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Lexmark CS748de, Service Manual

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Repair information

4-5

 

5026

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27S2837

M3.5X1.34 panhead 

8L, black

Left cover to lower frame

2

Rear left cover through lower swingout frame into left cover

1

Rear right cover to rear upper cover

1

Rear upper cover to top cover

1

Top cover to right cover

1

27S2838

Machine M3X0.5–

6GL

Contacts assembly to left/front edge of printer frame

2

Fax modem blank plate to left plate

1

ISP blank plate to left plate

2

Second USB connector to left frame

1

System board USB connector to frame

1

USB-A Blank plate to left plate

1

27S2839

Taptite M3 L6 

Taptite slotted hex 

black

Rear cover frame to frame

8

88A0003

Machine M3X0.5-

6G 8L

Printhead

3

88A0095

M2.5x10 Machine

5 V interlock switch actuator assembly

1

24 V interlock switch and shield to right frame

1

88A0212

Taptite M3.5x0.6 

PAN

Fuser AC cable's ground wire to left plate

1

88A0232

Taptite M3 L6 

PANHD

Cartridge right guide assembly to rightside plate

10

Lower plate to lower swingout frame assembly

1

Lower swingout frame assembly to left frame assembly

4

Lower frame support to right frame assembly

4

88A0233

Taptite M3 L8 

PANHD

Lower swingout frame assembly to leftside frame assembly (rearmost 

position)

1

Screw identification table (continued)

P/N

Screw type

Location

Qty

Summary of Contents for CS748de

Page 1: ...d CS748de 5026 3xx 5xx Table of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Revised July 30 2014 ...

Page 2: ...rence to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by t...

Page 3: ...er guidelines 1 14 Tools required for service 1 16 Acronyms 1 17 Diagnostic information 2 1 Start 2 1 Operator panel and menus 2 2 C746x operator panel 2 2 C746x buttons and light descriptions 2 2 C748x operator panel 2 3 C748x buttons and light descriptions 2 3 Administrative menus 2 8 Power on self test POST sequence 2 9 Symptom tables 2 9 Printer symptom table 2 9 Print quality symptom table 2 ...

Page 4: ...k 2 79 243 03 243 11 Paper Jam service check 2 80 243 05 Paper Jam service check 2 81 243 10 Paper Jam service check 2 82 243 17 Paper Jam service check 2 83 243 26 Paper Jam service check 2 84 243 27 Paper Jam service check 2 84 243 29 Paper Jam service check 2 84 244 02 Paper Jam service check 2 85 244 03 244 11 Paper Jam service check 2 86 244 05 Paper Jam service check 2 86 244 10 Paper Jam se...

Page 5: ...tray error service check 2 117 920 32 MPF paper present sensor not connected service check 2 117 925 01 925 03 925 05 Fan error service check 2 117 925 02 925 04 925 06 Cartridge cooling fan error service check 2 118 945 xx 947 xx Transfer roll error service check 2 119 950 00 950 29 EPROM mismatch failure 2 121 956 xx System board failure service check 2 122 5 V interlock switch service check 2 1...

Page 6: ...erification 3 39 Paper Jams 3 42 Error jam locations 3 42 Clearing jams 3 43 Theory of operation 3 51 Paper path 3 51 Electrophotographic EP process 3 63 Electrical interlock 3 73 Repair information 4 1 Safety information 4 1 Data Security Notice 4 1 Handling ESD sensitive parts 4 2 Handing the photoconductor unit 4 2 Transportation storage 4 2 Handling 4 2 Parts not to be touched 4 2 Screw and re...

Page 7: ... 4 120 Fuser DC cable removal 4 121 Hard drive assembly removal 4 122 High voltage power supply HVPS removal 4 123 High voltage power supply HVPS cable removal 4 125 Left bell crank assembly removal 4 126 Low voltage power supply LVPS removal 4 127 Motor driver card removal 4 129 Motor driver cable removal 4 130 Multipurpose feeder MPF duplex gear and housing removal 4 131 Multipurpose feeder MPF ...

Page 8: ...upter sensor with cable assembly removal 4 213 Top plate assembly removal 4 214 Connector locations 5 1 Locations 5 1 Connectors 5 2 System board diagram 5 2 Preventive maintenance 6 1 Safety inspection guide 6 1 Lubrication specifications 6 1 Maintaining the printer 6 1 Cleaning the exterior of the printer 6 1 Cleaning the printhead lenses 6 2 Moving the printer 6 2 Parts catalog 7 1 How to use t...

Page 9: ...betrachtet Der Drucker enthält im Inneren einen Laser der Klasse IIIb 3b AlGaAs der sichtbare Strahlung im Wellenlängenbereich von 770 bis 800 Nanometern abgibt Dieser befindet sich in einer Druckkopfeinheit die nicht gewartet werden kann Das Lasersystem und der Drucker sind so konstruiert dass unter normalen Betriebsbedingungen bei der Wartung durch den Benutzer oder bei den vorgeschriebenen Wart...

Page 10: ...ncionamiento normal mantenimiento del usuario o condición de servicio prescrita Declaração sobre Laser Este produto foi certificado nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR subcapítulo J para produtos a laser de Classe I 1 e nos demais países foi certificado como um produto a laser de Classe I em conformidade com os requisitos da IEC 60825 1 Os produtos a laser de Classe ...

Page 11: ...0 800 nanometer indkapslet i en ikke servicerbar printhovedsamling Lasersystemet og printeren er udviklet på en sådan måde at der ikke er en direkte laserstråling der overskrider Klasse I niveauet under normal brug brugers vedligeholdelse eller de foreskrevne servicebetingelser Laserilmoitus Tämä tuote on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J standardin mukaiseksi luokan I 1 lasertuo...

Page 12: ...inneholder en intern AlGaAs laser av klasse IIIb 3b som produserer synlig stråling i bølgelender på 770 800 nanometer i en ikke reparerbar skrivehodeenhet Lasersystemet og skriveren er utformet slik at mennesker ikke utsettes for laserstråling utover nivåene i klasse I under normal drift vedlikehold eller foreskrevet service Avís sobre el Làser Este producto está certificado en Estados Unidos para...

Page 13: ...Notices and safety information xiii 5026 Go Back Previous Next ...

Page 14: ...xiv Service Manual 5026 Go Back Previous Next ...

Page 15: ...nance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez Débranchez le produit avant de commencer ou faites preuve de vigilance si l exécution de la ...

Page 16: ...ación sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con...

Page 17: ...d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu t...

Page 18: ...nt problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples Change history Conventions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software There are several types of caution statements Revisio...

Page 19: ... Next Click to move the document view forward by one page Go Back Click to return to the last page viewed CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surfac...

