently pull the duplex unit assembly A from the printer left door assembly B Note When removing the duplex uni...

Page 309: ...the sensor duplex wait C to the bracket A 4 Remove the sensor duplex wait C 5 Disconnect the connector from the sensor duplex wait C Switch duplex left door interlock removal 1 Remove the duplex unit...

Page 310: ...eed unit assembly removal on page 4 8 4 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 5 Lay the printer left door assembly on a flat surface 6 Move the dupl...

Page 311: ...lex unit assembly See Duplex unit assembly removal on page 4 10 2 Remove the screw securing the connector access cover A to the duplex unit assembly B 3 Disconnect the connector from the duplex drive...

Page 312: ...ssembly removal on page 4 10 2 Remove the screw securing the connector access cover A to the duplex unit assembly C 3 Disconnect the connectors from the duplex controller card assembly B 4 Remove the...

Page 313: ...tremely hot handle with care to avoid getting burned 1 Open the printer left door assembly 2 Loosen the two thumb screws to release the fuser unit assembly A from the machine 3 Pull the two handles on...

Page 314: ...ont door assembly 2 Open the transfer belt access cover 3 Press the button on the transfer belt lift latch A 4 Raise the transfer belt lift latch A to its upper most position 5 Lower the transfer belt...

Page 315: ...he transfer belt cleaning assembly A Replacement warning When reinstalling the transfer belt unit assembly do not touch the belt surface or damage will occur Standard media exit shift assembly removal...

Page 316: ...iddle cover removal on page 4 6 3 Remove the rear left upper cover See Rear left upper cover removal on page 4 7 4 Remove the screw securing the standard exit top cover A to the machine 5 Gently lift...

Page 317: ...e that the rear left middle cover is removed before removing the rear left upper cover or damage will occur 2 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 3 Remove...

Page 318: ...the screw securing the bracket A to the standard media exit bin shift assembly 6 Remove the bracket A 7 Release the hooks securing the switch printer left door interlock B to the bracket A 8 Remove th...

Page 319: ...ator See Standard media exit bin full actuator removal on page 4 18 5 Remove the screw securing the bracket A to the machine 6 Remove the bracket A 7 Release the hooks securing the sensor standard bin...

Page 320: ...Remove the media out actuator See Media out actuator removal on page 4 22 5 Disconnect the connector from the sensor media out A 6 Release the hooks securing the sensor media out A to the media feed...

Page 321: ...Repair information 4 23 5057 XXX Go Back Previous Next 4 Remove the media out actuator A Front Bosses Lower view A...

Page 322: ...ft lower door assembly removal on page 4 8 2 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 21 3 Disconnect the connector from the sensor media level...

Page 323: ...clip securing the fuser exit roll assembly A to the machine 3 Remove the bushing B 4 Remove the fuser exit roll assembly A 5 Remove the two screws securing the sensor fuser exit C to the machine 6 Rem...

Page 324: ...A 6 Disconnect the three connectors from the printer left door assembly B 7 Gently pull the harnesses through the hole in the machine frame 8 Open the printer left door assembly B 9 Remove the front l...

Page 325: ...Previous Next Replacement warning When replacing the printer left door assembly B ensure that the black lines are aligned on the damper assembly E or the door will not properly operate B C clip D C Sa...

Page 326: ...Go Back Previous Next Replacement warning When replacing the printer left door assembly B ensure that the duplex media exit turn guide F is held in its upper most position or the printer left door ass...

Page 327: ...4 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 5 Remove the E clip securing the shaft A to the machine 6 Remove the shaft A 7 Remove the printer left door...

Page 328: ...dia exit turn guide E is held in its upper most position or the printer left door assembly D will not close properly Sensor media on belt removal 1 Open the printer left door assembly 2 Remove the scr...

Page 329: ...securing the bracket B to the machine 5 Slide the bracket B to remove it from the machine 6 Move the bracket B toward the front of the machine 7 Detach the bracket B 8 Disconnect the connector from t...

Page 330: ...vice Manual 5057 XXX Go Back Previous Next Replacement note When reinstalling the transfer roll retract cam assembly D ensure that the bushing E pin F and washer are replaced B Connector C Actuator Co...

Page 331: ...Repair information 4 33 5057 XXX Go Back Previous Next E F...

Page 332: ...A to the machine 3 Remove the registration pinch guide assembly A 4 Remove the screw securing the bracket B to the machine 5 Slide the bracket B to remove it from the machine 6 Move the bracket B towa...

Page 333: ...emove the screw securing the 2nd transfer roll retract motor assembly A to the 2nd transfer roll retract cam assembly B 4 Remove the 2nd transfer roll retract motor assembly A 2nd transfer roll assemb...

Page 334: ...l on page 4 5 2 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 3 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 4 Remove the printer...

Page 335: ...the registration transport roll assembly B 8 Remove the registration clutch A Replacement note Before reinstalling ensure that the notch on the registration clutch A is placed over the boss on the reg...

Page 336: ...e 4 6 3 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 4 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 5 Remove the two sc...

Page 337: ...te toner cartridge cover A to the left 7 Remove the waste toner cartridge cover A Waste toner cartridge sensor assembly removal 1 Remove the printer front door assembly See Printer front door assembly...

Page 338: ...on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 4 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly...

Page 339: ...eft cover See Front left cover removal on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 4 Remove the waste toner cartridge sensor assembly See...

Page 340: ...r assembly See Waste toner cartridge sensor assembly removal on page 4 39 5 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 6 Remove the toner w...

Page 341: ...motor assembly A to the machine 8 Remove the waste toner agitator motor assembly A PC cartridge unit removal Note The following procedure applies to the C M Y and K PC cartridge units Warning When rem...

Page 342: ...assembly See Printer front door assembly removal on page 4 3 2 Remove the front left cover See Front left cover removal on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge...

Page 343: ...ove the harness access cover A from the machine 9 Disconnect the three connectors from the image density sensor assembly B 10 Release the harnesses from the clamps 11 Remove the screw securing the ima...

Page 344: ...emoval on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 4 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor ass...

Page 345: ...Repair information 4 47 5057 XXX Go Back Previous Next 8 Remove the appropriate CMY toner add assemblies A A Shutter...

Page 346: ...curing the K toner add assembly A to the machine Warning Pull the shutter to reduce toner spillage into the machine 9 Remove the K toner add assembly A Developer interlock plate assembly removal Warni...

Page 347: ...assembly See K toner add assembly removal on page 4 48 9 Remove the harnesses from the clamps on the developer interlock plate assembly A Warning Use extreme caution when disconnecting the next seven...

Page 348: ...irmly inside the machine gently remove the developer interlock plate assembly A 15 Remove the developer interlock plate assembly A and allow it to gently hang down by the harness if removing the devel...

Page 349: ...evious Next Replacement note When replacing the developer interlock plate assembly A install the bottom edge first and ensure that all four developer unit assemblies are properly aligned when replacin...

Page 350: ...developer unit assembly harnesses are correctly installed in the clamps or they may become detached Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle...

Page 351: ...artridge cover See Waste toner cartridge cover removal on page 4 39 5 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Note The waste ton...

Page 352: ...agnetic roll engagement immediately after installing the new C M or Y developer unit assembly A A Enter the diagnostic mode B Select MOTOR TESTS C Select Finisher Motor Tests D Select CMY developer dr...