Page 20: ...xx Service Manual 5026 Go Back Previous Next ...

Page 21: ... with etask touch screen and duplex Lexmark C748dte 5026 530 Network ready with etask touch screen duplex and 550 sheet tray Lexmark CS748de 5026 539 Network ready with etask touch screen and duplex Lexmark C746n 5026 311 Network ready Lexmark C746dn 5026 331 Network ready with duplex Lexmark C746dtn 5026 331 Network ready with duplex and 550 sheet tray Lexmark C748e 5026 511 Network ready with et...

Page 22: ... compatible with the Lexmark C73x SFP X73x MFP and X74x MFP but not with any other Lexmark printers No other options are supported by the C74x The media options include 550 Sheet Drawer This optional input source installs beneath the printer and it holds approximately 550 sheets of 20 lb paper High Capacity Input Tray This optional input source installs beneath the printer and it holds approximate...

Page 23: ...l memory card The memory options for the C746x and C748x printers are 200 pin DDR2 SODIMM and they are available at 256MB 512MB and 1GB sizes Flash memory card Flash Memory cards are available in 256MB Hard disk If larger storage is required an optional hard disk is available ...

Page 24: ...ith 550 sheet optional drawer 581 7 mm 22 9 in 435 0 mm 17 1 in 545 0 mm 21 5 in 29 7 kg 65 5 lbs C748dte printer with 550 sheet optional drawer 581 7mm 22 9 in 435 0 mm 17 1 in 545 0 mm 21 5 in 30 1kg 66 4 lbs 550 sheet drawer 169 0 mm 6 6 in 435 0 mm 17 1 in 545 0 mm 21 5 in 4 5 kg 10 0 lbs 550 sheet special media drawer 169 0 mm 6 6 in 435 0 mm 17 1 in 545 0 mm 21 5 in 4 5 kg 10 0 lbs 2000 shee...

Page 25: ...onto the system board Memory size 512MB 512MB Optional memory Optional DIMM Dual Inline Memory Module is a card that can be plugged into an available memory slot on the system board Flash memory is a card that can also be plugged into an available slot Maximum number of memory DIMM slots 1 1 Maximum number of flash memory slots 1 1 DIMM memory sizes available 256MB 512MB 1024MB 256MB 512MB 1024MB ...

Page 26: ...disk Interface for optional hard disk 1 Environment Specifications Operating Air temperature Operating 15 6 to 32 2 C 60 to 90 F Air temperature Power off 10 to 40 C 50 to 104 F Air Relative Humidity Relative humidity 8 to 80 Wet Bulb Temperature Operating 22 8 C 73 0 F Maximum Web Bulb Temperature Power off 26 7 C 80 1 F Maximum Altitude 0 3 048 meters 10 000 ft Ambient Operating Environment 15 6...

Page 27: ...ls C746dn C746dtn C748de C748dte are Energy Star Qualified All models ship with Sleep Mode On The default time out to Sleep mode is 30 minutes Web Bulb Temperature Power Off 26 7 C 80 1 F Maximum In some cases performance specifications such as paper OCF and EP cartridge usage are specified to be measured at an ambient condition Printing states C746n dn dtn Lexmark C748e de dte Off 0W 0W Sleep mod...

Page 28: ...ode 1 meter average sound pressure dBA Declared sound power level Bels C746 Idle 32 dB 4 8 Bels Simplex printing mono 53 dB 6 8 Bels Simplex printing color 54 dB 6 8 Bels Duplex printing mono 54 dB 6 9 Bels Duplex printing color 55 dB 6 9 Bels Quiet mode printing mono 48 dB 6 3 Bels Quiet mode printing color 48 dB 6 3 Bels C748 Idle 32 dB 4 8 Bels Simplex printing mono 54 dB 6 8 Bels Simplex print...

Page 29: ...han 80 g m2 21 lb Recycled paper less than 75 g m2 20 lb Preprinted papers requiring a high degree of registration Recycled paper less than 80 g m2 21 lb may cause unacceptable results Envelopes All envelopes should be new unused and without package damage Envelopes with excessive curl or twist exceeding 6 mm those stuck together those with bent corners or nicked edges or those that interlock shou...

Page 30: ...ts have been engineered to work very well in laser printers despite surface texture Before using these types of paper consult your paper supplier Suitable sheet to sheet coefficient of friction 0 4 0 6 Sufficient bending resistance in the direction of feed Recycled paper paper of lower weight 60 g m2 16 lb bond and or lower caliper 3 8 mils 0 1 mm and paper that is cut grain short for portrait or ...

Page 31: ...ty sheets 650 Optional input sources 550 Sheet Drawer sheets 550 High capacity input tray HCIT sheets 2 000 Specialty Media Drawera sheets 550 or 85 envelopes Maximum number of 550 sheet drawers including Speciality Media Drawer 4 Maximum number of high capacity input tray must be installed on the bottom 1 Maximum number of standard and optional input sources 6 Maximum capacity for standard and op...

Page 32: ...urpose feeder Optional 550 sheet tray Optional Speciality Media Optional 2000 sheet feeder HCIT Duplex Paper sizes A4 210 x 297 mm A5 148 x 210 mm A6 105 x 148 mm JIS B5 182 x 257 mm Officio Mexico 216 x 340 mm Letter 8 5 x 11 in Legal 8 5 x 14 in Statement 5 5 x 8 5 in Executive 7 25 x 10 5 in Folio 8 5 x 13 in Universal ...

Page 33: ...Letter Legal A4 Xerographic and bond Long grain 60 g m2 162 7 g m2 16 lb 43 lb Short grain 162 7 g m2 198 9 g m2 43 lb 53 2 lb Recycled Long grain 75 g m2 177 g m2 20 lb 47 lb Short grain 105 g m2 218 g m2 28 lb 58 lb Cardstock maximum Index long short 162 7 g m2 198 9 g m2 90 lb 110 lb Cover long short 162 7g m2 198 9 g m2 60 1 lb 73 6 lb Tag long short 162 7g m2 198 9 g m2 100 lb 122 2 lb Transp...

Page 34: ...se it This limits the exposure of paper to moisture changes that can degrade its performance Condition paper before printing by storing it in its original wrapper in the same environment as the printer for 24 to 48 hours before printing Extend the time several days if the storage or transportation environment is very different from the printer environment Thick paper may also require a longer cond...

Page 35: ... use paper that has been cut or trimmed by hand Do not mix paper sizes types or weights in the same source mixing results in jams Do not use coated papers unless they are specifically designed for electrophotographic printing Selecting preprinted forms and letterhead Use these guidelines when selecting preprinted forms and letterhead Use grain long for 60 to 90 g m2 16 to 20 lb weight paper Use on...

Page 36: ...a pallet or shelf rather than on the floor Store individual packages on a flat surface Do not store anything on top of individual paper packages Tools required for service Flat blade screwdrivers various sizes 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade 7 32 inch 5 5 mm open end wrench 4 0 mm Allen wrench HCIT removal 7 0 mm nut drive...

Page 37: ... Capacity Input Tray HVPS High Voltage Power Supply K Black LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply M Magenta MPF Multipurpose Feeder NVRAM Nonvolatile Random Access Memory PC Photoconductor pel Picture element pixel POR Power On Reset POST Power On Self Test RIP Raster Imaging Processor SDRAM S...

Page 38: ...1 18 Service Manual 5026 Go Back Previous Next ...

Page 39: ...in the format XXX YY In most cases five digits are shown Paper jam messages 2xx xx User attendance messages that indicate a paper jam have been included with the service error codes since repeated instances may indicate an underlying service issue Go to 2xx paper jam messages on page 2 23 User status and attendance messages User status messages provide the user with information on the current stat...

Page 40: ...Sleep button is illuminated solid amber Entering or waking from Hibernate mode The indicator light is illuminated solid green The Sleep button is illuminated blinking amber Operating in Hibernate mode The indicator light is un illuminated The Sleep button is blinking amber for 0 1 second and then goes completely un illuminated for 1 9 seconds in pulsing pattern The following actions wake the print...

Page 41: ...B port supports flash drives Use the To 1 Display View printer status Allow printer setup and operation 2 Home button Go to the home screen 3 Keypad Enter numbers and letters Use the To Indicator light status Indicates Off Printer power is off Blinking green Printer is warming up processing data or printing a job Solid green Printer is on but idle Blinking red Operator intervention is required 1 2...

Page 42: ...seconds in pulsing pattern The following actions wake the printer from Sleep mode Pressing any button Touching the screen Opening Tray 1 or loading paper in the multipurpose feeder Opening a door or cover Sending a print job from the computer Performing a Power On Reset POR with the main power switch Loading paper into the scanner ADF Raising the scanner flatbed cover 5 Stop Cancel button Stops al...

Page 43: ...ettings administrative setup and active embedded solutions Touch To 1 Up arrow Scroll up 2 Delete folder Delete the file you selected 3 Left arrow Scroll to the left 4 Right arrow Scroll to the right 5 Right scroll increase Scroll to another value in increasing order 6 Left scroll decrease Scroll to another value in decreasing order 7 Down arrow Scroll down 1 2 3 4 5 6 7 8 9 10 ...

Page 44: ...he previous screen Touch To 1 Change Language Change the primary language of the printer 2 Bookmarks Create organize and save a set of bookmarks URLs into a tree view of folders and file links Note The tree view does not include bookmarks created within Forms and Favorites and the ones in the tree are not usable in Forms and Favorites 3 Held Jobs Display all current held jobs 4 USB or USB Thumbdri...

Page 45: ...ips Open a context sensitive Help information on the touch screen Touch To Search Held Jobs Search current held jobs Features Feature Description Attendance message alert If an attendance message affects a function then this icon appears and the red indicator light blinks Warning If an error condition occurs then this icon appears Printer IP address Sample 123 123 123 123 123 The IP address of you...

Page 46: ...P Network Setup Page Print Settings1 Yellow Cartridge Substitute Size Network x Setup Page Black Cartridge Paper Loading Profiles List Cyan Photoconductor Custom Types Print Fonts Magenta Photoconductor Custom Names1 Print Directory Yellow Photoconductor Universal Setup Asset Report Black Photoconductor Waste Toner Bottle Fuser Transfer Module Security Network Ports Help Miscellaneous Security Set...

Page 47: ...6 The LED light indicator blinks 7 The loading screen displays Symptom tables Printer symptom table Symptom Action Dead printer Go to Dead printer service check on page 2 127 Operator panel one or more buttons do not work Go to One or more operator panel buttons fail on page 2 130 Operator panel display is blank Printer sounds five beeps Go to Operator panel display blank five beeps and LED is off...

Page 48: ...horizontal line on page 2 135 Insufficient fusing Go to Print quality insufficient fusing on page 2 135 Missing image at edge Go to Print quality missing image at edge on page 2 135 Mottle 2 5mm speckles Go to Print quality mottle 2 5mm speckles on page 2 135 Narrow vertical line Go to Print quality narrow vertical line on page 2 135 Random marks Go to Print quality random marks on page 2 136 Resi...

Page 49: ...supplies If job parking is enabled and the job meets all the requirements for allowing the job to be parted the printer adds this message Load source size Load paper in the indicated source and of the indicated size and select Continue Additional messages may include Show Me the printer will present instructions Cancel Job the printer job can be cancelled Wait for supplies If job parking is enable...

Page 50: ...inue Restore Held Jobs Go Stop If the printer detects Print and Hold or parked jobs stored on the hard disk during Power On Self Test POST Choices are Restore Print jobs are restored and Restoring Held Jobs x y where x is the number of the job restored and y is the total number of jobs to restore You can quit restoring and the remainder of the jobs will remain on the disk but cannot be accessed un...

Page 51: ...cable if damaged If the problem still exists replace the system board See System board removal on page 4 163 34 Short Paper Select Continue to clear the message and continue printing Note The printer does not automatically reprint the page that prompted the message Check the tray length and width guides to ensure the media is properly fitted Make sure the print job is requesting the correct size o...

Page 52: ... again replace the hard drive If this does not fix the problem replace the system board See System board removal on page 4 163 37 Insufficient Defrag Memory There is insufficient memory to perform the Flash Memory Defragment operation The user can Delete font macros and other data in memory Install additional printer memory 38 Memory Full The following options are available Select Continue to clea...

Page 53: ...r the network interface POR the printer If this does not fix the problem replace the PCI card 55 Unsupported Option in Slot x 1 Turn the printer off 2 Unplug the power cord from the wall outlet 3 Remove the unsupported option 4 Connect the power cord to a properly grounded outlet 5 Turn the printer on If this does not fix the problem replace the system board See System board removal on page 4 163 ...

Page 54: ...e printing Install a different hard disk before performing any operations that require a hard disk If this does not fix the problem replace the system board See System board removal on page 4 163 62 Disk full Select Continue to clear the message and continue processing Any information not previously stored on the hard disk is deleted Delete fonts macros and other data stored on the hard disk Insta...