Page 353: ...harnesses are properly secured in the clamps by moving the transfer belt lift handle up and down several times before reinstalling the inner cover 11 Remove the printhead cleaning tool from the printe...

Page 354: ...4 56 Printer Service Manual 5057 XXX Go Back Previous Next 12 Clean the four printhead glass windows using the printhead cleaning tool...

Page 355: ...ee Front left cover removal on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Note The waste toner cartridge sensor assembly does not need to be...

Page 356: ...Manual 5057 XXX Go Back Previous Next 11 Remove the top cover A 12 Completely remove the carrier B from the assembly by dumping it and using a toner vacuum or if installing a new developer unit assem...

Page 357: ...59 5057 XXX Go Back Previous Next Replacement warning If reusing an existing developer unit assembly ensure that all traces of old carrier B are removed from the developer unit assembly or print quali...

Page 358: ...in the assembly before replacing the top cover A or spillage may occur which may lead to print quality problems Warning Ensure that the four plastic tabs in the top cover A are inserted into the four...

Page 359: ...all sources of light or damage will occur Note This procedure can be applied to either the C M Y or K PC unit assemblies 1 Open the printer front door assembly 2 Press the button on the transfer belt...

Page 360: ...vice Manual 5057 XXX Go Back Previous Next 5 Pull the appropriate PC unit assembly C from the machine Note When the PC unit assembly C is removed ensure that it is stored in the position as shown in t...

Page 361: ...ee Printer front door assembly removal on page 4 3 2 Remove the front left cover See Front left cover removal on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge cover remov...

Page 362: ...emoval on page 4 8 5 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 6 Remove the registration transport roll assembly See Registration transport roll assembl...

Page 363: ...embly See Waste toner agitator motor assembly removal on page 4 43 Note Ensure that the left transfer belt lift assembly is in the up position in order to remove the image density sensor assembly 16 R...

Page 364: ...4 66 Printer Service Manual 5057 XXX Go Back Previous Next 19 Remove the bracket A 20 Remove the two screws securing the left elevator assembly B to the front of the machine...

Page 365: ...washers must be removed The two E clips and two washers are located inside the machine in the area where the K PC unit is located Warning Do not loose the two E clips four washers and two bearings The...

Page 366: ...t note Ensure that the two E clips four washers and two bearings are properly reinstalled when installing the new left transfer belt lift assembly B Replacement warning When replacing the transfer bel...

Page 367: ...l occur Once the alignment is correctly set replace the two plastic rack gear caps Replacement warning When replacing the transfer belt lift handle assembly B ensure the two timing marks on the two se...

Page 368: ...d damage will occur Once the alignment is correctly set replace the two plastic rack gear caps Replacement warning When replacing the transfer belt lift handle assembly B ensure the two timing marks o...

Page 369: ...Remove the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 5 Remove the front left cover See Front left cover removal on page 4 9 6 Remove the screw securing the plas...

Page 370: ...ack Previous Next 8 Gently release the hooks on the two plastic rack gear caps with a small flat tip screwdriver 9 Remove the two plastic rack gear caps 10 Remove the screw and washer securing the lef...

Page 371: ...Repair information 4 73 5057 XXX Go Back Previous Next 12 Remove the E clip securing the right hinge pin 13 Remove the right hinge pin...

Page 372: ...gears ensure they do not become bent or damaged 15 Ensure the two rack gears are fully extended toward the front of the machine before reinstalling the transfer belt lift handle assembly B Warning Wh...

Page 373: ...l occur Once the alignment is correctly set replace the two plastic rack gear caps Replacement warning When replacing the transfer belt lift handle assembly B ensure the two timing marks on the two se...

Page 374: ...damage will occur 1 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 2 Remove the front left cover See Front left cover removal on page 4 9 3 Remove the wast...

Page 375: ...sensor assembly removal on page 4 39 4 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 5 Remove the transfer belt unit assembly See Transfer bel...

Page 376: ...inter Service Manual 5057 XXX Go Back Previous Next 13 Gently raise the rear of the K erase lamp assembly B to detach the mounting hook from the machine 14 Remove the K erase lamp assembly B Connector...

Page 377: ...See MPF feed unit assembly removal on page 4 8 4 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 5 Remove the registration transport roll assembly See Registr...

Page 378: ...er Service Manual 5057 XXX Go Back Previous Next Replacement warning When reinstalling the printhead shutter motor assembly A ensure that the plastic arm is inserted into the printhead shutter B A B C...

Page 379: ...Remove the right cover assembly See Right cover assembly removal on page 4 4 3 Remove the top cover assembly See Top cover assembly removal on page 4 4 4 Remove the connector form the switch printer...

Page 380: ...nterlock A 6 Disconnect the connector from the sensor printer left lower door interlock A RIP card cooling fan cover assembly removal 1 Remove the rear cover assembly See Rear cover assembly removal o...

Page 381: ...on page 4 86 5 Remove the controller box top cover assembly See RIP card cooling fan cover assembly removal on page 4 82 6 Remove the switch main power See Switch main power removal on page 4 84 7 Loo...

Page 382: ...ssembly removal on page 4 4 3 Remove the top cover assembly See Top cover assembly removal on page 4 4 4 Detach the metal rod A from the switch main power B 5 Release the two hooks securing the switch...

Page 383: ...y removal on page 4 86 5 Remove the controller box top cover assembly See RIP card cooling fan cover assembly removal on page 4 82 6 Remove the controller box assembly See Controller box assembly remo...

Page 384: ...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 comp...

Page 385: ...rom the defective RIP card assembly and installed on the replacement rip card assembly or the machine will not function Hard drive removal 1 Remove the RIP card assembly See RIP card assembly removal...

Page 386: ...ssembly A from the RIP card assembly B 3 Remove the interconnect card assembly A Upper printer engine card bracket assembly removal 1 Remove the rear cover assembly See Rear cover assembly removal on...

Page 387: ...X Go Back Previous Next 12 Remove the upper printer engine card bracket assembly A Replacement warning Ensure that the upper printer engine card B assembly and the lower printer engine card assembly C...

Page 388: ...controller box assembly See Controller box assembly removal on page 4 83 8 Remove the upper printer engine card bracket assembly See Upper printer engine card bracket assembly removal on page 4 88 9 R...

Page 389: ...stration adjustment Upper printer engine card assembly re installation 1 Install the NVM board from the defective PCBA to the replacement PCBA Warning Ensure that the NVM board D is installed on the n...

Page 390: ...e developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 112 3 Remove the fifteen connectors from the lower printer engine card bracket assembly A...

Page 391: ...astic retainers with needle nose pliers securing the lower printer engine card assembly A to the lower printer engine card bracket assembly B 6 Remove the lower printer engine card assembly A Transfer...

Page 392: ...ling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 111 3 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly remov...

Page 393: ...nector from the switch transfer belt access door interlock A 6 Release the hooks securing the switch transfer belt access door interlock A to the machine 7 Remove the switch transfer belt access door...

Page 394: ...bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 111 3 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 4 Disconnect the four connectors f...

Page 395: ...moval 1 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 111 2 Remove the developer transfer roll HVPS card assembly See Developer trans...

Page 396: ...val on page 4 111 2 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 112 3 Remove the lower printer engine card bracket assembly S...

Page 397: ...the 24V LVPS cooling fan A Replacement warning When replacing the 24V LVPS cooling fan A ensure that the label is facing up Rear lower cooling fan assembly 1 Remove the rear upper cooling fan bracket...