Page 55: ...page 4 47 Check the cable in connector JFUSER1 for proper connection to the system board the cable for pinch points and the cable or the connector for any other damage If the connector is damaged on system board replace the system board See System board removal on page 4 163 If the fuser cable is damaged replace the cable Check for the following continuity between the DC autoconnect and FUSER1 If ...

Page 56: ...t transfer module When print quality is reduced install the new transfer module using the instruction sheet that comes with the replacement transfer module If the problem persists replace the system board See System board removal on page 4 163 83 xx Replace Transfer Module Replace the transfer module using the instruction sheet that comes with the replacement transfer module See Transfer module re...

Page 57: ...ctor unit See Photoconductor unit removal on page 4 150 Remove the top access cover assembly see Top access cover assembly removal on page 4 54 and confirm that the camshaft follower A on the left side is not out of the groove B If the camshaft follower is out of the groove raise the arm use a screwdriver to ease the camshaft follower back into the groove You need to press down to snap it into pos...

Page 58: ...ation Replace the specified toner cartridge Select Continue to clear the message and continue printing If the problem persists replace the system board See System board removal on page 4 163 88 xx color Cartridge Nearly Low Show Me View Supplies and Tell Me More displays additional information Replace the specified toner cartridge Select Continue to clear the message and continue printing If the p...

Page 59: ... go to 111 xx 112 xx 113 xx and 114 xx Printhead error service check on page 2 46 120 00 120 21 Fuser Error An error has occurred in the fuser Remove and reseat the fuser See Fuser removal on page 4 118 POR the printer If the error message persists go to 120 xx Fuser error service check on page 2 47 140 01 140 10 Autocomp Motor Error Tray 1 motor has failed POR the printer If the error message per...

Page 60: ... 2 service check on page 2 60 161 01 161 06 Motor Error Tray 2 feed motor failed POR the printer If the error message persists go to 160 xx 161 xx Motor Error option tray 2 service check on page 2 60 162 01 162 06 Motor Error Tray 3 pick motor failed POR the printer If the error message persists go to 162 xx 163 xx Motor Error option tray 3 service check on page 2 61 163 01 163 06 Motor Error Tray...

Page 61: ...ting Incorrect paper loading Incorrect media restraint setting Transport belt module failure Lower guide failure Paper pick mechanism failure Input sensor failure 1 Clear away anything in the paper path that might cause the paper to jam 2 Ensure proper media is set for the type of paper used 3 Fan media and stack flat in the tray 4 Properly set media restraints in the paper tray 5 Check the pick a...

Page 62: ...g started Possible causes Paper jam leaving page over sensor Damaged bubble sensor Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system board 1 Clear away anything in the paper path that might cause the paper to jam 2 Ensure proper media is set for the type of paper used 3 Fan media and stack flat in the tray 4 Properly set media restraints in the paper tray If the...

Page 63: ...e paper tray 4 Clear away anything in the paper path that might cause the paper to jam If the problem persists go to Bubble sensor service check on page 2 125 201 21 Cartridge motor 1 top or cartridge motor 2 middle has stalled Possible causes Faulty cable connector Faulty cartridge motor Faulty system board Check for anything in the paper path that might cause the paper to jam If clearing a paper...

Page 64: ...e fuser exit sensor may not be functioning properly Go to 920 08 Exit sensor service check on page 2 103 202 13 Exit sensor never broke Possible causes Damaged paper exit sensor or paper exit sensor flag Faulty fuser Faulty system board Faulty output bin flag Check exit sensor flag on fuser for proper operation Ensure that paper is not hanging on the flag The fuser exit sensor may not be functioni...

Page 65: ...xit sensor service check on page 2 103 203 15 During duplex printing the exit sensor never broke Possible causes Damaged paper exit sensor or paper exit sensor flag Obstructed duplex Faulty fuser Faulty system board Duplex motor failure Faulty bin full sensor Check the duplex paper path for damage that would obstruct the print If damage is found replace the front door assembly See Front door assem...

Page 66: ...cause the paper to jam 2 Ensure proper media is set for the type of paper used 3 Fan media and stack it flat in the tray or multipurpose feeder 4 Properly set media restraints in paper tray 5 Check the pick arm rolls tires and replace if worn If the problem persists go to 200 11 250 03 Paper Jam error service check on page 2 65 241 05 While feeding from tray 1 the input sensor is never made Possib...

Page 67: ...tray 2 Check for anything in the paper path that might cause the paper to jam The exits pass thru sensor may not be functioning properly Go to 242 10 Paper Jam service check on page 2 75 242 11 Tray 2 sensor never broke Possible causes Incorrect tray 2 media setting Incorrect Tray 2 paper loading Incorrect media restraint setting Paper tray 2 failure Aligner failure Transport belt module failure L...

Page 68: ...is paper tray 2 assembly failure Make sure that tray 2 is correctly inserted Go to 242 29 Paper Jam service check on page 2 78 242 30 Tray 2 page reached pass through sensor early Possible cause Incorrect paper loading Paper pick mechanism failure Pick arm roll damaged Defective pass through sensor Input option damaged 1 Remove all media present in the paper path 2 Ensure proper media is set for t...

Page 69: ...r anything in the paper path that might cause the paper to jam The exit pass thru sensor may not be functioning properly Go to 243 10 Paper Jam service check on page 2 82 243 11 Tray 3 sensor never broke Possible causes Incorrect tray 3 media setting Incorrect tray 3 paper loading Incorrect media restraint setting Paper tray failure Aligner failure Transport belt module failure Loading card stock ...

Page 70: ...bly failure Make sure that tray 3 is correctly inserted If the problem persists go to 243 29 Paper Jam service check on page 2 84 243 30 Tray 3 page reached pass through sensor early Possible cause Incorrect paper loading Paper pick mechanism failure Pick arm roll damaged Defective pass through sensor Input option damaged 1 Remove all media present in the paper path 2 Ensure proper media is set fo...

Page 71: ...f the problem persists go to 244 05 Paper Jam service check on page 2 86 244 10 Tray 4 page exit pass thru made early Possible causes Defective pass thru sensor Faulty cable in connector OPT1 Make sure proper media is set for the type of paper used in tray 4 Check for anything in the paper path that might cause the paper to jam The exit pass thru sensor may not be functioning properly Go to 244 10...

Page 72: ...age 2 88 244 27 While feeding from a lower tray tray 4 pass thru sensor did not break Possible cause is paper tray 4 assembly failure Clear away anything in the paper path that might cause the paper to jam Reseat option tray 4 If the problem persists go to 244 27 Paper Jam service check on page 2 89 244 29 Tray 4 is not ready or missing while printing Possible cause is paper tray 4 assembly failur...

Page 73: ...e pick arm rolls tires in tray 5 and replace if worn If the problem persists go to 245 05 Paper Jam service check on page 2 91 245 10 Tray 5 page exits pass thru sensor broken early Possible causes Defective pass thru sensor Faulty cable in connector JOPT1 on the system board Make sure the proper media is set for the type of paper used in tray 5 Check for anything in the paper path that might caus...

Page 74: ...or during input options warm up Possible damage Obstruction on the pass through sensor Damage on the pass through sensor and flag Input option damaged Damaged option autoconnect cable Damaged system board Go to 242 32 243 32 244 32 245 32 Paper Jam service check on page 2 79 250 03 While feeding from the multipurpose feeder the input sensor did not break Possible causes Incorrect media setting Inc...

Page 75: ...d failure Defective media present sensor 1 Remove all the media present in the paper path 2 Ensure proper media is set for the type of paper used 3 Fan media and stack it flat in the tray or multipurpose feeder 4 Properly set media restraints in the multipurpose feeder If the previous actions do not fix the problem go to 146 xx 148 xx Motor MPF duplex error service check on page 2 55 Error code De...

Page 76: ...tware errors POR the printer If the error message persists replace the system board See System board removal on page 4 163 904 01 904 04 Software Error Unrecoverable system software errors POR the printer If the error message persists replace the system board See System board removal on page 4 163 905 00 905 99 Software Error Unrecoverable system software errors POR the printer If the error messag...

Page 77: ...nnected error service check on page 2 104 920 10 POST Error Three toner sensors are not connected POR the printer If the error message persists go to 920 10 POST Three toner sensors not connected error service check on page 2 105 920 11 POST Error Two toner sensors are not connected POR the printer If the error message persists go to 920 11 POST power on self test Two toner sensors not connected e...

Page 78: ... page 2 111 920 21 POST Error 24 V power supply failure POR the printer If the error message persists replace the low voltage power supply See Low voltage power supply LVPS removal on page 4 127 920 22 POST Error Fuser bubble sensor is not connected If the error message persists go to Bubble sensor service check on page 2 125 920 23 POST Error Duplex motor is not connected POR the printer If the e...

Page 79: ...18 925 03 Fan Error Fan has stalled POR the printer If the error message persists go to 925 01 925 03 925 05 Fan error service check on page 2 117 925 04 Blower Error Blower has stalled POR the printer If the error message persists go to 925 02 925 04 925 06 Cartridge cooling fan error service check on page 2 118 925 05 Fan Error Fan has stalled POR the printer If the error message persists go to ...

Page 80: ...essage persists go to 950 00 950 29 EPROM mismatch failure on page 2 121 951 01 951 99 NVRAM Failure System board NVRAM failure POR the printer If the error message persists replace the system board See System board removal on page 4 163 952 01 952 99 NVRAM Error CRC error has occurred This is recoverable Perform a POR to clear the error 953 01 953 99 NVRAM Failure Operator panel assembly NVRAM fa...

Page 81: ...r If the error message persists replace the system board See System board removal on page 4 163 963 00 963 99 Memory Failure Memory failure POR the printer If the error message persists replace the system board See System board removal on page 4 163 964 00 964 88 Emulation Error Download emulation CRC error POR the printer If the error message persists download code a second time 975 00 975 99 Net...

Page 82: ...9 device Communications Error Invalid command parameter by specified device POR the printer If the error message persists replace the system board See System board removal on page 4 163 990 00 990 29 Option Error Contact your next level of support 991 00 991 29 device Error Specified device has detected an error POR the printer If the error message persists replace the system board See System boar...

Page 83: ...ell crank Note Only replace the parts that are damaged Go to step 6 6 1 Check JSB1 on the system board for proper connection 2 Check for damage and pinch points on the connector 3 Reseat cable Is the cable connector free of damaged Replace the cartridge contact with bell crank Note Only replace the parts that are damaged Go to step 7 7 Check the whole length of the cable going to the cartridge con...

Page 84: ... Yes No 1 View the Event Log 1 Turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Select EVENT LOG 3 Select Display Log Has an 111 xx 112 xx 113 xx or 114 xx error occurred three times or more Replace the printhead See Printhead removal installation and adjustment on page 4 153 Go to step 2 2 Turn the printer off and then remove the rear frame cover See Rear frame cover...

Page 85: ... the switch for the proper country voltage 2 1 Remove the fuser See Fuser removal on page 4 118 2 Check the fuser AC autoconnect cable for damage check the other end of the cable for damaged pins 3 Check the fuser DC autoconnect cable for damaged pins Are the connections damaged Replace the appropriate cable See Fuser AC cable removal on page 4 120 or Fuser DC cable removal on page 4 121 Go to ste...

Page 86: ... removal on page 4 127 Go to step 6 6 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 163 Go to step 7 7 Check for the following continuity between the DC autoconnect JFUSER1 on the system board Is continuity present Go to step 8 Replace the fuser DC cable See Fuser DC cable removal on page 4 ...

Page 87: ...val on page 4 163 Go to step 3 3 1 Disconnect the cable in the connector JFDPCK1 2 Connect the cable for the new paper pick mechanism 3 Bring the printer up in Diagnostics Menu Turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Navigate to MOTOR TESTS Tray 1 Did the new pick motor turn before the feed error occur Replace the paper pick mechanism See Paper pick mechanism...

Page 88: ...rify if the new cable is working properly If new cable does not correct problem do not install it Did the error clear Problem resolved Go to step 4 4 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 163 Go to step 5 5 1 Plug the cartridge motor1 fuser motor cable to a new EP drive assembly 2 Br...

Page 89: ...le A for proper connection to the EP drive assembly for pinch points for the cable or damage to the cable or connector Is either cable damaged Replace the cartridge motor 1 fuser motor cable See Cartridge motor 1 fuser cable removal on page 4 74 Go to step 3 3 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board rem...

Page 90: ... 6 6 1 Connect the new EP drive assembly with a new cable from outside the machine 2 Run diagnostics motor check Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 3 Select MOTOR TESTS Did motor run Replace the cable Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Turn the printer o...

Page 91: ...and on the system board 3 Run diagnostics motor check Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Select MOTOR TESTS Did the motor run Replace the cartridge motor 2 3 cable See Cartridge motor 2 3 cable removal on page 4 77 Go to step 5 5 1 Return the old cartridge motor 2 3 motor cable 2 Disconnect the motor drive cable f...

Page 92: ...to the EP drive assembly pinch points for the cable and damage to the cable or connector A Is either cable damaged Replace the cartridge motor 2 3 cable See Cartridge motor 2 3 cable removal on page 4 77 Go to step 3 3 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 163 Go to step 4 4 1 Discon...