Page 398: ...HVPS card assembly removal on page 4 112 3 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 92 4 Remove the 5V LVPS card bracket a...

Page 399: ...e the transfer belt drive motor cooling fan See Transfer belt drive motor cooling fan removal on page 4 93 7 Remove the transfer belt drive motor assembly See Transfer belt drive motor assembly remova...

Page 400: ...the fuser cooling fan A 3 Remove the harness from the clamps 4 Lift the fuser cooling fan A 5 Remove the fuser cooling fan Main power switch actuator removal 1 Remove the top cover assembly See Top c...

Page 401: ...mbly removal on page 4 39 6 Remove the inner cover See Inner cover removal on page 4 42 7 Remove the three CMY toner add assemblies See CMY toner add assembly removal on page 4 46 8 Remove the K toner...

Page 402: ...12 5 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 96 6 Disconnect the two connectors from the CMYK transfer HVPS card assembly A 7 Disconnect the four...

Page 403: ...from the clamps 8 Remove the two screws securing the printhead assembly A to the machine 9 Gently pull the printhead assembly A from the machine Replacement warning When replacing the printhead assem...

Page 404: ...e MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 7 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 112 8 R...

Page 405: ...Repair information 4 107 5057 XXX Go Back Previous Next 16 Gently remove the K developer transport drive motor assembly A A Connector Frame clamp Connector Clamp Connectors Clamps Clamps B...

Page 406: ...6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 7 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on pa...

Page 407: ...er transfer roll HVPS card assembly removal on page 4 112 5 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 96 6 Remove the CMYK transfer HVPS card assem...

Page 408: ...sfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 112 5 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 96 6...

Page 409: ...ling fan bracket assembly A 3 Remove the two screws securing the upper cooling fan bracket assembly A to the machine 4 Remove the rear upper cooling fan bracket assembly A Rear upper cooling fan remov...

Page 410: ...ently attached to the developer transfer roll HVPS card assembly B do not attempt to remove these connectors or damage will occur 5 Disconnect the five connectors from the developer transfer roll HVPS...

Page 411: ...2 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 111 3 Remove the developer transfer roll HVPS card assembly Go to Developer transfer...

Page 412: ...ft middle cover See Rear left middle cover removal on page 4 6 4 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 112 5 Remove the...

Page 413: ...tor assembly A Feed roll removal 1 Remove the media tray 2 Move the feed unit front guide A in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed r...

Page 414: ...the media feed unit front guide A in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber surface of the feed rol...

Page 415: ...nter front door assembly removal on page 4 3 3 Remove the front left cover See Front left cover removal on page 4 9 4 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on...

Page 416: ...ve the fuser exit roll assembly A MPF media out actuator removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Remove the rear left middle cover See Rear left middle c...

Page 417: ...upper frame cover A 5 Remove the upper frame cover A 6 Release the hooks securing the sensor MPF media out B to the upper frame cover A 7 Remove the sensor MPF media out B MPF pick roll assembly remo...

Page 418: ...note When replacing the MPF feed roll assemblies C do not touch the rubber surface Replacement note When replacing the MPF feed roll assemblies C ensure that the directional arrow is properly aligned...

Page 419: ...Note This procedure can be applied to tray 1 or tray 2 switch media size 1 Remove media Tray 1 and media Tray 2 2 Remove one screw securing the switch media size A to the bracket inside the machine 3...

Page 420: ...put TTM top cover removal 1 Pull out tray 2 assembly 2 Remove the two screws securing the top cover A 3 Remove the top cover A 2000 sheet dual input TTM foot cover removal 1 Pull out the media tray 3...

Page 421: ...r A 2000 sheet dual input TTM right cover removal 1 Remove the four screws securing the right cover A 2 Remove the right cover A by lifting up and out 2000 sheet dual input TTM tray module left cover...

Page 422: ...removal 1 Remove the media tray 2 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 123 3 Remove media tray 3 assembly See 2000 sheet dual inp...

Page 423: ...TTM TTM media tray 3 assembly removal on page 4 128 3 Remove media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 127 4 Remove the foot cover See 2000 sheet...

Page 424: ...4 126 Printer Service Manual 5057 XXX Go Back Previous Next 8 Remove the shafts D 9 Remove the tray support rolls B...

Page 425: ...screws securing the TTM tray 4 media transport assembly A to the TTM media tray 4 assembly B 3 Push the TTM tray 4 media transport assembly A into the machine in the direction of the arrow 4 Remove t...

Page 426: ...e TTM tray 3 stopper A 4 Move the TTM tray 3 stopper A out in the direction of the arrow while pulling out the TTM media tray 3 assembly B 5 Remove the TTM media tray 3 assembly B 2000 sheet dual inpu...

Page 427: ...000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 128 4 Remove the tray 3 front cover See 2000 sheet dual input TTM tray 3 front cover removal on page 4 128 5 Remove the E clip with...

Page 428: ...of the frame assembly 11 Remove the two small guides G and the two small pulleys F 12 Remove the E clip with a prying tool securing the large guide H and the large pulley I to the frame assembly 13 R...

Page 429: ...Remove the E clip with a prying tool securing the tray lift pulley A to the tray lift shaft assembly B 6 Remove the lift cable pulley A Note The tray 3 front cables C become detached 7 Remove the tra...

Page 430: ...y 4 assembly removal on page 4 127 2 Remove the TTM tray 4 media transport assembly A Replacement note Before re installing insert the TTM tray 4 media transport assembly A into the rails of the frame...

Page 431: ...he tray lift shaft assembly B away from the frame 7 Move the rear the rear lift cable pulley E toward the rear of the tray to release the two tray 4 rear cables D from the tray lift shaft assembly B 8...

Page 432: ...om the bottom plate H Replacement note Before re installing It is recommended that all four cables be replaced Ensure tray 4 rear cables D are not twisted or kinked Route the cables properly as shown...

Page 433: ...ay 4 assembly on its right side as shown in the figure 4 Remove the E clip with a prying tool securing the front tray lift pulley A to the tray lift shaft assembly B 5 Remove the front tray lift pulle...

Page 434: ...ut TTM media feed unit assembly removal tray 4 1 Remove the media tray 2 assembly 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 123 3 Remov...

Page 435: ...left and up in the direction of the arrow 11 Remove the media feed unit assembly A 12 Remove the two screws securing the lower guide C to the media feed unit assembly A 13 Remove the lower guide C 14...

Page 436: ...al on page 4 123 3 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 128 4 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM m...

Page 437: ...moval Note This procedure can be applied to tray 1 or tray 2 switch media size 1 Remove media Tray 1 and media Tray 2 2 Remove one screw securing the switch media size A to the bracket inside the mach...

Page 438: ...dual input TTM tray module left cover removal on page 4 123 2 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 128 or media tray 4 assembly 2...

Page 439: ...bly removal tray 3 1 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 123 2 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM m...

Page 440: ...4 142 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 441: ...t door assembly 2 Remove the two screws securing the two support straps A to the machine 3 Disconnect the connector to the bracket B 4 Remove the two screws securing the bracket B to the machine 5 Rem...

Page 442: ...eft cover removal on page 4 123 2 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 128 3 Remove the media tray 4 assembly See 2000 sheet dual...

Page 443: ...Repair information 4 145 5057 XXX Go Back Previous Next 8 Remove the media feed lift motor B A B Connector Rear...

Page 444: ...he tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 132 5 Remove the media feed unit assembly See 2000 sheet dual input TTM media fee...

Page 445: ...n 4 147 5057 XXX Go Back Previous Next 10 Remove the tray lift one way gear 24 tooth C Replacement note Before re installing ensure all gears and washers are securely attached to the bracket A Harness...

Page 446: ...media tray 4 assembly removal on page 4 127 4 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 132 5 Remove the media fee...

Page 447: ...page 4 127 4 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 132 5 Remove the media feed unit assembly See 2000 sheet du...

Page 448: ...sembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 132 5 Remove the media feed unit assembly See 2000 sheet dual input TTM media feed unit assembly 2 removal on...

Page 449: ...y assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the r...

Page 450: ...revious Next 2000 sheet dual input TTM feed roll one way clutch removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 151 3 Remove t...

Page 451: ...tooth removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 151 3 Remove the feed roll one way clutch See 2000 sheet dual input TTM...

Page 452: ...put TTM separation roll one way friction clutch removal 1 Remove the media tray assembly 2 Remove the separation roll See 2000 sheet dual input TTM separation roll removal on page 4 155 3 Remove the s...

Page 453: ...revious Next 2000 sheet dual input TTM separation roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook sec...

Page 454: ...Manual 5057 XXX Go Back Previous Next 4 Remove the separation roll B Note Do not touch the rubber surface of the feed roll B Replacement note Before re installing do not touch the rubber surface of t...

Page 455: ...a tray assembly 2 Move the front guide A toward the front in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber...

Page 456: ...dual input TTM tray module left cover removal on page 4 123 2 Open the TTM left door assembly 3 Remove the two screws securing the two support straps A to the machine 4 Remove one screw securing the...

Page 457: ...ly 2 Remove the screw securing the support strap A to the machine 3 Remove the screw securing the bracket B to the machine 4 Remove the bracket B 5 Disconnect the two connectors from the switch TTM le...

Page 458: ...ving the tray 3 lift gear assembly A the tray lift coupling assembly B my become detached 4 Remove the tray 3 lift gear assembly A 2000 sheet dual input TTM tray 4 lift gear assembly removal 1 Remove...

Page 459: ...000 sheet dual input TTM tray 4 lift gear assembly removal on page 4 160 2 Remove the tray lift coupling assembly A from the machine 3 Remove the bushing B from the tray lift coupling assembly A 4 Rem...

Page 460: ...4 162 Printer Service Manual 5057 XXX Go Back Previous Next 4 Remove the tray module drive motor A A Connector...

Page 461: ...m the clamp 4 Remove the two screws securing the TTM tray 4 transport motor A to the machine 5 Remove the TTM transport drive motor A 2000 sheet dual input TTM TTM controller card assembly removal 1 R...

Page 462: ...Manual 5057 XXX Go Back Previous Next 3X 500 sheet drawer 3TM removals 3X 500 sheet drawer 3TM top cover removal 1 Pull out tray 2 assembly A 2 Remove the two screws securing the top cover B 3 Remove...

Page 463: ...ove the media tray 4 assembly 2 Remove the two screws securing the foot cover A to the machine 3 Remove the foot cover A 3X 500 sheet drawer 3TM right cover removal 1 Remove the four screws securing t...

Page 464: ...heet drawer 3TM tray module left cover removal 1 Remove the four screws securing the tray module left cover A 2 Remove the tray module left cover A 3X 500 sheet drawer 3TM rear cover removal 1 Remove...

Page 465: ...ing the caster A 6 Remove the caster A 3X 500 sheet 3TM media feed unit assembly removal tray 4 1 Remove the media tray 4 assembly 2 Open the 3TM left door assembly 3 Remove the two screws securing th...

Page 466: ...r assembly 2 Remove the two screws securing the two support straps A to the machine 3 Disconnect the connector from the sensor tray 4 feed out B 4 Remove the two screws securing bracket C to the machi...

Page 467: ...ut removal 1 Open the 3TM left door assembly 2 Remove the two screws securing bracket A to the machine 3 Remove the bracket A 4 Disconnect the connector from the sensor tray 2 feed out B 5 Release the...

Page 468: ...ied to media tray 2 3 and media tray 4 assemblies 1 Remove the media tray 2 assembly 2 Remove the media tray 3 assembly 3 Remove the media tray 4 assembly 4 Disconnect the connector from the appropria...

Page 469: ...Open the 3TM left door assembly 3 Remove the two screws securing the two support straps A to the machine 4 Release the harness from the clamp 5 Disconnect the connector from the media feed unit assem...

Page 470: ...4 172 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 471: ...ray 2 assembly 2 Open the 3TM left door assembly 3 Remove the two screws securing the two support straps A to the machine 4 Release the harness from the clamp 5 Disconnect the connector from the media...

Page 472: ...en the 3TM left door assembly 2 Remove the two screws securing the two support straps A to the machine 3 Disconnect the connector from the sensor tray 3 feed out B 4 Remove the two screws securing bra...

Page 473: ...3TM media feed unit assembly removal tray 2 on page 4 173 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 171 or 3X 500 sheet drawer 3TM media out actuator removal on page 4...

Page 474: ...assembly removal tray 3 on page 4 171 2 Remove the harness from the bracket A 3 Remove the three screws securing the bracket A to the media feed unit assembly 4 Remove the bracket A Note The gears ma...

Page 475: ...eed unit assembly See 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 on page 4 173 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 171 2 Release the two b...

Page 476: ...heet drawer 3TM media feed unit assembly removal tray 2 on page 4 173 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 171 2 Disconnect the connector from the sensor media...

Page 477: ...2 on page 4 173 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 171 2 Remove the media out actuator See 3X 500 sheet drawer 3TM media out actuator removal on page 4 177 3...

Page 478: ...bly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the rubber s...

Page 479: ...s Next 3X 500 sheet drawer 3TM feed roll one way clutch removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 151 3 Remove the feed...

Page 480: ...h removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 151 3 Remove the feed roll one way clutch See 2000 sheet dual input TTM feed...

Page 481: ...eparation roll one way friction clutch removal 1 Remove the media tray assembly 2 Remove the separation roll See 2000 sheet dual input TTM separation roll removal on page 4 155 3 Remove the separation...

Page 482: ...ious Next 3X 500 sheet drawer 3TM separation roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing...

Page 483: ...5057 XXX Go Back Previous Next 4 Remove the separation roll B Note Do not touch the rubber surface of the feed roll B Replacement note Before re installing do not touch the rubber surface of the separ...

Page 484: ...assembly 2 Move the front guide A toward the front in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber surfac...

Page 485: ...assembly C to the front and out in the direction of the arrow 6 Remove the tray module left door assembly C 3X 500 sheet drawer 3TM switch tray module left door interlock removal 1 Open the 3TM left d...

Page 486: ...t drawer 3TM tray module drive motor assembly removal 1 Remove the rear cover See 3X 500 sheet drawer 3TM rear cover removal on page 4 166 2 Disconnect the connector from the tray module drive motor A...

Page 487: ...sembly removal 1 Remove the rear cover See 3X 500 sheet drawer 3TM rear cover removal on page 4 166 2 Disconnect the nine connectors from the 3TM controller card assembly A 3 Remove the four screws se...

Page 488: ...ce Manual 5057 XXX Go Back Previous Next 1X 500 sheet drawer 1TM removals 1X 500 sheet drawer 1TM top cover removal 1 Pull out tray 2 assembly A 2 Remove the two screws securing the top cover B 3 Remo...