Page 93: ...STS Did motor run Replace the cable Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Open the rear frame cover 2 Reseat JDX1 cable Does the problem persist Go to step 2 Problem resolved 2 1 Remove the tray 2 Check the MPF duplex gear for any damage 3 Check if the MPF duplex gear can engage the duplex drive gear 4 Manually turn the gear and check for...

Page 94: ...gate to MOTOR TESTS MPF Test Forward or Reverse Note Perform this test for 5 to 10 seconds only 6 Check if the motor would turn for each test Does the error still exist Go to step 6 Replace the MPF duplex motor assembly See Multipurpose feeder MPF duplex motor assembly removal on page 4 133 6 Connect a new MPF motor cable to the old MPF motor and connect it to JDX1 connector on the system board Do...

Page 95: ... the printer press and hold buttons 3 and 6 then turn on the printer 4 Lift the MPF pick arm using the lever 5 Select MOTOR TESTS MPF Forward 6 Check if the pick arm would turn Is the MPF pick arm assembly free of damage Go to step 10 Replace the input tray 10 Remove the input tray and insert a new one Does this fix the problem Problem resolved Replace the system board See System board removal on ...

Page 96: ...the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Check the motor driver cable in connector JDVR1 on the system board for proper connection for cable pinch points and for any other damage to the cable or connector Is the cable damaged Replace the motor driver cable...

Page 97: ...o step 6 6 1 Connect a new motor driver card without mounting it to the printer 2 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 3 Navigate to MOTOR TESTS CAM Did the motor run Install the new motor driver card Go to step 7 7 1 Reinstall old motor driver card to the printer 2 Plug in the CAM motor of the EP drive assembly to th...

Page 98: ...mbly 2 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 3 Navigate to MOTOR TESTS COD Forward If nothing happens select Reverse Did the COD motor pass the test Replace the COD assembly See Color on demand assembly removal on page 4 78 Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 ...

Page 99: ...ttons 3 and 6 then turn on the printer 4 Navigate to PRINT TESTS Tray 3 Single Did the page print Problem resolved Go to step 2 2 1 Remove all input options connected to the machine 2 Connect tray 3 directly on the printer making it tray 2 3 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 and turn on the printer 4 Navigate to PRINT TESTS Tray 2 Single D...

Page 100: ...ption tray 4 3 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Navigate to PRINT TESTS Tray 4 Single Did the page print Problem resolved Go to step 2 2 1 Remove all input options connected to the machine 2 Connect tray 3 directly on the printer making it tray 2 3 Bring the printer up in Diagnostics Menu turn off the printer pr...

Page 101: ...e assembly Step Questions actions Yes No 1 1 Turn the printer off 2 Reseat option tray 5 3 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Navigate to PRINT TESTS Tray 5 Single Did the page print Problem resolved Go to step 2 2 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Che...

Page 102: ...k Previous Next 4 Is the option tray 5 the high capacity input tray 2 000 sheet feeder Replace the HCIT top plate assembly See Top plate assembly removal on page 4 214 Replace the option tray 5 assembly Step Questions actions Yes No ...

Page 103: ...r off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Check the option cable in connector JOPT1 on the system board for proper connection for cable pinch points and for any other damage to the cable or connector Is the cable damaged Replace the option cable See Option cable removal on page 4 143 Go to step 4 4 1 Remove the HCIT right cover See HCIT right cover removal on ...

Page 104: ...6 then turn on the printer 3 Navigate to MOTOR TESTS Align Motor Test Forward Can you hear the align motor run Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 145 Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 Open the front access door Turn the transport belt gear clockwise Did the transport belt move Go to step...

Page 105: ... 2 Turn the printer off 3 POR the printer Did the error clear Problem resolved Replace the original fuser and go to step 6 6 Remove the rear frame cover See Rear frame cover removal on page 4 47 Check the fuser DC cable in the connector JFUSER1 for proper connection to the system board for pinch points and for any other damage to the cable or the connector Is the cable damaged Replace the fuser DC...

Page 106: ...ace the fuser See Fuser removal on page 4 118 2 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 3 Navigate to SENSOR TESTS Dynamic Sensors Fuser Exit 4 Open the front access door and the top access cover Did the fuser exit sensor change from Open to Closed Problem resolved Replace the system board See System board removal on pag...

Page 107: ...on page 4 118 Go to step 3 3 Verify the paper is loaded properly in the paper tray or manual feed slot Is the paper properly loaded Go to step 4 Load paper correctly 4 Replace the fuser See Fuser removal on page 4 118 POR the printer Did the error clear Problem resolved Remove the new fuser and go to step 5 5 1 Remove the rear frame cover See Rear frame cover removal on page 4 47 2 Check the fuser...

Page 108: ...the system board 3 Does the meter read 5 V dc Go to step 7 Replace the system board See System board removal on page 4 163 7 Place a voltmeter between the fuser autoconnect pin 8 and ground 6 Does the meter read 5 V dc Go to step 8 Replace the fuser DC cable See Fuser DC cable removal on page 4 121 Step Questions actions Yes No Pin 6 ground Pin 8 ...

Page 109: ...maged Replace the tray Go to step 2 2 Check the MPF duplex gear for any damage Is the MPF Duplex gear damaged Replace the MPF duplex gear See Multipurpose feeder MPF duplex gear and housing removal on page 4 131 Go to step 3 3 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Check the MPF duplex motor cable in connector JDX1 for proper connection to ...

Page 110: ...aged Replace the front door assembly See Front door assembly removal on page 4 108 Go to step 8 8 1 Remove the right cover See Right cover removal on page 4 51 2 Check the MPF duplex motor assembly for proper installation 3 Check the connectors Reseat the connector on the motor side and JDX1 on the system board Is the MPF duplex motor assembly damage Replace the MPF duplex motor assembly See Multi...

Page 111: ... Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Select PRINT TESTS 3 Select a tray below tray 2 4 Select Single Did the page feed correctly Problem resolved Go to step 2 2 1 Turn the printer off 2 Open the front access door 3 Turn the transport belt gear clockwise Did the transport belt move Go to step 3 Replace the transport belt See Transfer module removal on...

Page 112: ...inter press and hold buttons 3 and 6 then turn on the printer 2 Navigate to PRINT TESTS select a tray below tray 2 Single Did the page feed correctly Problem resolved Go to step 3 3 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Remove the right cover See Right cover removal on page 4 51 4 Check the cable in connector JOPT1 for proper connection to...

Page 113: ...the tray 2 option Does the error clear Problem resolved Replace the system board See System board removal on page 4 163 7 Replace the HCIT top plate See Top plate assembly removal on page 4 214 Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and ...