Page 489: ...val 1 Open the 1TM front door 2 Remove the two screws securing the foot cover A to the machine 3 Remove the foot cover A 1X 500 sheet drawer 1TM right cover removal 1 Remove the four screws securing t...

Page 490: ...eet drawer 1TM tray module left cover removal 1 Remove the four screws securing the tray module left cover A 2 Remove the tray module left cover A 1X 500 sheet drawer 1TM rear cover removal 1 Remove t...

Page 491: ...ng the caster A 4 Remove the caster A 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 1 Remove the media tray 2 assembly 2 Open the 1TM left door assembly 3 Release the harness from th...

Page 492: ...Open the 1TM left door assembly 2 Remove the two screws securing bracket A to the machine 3 Remove the bracket A 4 Disconnect the connector from the sensor tray 2 feed out B 5 Release the hooks secur...

Page 493: ...t 1X 500 sheet drawer 1TM switch media size removal 1 Remove the media tray 2 assembly 2 Open the 1TM front door 3 Disconnect the connector from the switch media size A 4 Remove the screw securing the...

Page 494: ...motor to the media feed unit assembly B 4 Remove the media feed lift motor B 1X 500 sheet drawer 1TM one way clutch gear assembly removal 1 Remove the media feed unit assembly See 1X 500 sheet drawer...

Page 495: ...on 4 197 5057 XXX Go Back Previous Next 6 Remove the tray lift one way gear 24 tooth C Replacement note Before re installing ensure all gears and washers are securely attached to the bracket A Harness...

Page 496: ...out actuator removal 1 Remove the media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 193 2 Release the two bosses on the media out actuator A from...

Page 497: ...e media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 193 2 Disconnect the connector from the sensor media level A 3 Release the hooks securing the s...

Page 498: ...r 1TM media feed unit assembly removal tray 2 on page 4 193 2 Remove the media out actuator See 1X 500 sheet drawer 1TM media out actuator removal on page 4 198 3 Disconnect the connector from the sen...

Page 499: ...assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the ru...

Page 500: ...Previous Next 1X 500 sheet drawer 1TM feed roll one way clutch removal 1 Remove the media tray assembly 2 Remove the feed roll See 1X 500 sheet drawer 1TM feed roll removal on page 4 201 3 Remove the...

Page 501: ...tooth removal 1 Remove the media tray assembly 2 Remove the feed roll See 1X 500 sheet drawer 1TM feed roll removal on page 4 201 3 Remove the feed roll one way clutch See 1X 500 sheet drawer 1TM fee...

Page 502: ...separation roll one way friction clutch removal 1 Remove the media tray assembly 2 Remove the separation roll See 1X 500 sheet drawer 1TM separation roll removal on page 4 205 3 Remove the separation...

Page 503: ...bly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the separation roll B to the shaft C 4 Remove the separation roll B Note Do not touch...

Page 504: ...ia tray assembly 2 Move the front guide A toward the front in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubbe...

Page 505: ...M TMM left door assembly 2 Remove the two screws securing the two supports straps A to the machine 3 Remove the screw securing the bracket B to the machine 4 Remove the bracket B 5 Move the tray modul...

Page 506: ...rew securing the support strap A to the machine 3 Remove the screw securing the bracket B to the machine 4 Remove the bracket B 5 Disconnect the two connectors from the switch tray module left door in...

Page 507: ...3 Remove the two screws securing the tray module drive motor A to the machine 4 Remove the tray module drive motor A 1X 500 sheet drawer 1TM 1TM controller card assembly removal 1 Remove the rear cov...

Page 508: ...from the sensor ATC on each of the new developer unit assemblies in step 1 locate the values for the following settings using the ATC value conversion chart shown after step 5 Sensitivity gradient Se...

Page 509: ...Note Ensure that all photoconductor unit assemblies are installed before performing this step Finalize the newly updated settings 1 Enter the Diagnostics Menu 2 Touch ENGINE ADJUST 3 Touch ATC Sensor...

Page 510: ...63 162 24 708 158 25 753 154 26 799 150 27 844 146 28 889 142 29 934 138 30 527 176 31 572 172 32 617 168 33 663 164 34 708 160 35 753 156 36 799 152 37 844 148 38 889 144 39 934 140 40 527 178 41 572...

Page 511: ...164 55 753 160 56 799 156 57 844 152 58 889 148 59 934 144 60 526 181 61 572 178 62 617 174 63 663 170 64 708 166 65 753 162 66 799 158 67 844 154 68 889 150 69 934 146 70 526 183 71 572 180 72 617 1...

Page 512: ...185 81 572 182 82 617 178 83 663 174 84 708 170 85 753 166 86 799 162 87 844 158 88 889 154 89 934 150 90 526 187 91 572 184 92 617 180 93 663 176 94 708 172 95 753 168 96 799 164 97 844 160 98 889 15...

Page 513: ...mbly for damage Does above component show signs of damage on the frame or on the belt Replace the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 Go to step 3 3 Check...

Page 514: ...sensor check test again Does the above test pass Perform the Control sensor cycle See Control sensor cycle on page 4 216 Contact next level of support Step Check Yes No 1 Perform the Control sensor cy...

Page 515: ...setup See Skew fine setup on page 4 217 Go to step 2 2 Replace the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 Does the error continue Perform Skew setup See Skew...

Page 516: ...number of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG Y Skew adju...

Page 517: ...le result values Locate the following new values for the following settings Patch B in Patch B out Is the value for both of the above settings a 4 Go to step 4 Go to step 6 4 Perform the skew rough se...

Page 518: ...d and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG Y Skew adjustment 10 Turn the screw CW 10 clicks EG Y Skew adjus...

Page 519: ...GINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Skew fine setup Does the above test pass Perform the In Out setup See In out setup on page 4 222 Replace the image density sen...

Page 520: ...ut setup 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Cycle result values Locate the following new values for the following setting...

Page 521: ...rtridge the number of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG...

Page 522: ...r of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG Y Skew adjustment...

Page 523: ...ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select In out setup Does the above test pass Perform the Center setup See Center setup on page 4 226 Replace the image density sen...

Page 524: ...Place the hook on the end of the printhead cleaning tool into the front of the image density sensor assembly as shown in the diagram 5 Remove the screw as shown in the diagram 6 Push the image densit...

Page 525: ...ct Center setup Does the above test pass Move the image density sensor back to its original position The color registration RegCon procedure is now complete Go to step 3 3 The image density sensor is...

Page 526: ...t lift latch assembly 3 Lower the transfer belt lift handle assembly Does the transfer belt lift handle assembly lower and raise smoothly without binding Go to step 7 Go to next step 2 Check that the...

Page 527: ...Replace the appropriate assemblies See Left transfer belt lift assembly removal on page 4 64 or Transfer belt drive motor assembly removal on page 4 94 Need correct links Go to next step 4 Check for...

Page 528: ...transfer belt E and the top of the right side cover F must be parallel as shown in the following image The metal edge at the top of the registration frame assembly G must be parallel to the top of th...

Page 529: ...the timing marks E located on the following components Left transfer belt lift assembly plunger Right transfer belt lift assembly plunger Transfer belt lift handle Are the timing marks aligned correct...

Page 530: ...4 232 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 531: ...Connector locations 5 1 5057 XXX Go Back Previous Next 5 Connector locations Locations Waste toner agitator motor assembly Sensor waste toner cartridge full Switch waste toner cartridge interlock...

Page 532: ...5 2 Printer Service Manual 5057 XXX Go Back Previous Next Image density sensor assembly Duplex unit assembly Printer left door assembly...

Page 533: ...nector locations 5 3 5057 XXX Go Back Previous Next Thumb screws Fuser unit assembly K toner add motor C toner add motor M toner add motor Y toner add motor Main power switch activator Switch main pow...

Page 534: ...5 4 Printer Service Manual 5057 XXX Go Back Previous Next Printhead Polygon mirror motor...

Page 535: ...Connector locations 5 5 5057 XXX Go Back Previous Next Charge roll HVPS card assembly 24 V LVPS card assembly Developer transfer roll HVPS card assembly...

Page 536: ...5 6 Printer Service Manual 5057 XXX Go Back Previous Next AC drive card assembly Printer power hookup connector Finisher power hookup connector Upper printer engine card assembly NVM card assembly...

Page 537: ...Connector locations 5 7 5057 XXX Go Back Previous Next 5V LVPS card assembly Lower printer card assembly CMYK transfer roll HVPS card assembly...

Page 538: ...ice Manual 5057 XXX Go Back Previous Next Feed lift motor Sensor media out Sensor media level Media feed unit assembly Printer left lower door assembly Sensor tray 1 feed out Sensor printer left lower...

Page 539: ...Connector locations 5 9 5057 XXX Go Back Previous Next...

Page 540: ...5 10 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 541: ...M controller card assembly Tray module drive motor Switch tray module left door interlock Feed lift motor Sensor media out Sensor media level Media feed unit assembly Sensor tray 2 feed out Sensor tra...

Page 542: ...5 12 Printer Service Manual 5057 XXX Go Back Previous Next TTM controller card assembly Tray module drive motor TTM tray 4 transport drive motor...

Page 543: ...Connector locations 5 13 5057 XXX Go Back Previous Next Switch media size Switch TTM media size...

Page 544: ...5 14 Printer Service Manual 5057 XXX Go Back Previous Next Media feed unit assembly Sensor tray 4 feed out...

Page 545: ...any non Lexmark attachments LEXMARK C935 EVERY SERVICE CALL EVERY 100K EVERY 600K NOTE MEDIA TRAY ALL Media Side Guides Inspect Inspect Check for correct positioning Media End Guide Inspect Inspect Ch...

Page 546: ...a maintenance kit with the following part numbers 40X4031 100K Maintenance Kit 110 V 40X4093 100K Maintenance Kit 220 V 40X4032 600K Maintenance Kit 110 220 V The ADF requires scheduled maintenance a...

Page 547: ...from the Configuration Menu 6 Reset Maintenance Counter appears in the header and Yes and No appears below the header 7 To cancel the reset operation press Back or No All other button presses are ign...

Page 548: ...6 4 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 549: ...he number of FRUs used in the product Units FRU Refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procur...

Page 550: ...FRUs mach Units FRU Description 1 40X0840 3 1 Switch printer front door interlock 2 40X0553 3 1 Switch transfer access door interlock 3 40X3780 1 1 Right cover assembly 4 40X3778 1 1 Printer front do...

Page 551: ...Parts catalog 7 3 5057 XXX Go Back Previous Next Assembly 2 Covers 2 2 1 11 8 7 9 5 6 4 3 10...

Page 552: ...R 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 a component has been inst...

Page 553: ...Us mach Units FRU Description 1 40X3796 1 1 Rear left upper cover 2 40X3793 1 1 Rear left middle cover 3 40X3795 1 1 Left front cover 4 40X3794 1 1 Rear left lower cover 5 40X3788 1 1 Rear blind cover...

Page 554: ...s FRU Description 1 40X3671 4 1 Developer idler gear assembly 2 40X3669 1 1 CMY developer drive motor assembly 3 40X3670 1 1 Developer transport drive motor assembly 4 40X3672 1 1 MPF transport drive...

Page 555: ...7 XXX Go Back Previous Next Assembly 5 ID sensor and transfer belt steering Asm index Part number FRUs mach Units FRU Description 1 40X3674 1 1 Image density sensor assembly 2 40X3673 1 1 Transfer bel...

Page 556: ...tray Asm index Part number FRUs mach Units FRU Description 1 40X3677 2 1 Switch media size 2 40X3676 8 1 Media tray slide 3 40X3678 3 6 Media tray assembly kit Media tray assembly 1 label 2 label 3 la...

Page 557: ...x Part number FRUs mach Units FRU Description 1 40X3679 4 1 Media feed unit assembly 2 40X3688 30 1 Sensor printer left lower door interlock 3 40X0613 1 1 Hinge pin 4 40X3680 1 1 Printer left lower do...

Page 558: ...7 10 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 8 Media feed unit 3 11 13 5 9 2 10 6 4 12 1 8 6 7 14...

Page 559: ...0 1 Sensor tray media level 5 40X3684 4 1 Media feed lift motor 6 40X0888 6 1 Bushing 6 mm 7 40X0590 2 1 Pick roll assembly spring 8 40X3686 4 1 Media tray lift one way gear 9 40X3685 4 1 Media tray l...

Page 560: ...12 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 9 MPF feed unit assembly 1 Asm index Part number FRUs mach Units FRU Description 1 40X4079 1 1 MPF feed unit assembly this comes assembled...

Page 561: ...sembly 10 MPF feed unit assembly 2 Asm index Part number FRUs mach Units FRU Description 1 40X4079 1 1 MPF feed unit assembly this comes assembled 2 40X3688 30 1 Sensor MPF media out 3 40X3709 1 1 MPF...

Page 562: ...k Previous Next Assembly 11 MPF feed unit assembly 3 Asm index Part number FRUs mach Units FRU Description 1 40X4079 1 1 MPF feed unit assembly this comes assembled 2 40X3711 1 2 MPF pick roll kit MPF...

Page 563: ...ion transport roll assembly Asm index Part number FRUs mach Units FRU Description 1 40X3692 1 1 Registration transport roll assembly this comes assembled 2 40X3695 1 1 Sensor transparency detect 3 40X...

Page 564: ...number FRUs mach Units FRU Description 1 40X4078 1 1 Printer left door assembly this comes assembled 2 40X3697 1 1 Printer left door damper assembly 3 40X3696 1 1 Printer left door damper idler gear...

Page 565: ...1 Asm index Part number FRUs mach Units FRU Description 1 40X4078 1 1 Printer left door assembly this comes assembled 2 40X3699 1 1 Sensor fuser exit 3 40X4098 1 1 Printer left door closed actuator 4...

Page 566: ...h Units FRU Description 1 40X4078 1 1 Printer left door assembly this comes assembled 2 40X3704 1 1 Printer left door damper sector gear 3 40X3688 30 1 Sensor 2nd transfer roll retract HP 4 40X3701 1...

Page 567: ...Parts catalog 7 19 5057 XXX Go Back Previous Next Assembly 16 Duplex media inverter assembly Asm index Part number FRUs mach Units FRU Description 1 40X3797 1 1 Duplex media inverter assembly 1...

Page 568: ...m index Part number FRUs mach Units FRU Description 1 40X3799 1 1 Duplex unit assembly this comes assembled 2 40X3802 1 1 Duplex drive motor 3 40X3801 1 1 Sensor duplex wait 4 40X3800 1 1 Duplex contr...