Page 114: ...per connection to the system board cable pinch points and any other damage to the cable or connector Is the cable damaged Replace the option cable See Option cable removal on page 4 143 Go to step 3 3 Carefully lift the printer off the option and lay the printer on its back Check the option connector for damage Is the option cable connector or cable damaged Replace the option cable See Option cabl...

Page 115: ...on For HCIT input option replace the HCIT top plate assembly See Top plate assembly removal on page 4 214 Go to step 3 3 For 550 input option install a new 550 input option For HCIT input option install a new top plate assembly See Top plate assembly removal on page 4 214 Does this fix the problem For 550 input option replace the 550 input option For HCIT input option replace the HCIT top plate as...

Page 116: ...e Go to step 3 Replace the transport belt See Transfer module removal on page 4 179 3 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate to MOTOR TESTS Align Motor Test Can you hear the align motor run Replace the complete tray 2 option Replace the paper pick mechanism See Paper pick mechanism assembly removal on page ...

Page 117: ...the system board See System board removal on page 4 163 Go to step 3 3 For 550 input option try installing an new 550 input option For HCIT input option install a new top plate assembly to verify the problem Does this fix the problem For 550 input option replace the 550 input option assembly For HCIT input option replace the top plate assembly See Top plate assembly removal on page 4 214 Go to ste...

Page 118: ...143 Go to step 3 3 Carefully lift the printer off the option and lay the printer on its back Check the option connector for damage Is the connector damaged Replace the option cable See Option cable removal on page 4 143 Go to step 4 4 Replace the complete tray 3 option Does the error clear Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes N...

Page 119: ...s Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate to PRINT TESTS select a tray below tray 3 Single Did the page print correctly Problem resolved Go to step 3 3 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Remove the right cover See Right cover removal on page 4 51 4 Check the connector at JOPT1 on the ...

Page 120: ...ce the complete tray 3 option Does the error clear Problem resolved Replace the system board See System board removal on page 4 163 7 Replace the high capacity input tray 2 000 sheet feeder Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 th...

Page 121: ... proper connection to the system board cable pinch points and any other damage to the cable or connector Is the cable damaged Replace the option cable See Option cable removal on page 4 143 Go to step 3 3 Carefully lift the printer off the option and lay the printer on its back Check the option connector for damage Is the option cable connector or cable damaged Replace the option cable See Option ...

Page 122: ...14 Replace the complete tray 4 option Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate to PRINT TESTS select a tray below tray 4 Single Did the page feed correctly Problem resolved Replace the complete tray 4 option Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics ...

Page 123: ...T1 for proper connection to the system board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the option cable See Option cable removal on page 4 143 Go to step 3 3 1 Carefully lift the printer off the options and lay the printer on its back 2 Check the option connector for damage Is the connector damaged Replace the option cable See Option ca...

Page 124: ...omplete tray 4 option Step Questions actions Yes No 1 Has paper been fed from an input option before Go to step 5 Go to step 2 2 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate to PRINT TESTS select a tray below tray 3 Single Did the page print correctly Problem resolved Go to step 3 3 1 Turn the printer off 2 Remov...

Page 125: ...s the error clear Problem resolved Replace the system board See System board removal on page 4 163 7 Replace the high capacity input tray 2 000 sheet feeder Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate...

Page 126: ...arefully lift the printer off the option and lay the printer on its back Check the option connector for damage Did the page feed correctly Replace the option cable See Option cable removal on page 4 143 Go to step 4 4 Is tray 4 an high capacity input tray HCIT Replace the HCIT top plate See Top plate assembly removal on page 4 214 Replace the complete tray 4 option Step Questions actions Yes No 1 ...

Page 127: ...on the printer 2 Navigate to PRINT TESTS select a tray below tray 4 Single Did the page feed correctly Problem resolved Replace the complete tray 4 option Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate to PRINT TESTS Tray 4 Single Did the page feed correctly Problem resolved Go to st...

Page 128: ... for proper connection to the system board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the option cable See Option cable removal on page 4 143 Go to step 3 3 Carefully lift the printer off the options and lay the printer on its back Check the option connector for damage Is the connector damaged Replace the option cable See Option cable re...

Page 129: ...omplete tray 5 option Step Questions actions Yes No 1 Has paper been fed from an input option before Go to step 5 Go to step 2 2 1 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 2 Navigate to PRINT TESTS Tray 5 Single Did the page feed correctly Replace the option cable See Option cable removal on page 4 143 Go to step 3 3 1 Tu...

Page 130: ...mplete tray 5 option Does the error clear Problem resolved Replace the system board See System board removal on page 4 163 7 Replace the HCIT top plate See Top plate assembly removal on page 4 214 Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Bring the printer up in Diagnostic menu turn off the printer press and hold buttons 3 an...

Page 131: ...OPT1 for proper connection to the system board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the option cable See Option cable removal on page 4 143 Go to step 3 3 Carefully lift the printer off the options and lay the printer on its back Check the option connector for damage Is the connector damaged Replace the option cable See Option cabl...

Page 132: ...ecting the firmware logs Fwdebug and logs tar gz from the SE menu Notes Make sure your printer is connected to a network or to a print server Some printers are designed to restart automatically after a 9yy error On these printers you can retrieve the secondary crash code information using the SE menu Fwedebugs can also be referred to as LBtrace If FWEdebugs does not appear in the list then look fo...

Page 133: ...end it to your next level of support D Collecting information from the user Ask the user for information about the following Print job being run Operating system used Print driver used Other information on what was happening when the 9yy error occurred 900 00 900 99 except 900 05 System software error service check Note Make sure to perform the Steps before starting the 9yy service checks on page ...

Page 134: ...o to step 31 6 Print the following Error log Menu settings page Network settings page Does the 900 xx error reoccur while these pages were printing Go to step 31 Go to step 7 7 Re attach the communications cable Restart the printer to operating mode Send the printer a print job Does the 900 xx error reoccur Note Before performing this step write down this information about the file being sent to t...

Page 135: ...e modem Restart the device Does the 900 xx error reoccur Go to step 31 Problem resolved 20 Run a fax job Does the 900 xx error reoccur Go to step 31 Go to step 21 21 Are there any ISP internal solutions port options installed Go to step 22 Problem resolved 22 Reinstall the first ISP option Restart the device Does the 900 xx error reoccur Go to step 24 Go to step 23 23 Run a job to test the option ...

Page 136: ...tep Questions actions Yes No 1 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Check the transport cable in connector JTPS1 for proper connection to the system board 4 Open the front access door and check the transport cable for pinch points and any other damage to the cable or connector Is the cable damaged Replace the transport cable See Transport...