Page 569: ...ption 1 40X3705 1 1 Standard media exit shift assembly this comes assembled 2 40X3707 1 1 Standard bin full actuator 3 40X3688 30 1 Sensor standard bin full 4 40X0840 3 1 Switch printer left door inte...

Page 570: ...7 22 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 19 Printhead assembly Asm index Part number FRUs mach Units FRU Description 1 40X3712 1 1 Printhead assembly 1...

Page 571: ...Us mach Units FRU Description 1 40X3713 1 1 Waste toner cartridge cover 2 40X3715 1 1 Switch waste toner cartridge interlock 3 40X3717 1 1 Sensor waste toner cartridge full 4 40X3714 1 1 Waste toner c...

Page 572: ...ous Next Assembly 21 Erase lamps and developer interlock plate Asm index Part number FRUs mach Units FRU Description 1 40X3720 1 1 K erase lamp assembly 2 40X3719 3 1 CMY erase lamp assembly 3 40X3718...

Page 573: ...t lift 1 Asm index Part number FRUs mach Units FRU Description 1 40X3722 1 1 Right transfer belt lift assembly 2 40X3727 1 1 Transfer belt lift handle assembly 3 40X3723 1 1 Transfer belt lift latch a...

Page 574: ...r FRUs mach Units FRU Description 1 40X3732 1 1 Transfer belt unit assembly 2 40X3733 1 1 Transfer belt cleaner assembly 3 40X3729 1 1 Transfer belt auger front gear 14T 4 40X3731 1 1 Transfer belt au...

Page 575: ...ssembly 24 Transfer belt lift 2 Asm index Part number FRUs mach Units FRU Description 1 40X3735 4 1 Transfer belt lift rear plunger assembly 2 40X3734 8 1 Transfer belt lift recoil spring 3 40X3736 4...

Page 576: ...Part number FRUs mach Units FRU Description 1 40X3740 1 1 K toner dispense assembly 2 40X3739 1 1 C toner dispense assembly 3 40X3738 1 1 M toner dispense assembly 4 40X3737 1 1 Y toner dispense asse...

Page 577: ...26 Developer unit assemblies Asm index Part number FRUs mach Units FRU Description 1 40X6788 4 1 Developer unit assembly 2 40X3744 1 1 Y developer carrier 3 40X3745 1 1 M developer carrier 4 40X3746...

Page 578: ...al 5057 XXX Go Back Previous Next Assembly 27 Fuser assembly Asm index Part number FRUs mach Units FRU Description 1 40X4153 1 1 Fuser assembly 100 V 1 40X3747 1 1 Fuser assembly 110 V 1 40X3748 1 1 F...

Page 579: ...ng fans Asm index Part number FRUs mach Units FRU Description 1 40X3750 1 1 Fuser cooling fan 2 40X3749 1 1 Printhead shutter motor assembly 3 40X3752 1 1 Rear lower cooling fan assembly this comes as...

Page 580: ...7 32 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 29 Electrical 1 3 5 9 2 10 6 4 8 1 7...

Page 581: ...ine card assembly 3 40X3758 1 1 24 V LVPS card assembly 4 40X3763 1 1 Rear upper cooling fan 5 40X3759 1 1 24 V LVPS cooling fan 6 40X3760 1 1 CMYK transfer roll HVPS card assembly 7 40X3755 3 1 5 V L...

Page 582: ...30 Electrical 2 Asm index Part number FRUs mach Units FRU Description 1 40X3764 1 1 AC drive card bracket assembly 110 V this comes assembled 1 40X3765 1 1 AC drive card bracket assembly 220 V this c...

Page 583: ...Parts catalog 7 35 5057 XXX Go Back Previous Next Assembly 31 Electrical 3 8 9 2 3 7 10 1 5 6 4...

Page 584: ...rear right cable assembly 3 40X3774 1 1 2nd transfer charge roll cable 4 40X3771 1 1 CK transfer roll cable assembly 5 40X3770 1 1 YM transfer roll cable assembly 6 40X3772 1 1 Transfer belt charge ca...

Page 585: ...Parts catalog 7 37 5057 XXX Go Back Previous Next Assembly 32 Electrical 4...

Page 586: ...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...

Page 587: ...x Part number FRUs mach Units FRU Description 1 40X3825 1 1 Tray module right cover 2 40X3824 1 1 Tray module foot cover 3 40X4142 1 1 1TM front door assembly 4 40X3826 2 1 Tray module left cover 5 40...

Page 588: ...7 40 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 34 1TM feed unit assembly 4 3 5 4 1 2...

Page 589: ...ndex Part number FRUs mach Units FRU Description 1 40X3677 3 1 Switch media size 2 40X3676 6 1 Media tray slide 3 40X3675 3 1 Media tray catch 4 40X3678 3 6 Media tray assembly kit Media tray assembly...

Page 590: ...7 42 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 35 1TM media feed unit 3 11 13 5 9 2 10 6 4 12 1 8 6 7 14...

Page 591: ...30 1 Sensor tray media level 5 40X3684 4 1 Media feed lift motor 6 40X0888 6 1 Bushing 6 mm 7 40X0590 2 1 Pick roll assembly spring 8 40X3686 4 1 Media tray lift one way gear 9 40X3685 4 1 Media tray...

Page 592: ...er FRUs mach Units FRU Description 1 40X3818 1 1 Tray 2 feed out sensor cable assembly 2 40X3817 1 1 Sensor tray 2 feed out 3 40X3821 1 1 Switch tray module left door interlock 4 40X4141 1 1 1TM left...

Page 593: ...Parts catalog 7 45 5057 XXX Go Back Previous Next Assembly 37 1TM drive and electrical...

Page 594: ...mbly 2 40X3812 1 1 Tray module drive motor assembly 3 40X4068 1 1 Tray module left retaining bracket 4 40X4034 2 1 Tray module retainer screw 5 40X3815 1 3 Media transport gear 33T 6 40X3813 1 1 Media...

Page 595: ...Parts catalog 7 47 5057 XXX Go Back Previous Next Assembly 38 3TM covers 3 5 2 4 1...

Page 596: ...embly 38 3TM covers Asm index Part number FRUs mach Units FRU Description 1 40X3825 1 1 Tray module right cover 2 40X3824 1 1 Tray module foot cover 3 40X3826 2 1 Tray module left cover 4 40X3827 1 1...

Page 597: ...Parts catalog 7 49 5057 XXX Go Back Previous Next Assembly 39 3TM feed unit assembly 4 3 5 4 1 2 4 4...

Page 598: ...m index Part number FRUs mach Units FRU Description 1 40X3677 3 1 Switch media size 2 40X3676 6 1 Media tray slide 3 40X3675 3 1 Media tray catch 4 40X3678 3 6 Media tray assembly kit Media tray assem...

Page 599: ...Parts catalog 7 51 5057 XXX Go Back Previous Next Assembly 40 3TM media feed unit 3 11 13 5 9 2 10 6 4 12 1 8 6 7 14...

Page 600: ...688 30 1 Sensor tray media level 5 40X3684 4 1 Media feed lift motor 6 40X0888 6 1 Bushing 6 mm 7 40X0590 2 1 Pick roll assembly spring 8 40X3686 4 1 Media tray lift one way gear 9 40X3685 4 1 Media t...

Page 601: ...Parts catalog 7 53 5057 XXX Go Back Previous Next Assembly 41 3TM left door 5 8 6 1 2 3 7 4 8 4 9 9 9...

Page 602: ...bly 2 40X3817 1 1 Sensor tray 2 feed out 3 40X3821 1 1 Switch tray module left door interlock 4 40X3819 1 1 Tray 3 4 feed out sensor actuator 5 40X3820 2 1 Sensor tray 3 feed out 6 40X3820 2 1 Sensor...

Page 603: ...Parts catalog 7 55 5057 XXX Go Back Previous Next Assembly 42 3TM drive and electrical...

Page 604: ...ray module drive motor assembly 3 40X4068 1 1 Tray module left retaining bracket 4 40X4034 2 1 Tray module retainer screw 5 40X3815 1 3 Media transport gear 33T 6 40X3813 1 1 Media transport gear 23 4...

Page 605: ...TTM covers Asm index Part number FRUs mach Units FRU Description 1 40X3825 1 1 Tray module right cover 2 40X3824 1 1 Tray module foot cover 3 40X3826 2 1 Tray module left cover 4 40X3827 1 1 Tray mod...

Page 606: ...7 58 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 44 TTM media trays 3 5 4 3 7 2 6 8 1...

Page 607: ...1 label 2 label 3 label 4 label Instruction label 2 40X3830 2 1 Switch TTM media size 3 40X3831 4 1 TTM tray support roll 4 40X3829 1 3 TTM media tray 4 assembly kit TTM media tray 4 4 label Instructi...

Page 608: ...7 60 MFP Service Manual 5057 XXX Go Back Previous Next Assembly 45 TTM media tray 3 3 7 5 2 6 1 5 9 8 4 4 3...

Page 609: ...ay separation pad 2 40X3832 1 1 TTM tray 3 front cover 3 40X4126 4 1 TTM tray lift idler pulley 4 40X4127 4 1 TTM tray lift idler pulley guide 5 40X4084 4 1 TTM tray 3 lift cable 6 40X0708 2 1 TTM lar...

Page 610: ...mber FRUs mach Units FRU Description 1 40X3836 1 1 TTM tray 4 front cover 2 40X4126 4 1 TTM tray lift idler pulley 3 40X4127 4 1 TTM tray lift idler pulley guide 4 40X4085 4 1 TTM tray 4 lift cable 5...

Page 611: ...nsport Asm index Part number FRUs mach Units FRU Description 1 40X3838 1 1 TTM tray 4 media transport assembly 2 40X3679 1 1 Media feed unit assembly 3 40X3841 1 1 TTM tray 4 lower media guide 4 40X38...

Page 612: ...ts FRU Description 1 40X3817 2 1 Sensor tray 2 feed out 2 40X3843 1 1 TTM vertical turn guide 3 40X3679 1 1 Media feed unit assembly 4 40X3842 1 1 Tray 3 feed out sensor assembly this comes assembled...

Page 613: ...7 XXX Go Back Previous Next Assembly 49 TTM left door Asm index Part number FRUs mach Units FRU Description 1 40X3844 1 1 TTM left door assembly this comes assembled 2 40X3821 1 1 Switch tray module l...

Page 614: ...ift drive Asm index Part number FRUs mach Units FRU Description 1 40X3848 2 1 TTM tray lift coupling assembly 2 40X3847 2 1 TTM tray lift gear 17T 3 40X0880 2 1 Bushing 6 mm 4 40X3845 1 1 TTM tray 3 l...

Page 615: ...Parts catalog 7 67 5057 XXX Go Back Previous Next Assembly 51 TTM drive and electrical 4 8 7 6 5 8 11 3 2 1 10 9 12...

Page 616: ...or assembly 3 40X3812 2 1 Tray module drive motor assembly 4 40X4068 1 1 Tray module left retaining bracket 5 40X3815 2 1 Media transport gear 33T 6 40X3813 1 1 Media transport gear 23 46T 7 40X3814 1...

Page 617: ...S 56P2744 1 1 N4050e 802 11g Wireless Print Server Americas Argentina Brazil w out power cord NA 56P2745 1 1 N4050e 802 11g Wireless Print Server European UK Ireland Australia w out power cord NS 40X0...

Page 618: ...1 1 Marknet N8000 10 100BaseTX ethernet NS 40X1376 1 1 Marknet N8020 10 100 1000BaseT Ethernet NS 40X1377 1 1 Marknet N8030 10BaseFL 100BaseFX Ethernet multimode fiber NS 40X1378 1 1 Marknet N8050 80...

Page 619: ...Log 3 17 Print the Event Log 3 18 FINISHER TESTS Feed Tests 3 12 Hole Punch Test 3 12 Sensor Test 3 12 Staple Test 3 11 HARDWARE TESTS 3 7 Button Test 3 7 CACHE Test 3 8 DRAM Test 3 8 Panel Test 3 7...

Page 620: ...bly NVRAM failure 2 122 955 XX RIP card assembly NAND CRC failure 2 123 956 00 RIP card assembly processor failure 2 123 956 01 RIP card assembly processor over temperature failure 2 124 956 02 RIP ca...

Page 621: ...essor 1 1 R removals feed roll 4 115 pick roll 4 116 sensor media level 4 24 sensor media out 4 22 sensor RFID PC cartridge and sensor RFID toner cartridge 4 117 separation roll 4 117 switch media siz...

Page 622: ...90 4 191 4 192 4 193 S safety information ii xxiii safety inspection guide 6 1 scheduled maintenance 6 2 Service checks 2 23 service checks 900 xx System software 2 60 service error 900 xx System soft...

Page 623: ...6 mm 7 11 7 43 7 52 40X0948 Assorted E clip packet 7 69 40X0949 Assorted screw packet 7 69 40X0952 Bushing 6 mm 7 11 7 43 7 52 40X1375 Marknet N8000 10 100BaseTX ethernet 7 70 40X1376 Marknet N8020 10...

Page 624: ...MPF media out 7 13 40X3688 Sensor printer left lower door interlock 7 9 40X3688 Sensor standard bin full 7 21 40X3688 Sensor tray 1 media level 7 11 7 43 7 52 40X3688 Sensor tray 1 media out 7 11 7 4...

Page 625: ...31 40X3751 Transfer belt drive motor cooling fan 7 31 40X3752 Rear lower cooling fan assembly 7 31 40X3753 Developer transfer roll HVPS card assembly 7 33 40X3754 Charge roll HVPS card assembly 7 33 4...

Page 626: ...ensor cable assembly 7 44 7 54 7 64 40X3819 Tray 3 4 feed out sensor actuator 7 54 40X3820 Sensor tray 3 feed out 7 54 40X3820 Sensor tray 4 feed out 7 54 40X3821 Switch tray module left door interloc...

Page 627: ...08 3TM main cable assemlby 7 56 40X4109 1TM main cable assemlby 7 46 40X4111 Front left cover 7 4 40X4112 SFP relocation kit with options 7 69 40X4117 Front locking caster 7 46 7 56 7 68 40X4119 Tray...

Page 628: ...I 10 Printer Service Manual 5057 XXX Go Back Previous Next...

Page 629: ......

Page 630: ...t 3 2 1 SWITCH TTM media size 3 P549 B 12 11 10 9 8 7 6 5 4 3 2 1 B A 1 2 3 4 5 6 7 8 9 10 11 12 A 5VDC 5V RTN 5VDC 5V RTN 24VDC 24VDC 24VDC 24VDC 5V RTN 5VDC 5V RTN 5VDC 1 2 3 SENSOR media out 3 1 2...

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