Page 137: ...age 4 181 5 Connect a new printhead assembly from outside of the printer and verify the printhead See Printhead verification on page 3 39 Does the problem persist Replace the system board See System board removal on page 4 163 Replace the printhead assembly See Printhead removal installation and adjustment on page 4 153 Step Questions actions Yes No 1 Open the front access door Reseat the transpor...

Page 138: ...otor 1 fuser cable in connector JCARTP1 and JCARTS1 for pinch points and the cables or connectors for any other damage Are the cables damaged Replace the cartridge motor1 fuser cable See Cartridge motor 1 fuser cable removal on page 4 74 Go to step 3 3 Remove the right cover See Right cover removal on page 4 51 Check the cartridge motor 1 fuser motor cable A for proper connection to the EP drive a...

Page 139: ... to step 3 3 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 163 Go to step 4 4 1 Perform the printhead verification to check whether the new printhead solves the problem See Printhead verification on page 3 39 2 Navigate to PRINTHEAD TESTS Mirror Motor Test Did the mirror motor pass the test ...

Page 140: ...JTRAY1 Does the error clear Problem resolved Go to step 2 2 Check the cable in connector JTRAY1 for pinch points and the cable or connector for any other damage Is the cable damaged Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 145 Go to step 3 3 POR the printer Place a voltmeter between JTRAY1 pin 4 and ground pin 1 Does the meter read 5 V dc Go to step 4 Re...

Page 141: ...ee Fuser removal on page 4 118 Remove the new fuser and go to step 3 3 Remove the rear frame cover See Rear frame cover removal on page 4 47 Check the fuser DC cable in the connector JFUSER1 for proper connection to the system board for pinch points and for any other damage to the cable or the connector Is the cable damaged Replace the fuser DC cable See Fuser DC cable removal on page 4 121 Go to ...

Page 142: ... fuser exit sensor change from Open to Closed Replace fuser and reset the fuser count See Fuser removal on page 4 118 Replace the system board See System board removal on page 4 163 Step Questions actions Yes No 1 1 Turn the printer off 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Reseat the cable in connector JHVPS1 Does the error clear Problem resolved Go to step 2 2...

Page 143: ...p 5 Replace the failing toner level sensors See Toner level sensor removal on page 4 171 5 Replace the HVPS board See High voltage power supply HVPS removal on page 4 123 Does the error clear Problem resolved Go to step 6 6 1 Install the old HVPS back to the machine 2 Replace the HVPS cable See High voltage power supply HVPS cable removal on page 4 125 Does the problem persist Replace the system b...

Page 144: ...ailing toner level sensors See Toner level sensor removal on page 4 171 5 Replace the HVPS board See High voltage power supply HVPS removal on page 4 123 Does the error clear Problem resolved Go to step 6 6 1 Install the old HVPS back to the machine 2 Replace the HVPS cable See High voltage power supply HVPS cable removal on page 4 125 Does the problem persist Replace the system board See System b...

Page 145: ...number of failing sensors Keep the old sensor which does not reduce the failing number leaving three new sensors and no error reported Does the problem persist Go to step 5 Replace the failing toner level sensors See Toner level sensor removal on page 4 171 5 Replace the HVPS board See High voltage power supply HVPS removal on page 4 123 Does the error clear Problem resolved Go to step 6 6 1 Insta...

Page 146: ...ed to the rear of the HVPS for damages and if they are installed correctly Does the problem persist Go to step 4 Problem resolved 4 Connect four new toner level sensors outside the machine and perform a POR Note Keep track of which sensors change the error code to reduce the number of failing sensors Keep the old sensor which does not reduce the failing number leaving three new sensors and no erro...

Page 147: ...ion to the EP drive assembly pinch points for the cable or any other damage to the cable or connector Is either cable damaged Replace the cartridge motor 1 fuser motor cable See Cartridge motor 1 fuser cable removal on page 4 74 Go to step 4 4 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 16...

Page 148: ...e for the proper connection to the EP drive assembly pinch point for the cable or damage to the cable or connectors Is either cable damaged Replace the cartridge motor 2 3 cable See Cartridge motor 2 3 cable removal on page 4 77 Go to step 4 4 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 16...

Page 149: ...e problem persist Return the old transport belt module and old transport cable then replace the system board See System board removal on page 4 163 Return the old transport belt module and replace the transport cable See Transport cable removal on page 4 181 Step Questions actions Yes No 1 Turn the printer off and then remove the rear frame cover See Rear frame cover removal on page 4 47 Reseat th...

Page 150: ...nector Is the cable damaged Replace the bin full sensor with cable See Bin full sensor removal on page 4 65 Go to step 3 3 1 Disconnect the cable in the JBIN1 connector 2 Connect the new bin full flag cable in the JBIN connector 3 Bring the printer up in Diagnostic menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Navigate to SENSOR TESTS Other Sensors Bin Full Te...

Page 151: ... cable from outside of the machine then POR the printer Note Verify first if the cable is working properly by testing connections of the cable on motor 2 and 3 to the JCARTP2 and JCARTS2 connectors Route the cables properly only when you have verified that the cables are working properly Did the error clear Replace the cartridge motor 2 3 cable See Cartridge motor 2 3 cable removal on page 4 77 Go...

Page 152: ...g properly Did this clear the error Replace the motor driver cable See Motor driver cable removal on page 4 130 Go to step 5 5 Connect a new transport motor cable Did this clear the error Return the original part from the printer and replace the transport motor cable See Transport motor cable removal on page 4 183 Go to step 6 6 Connect a new motor driver card Did this clear the error Return the o...

Page 153: ...em resolved Go to step 4 4 1 Disconnect the cable in connector JCVR1 2 Connect a new 24 V interlock switch without properly routing the cables Note The 24V interlock switch should be plugged in without installing inside the machine Close the covers manually actuate the switch and then turn on the machine Did the error clear Replace the 24 V interlock switch See 24 V interlock switch removal on pag...

Page 154: ...otor cable in connector JDX1 for pinch points and any other damage to the cable or connector Check both ends of the cable Is the cable damaged Replace the MPF duplex motor cable See Multipurpose feeder MPF duplex motor cable removal on page 4 136 Note Make sure to verify if the new cable is working properly first Route the cables properly only when you have verified that the cables are working pro...

Page 155: ... step 2 2 1 Check the connection on the paper present sensor side 2 Check for damage and pinch points on the cable 3 Reseat cable Did this fix the problem Problem resolved Go to step 3 3 Replace the MPF paper present sensor See Multipurpose feeder MPF paper present sensor on page 4 137 Note Before replacing a part always verify by connecting the part outside of the machine Did the error clear Prob...

Page 156: ...ver removal on page 4 47 Check the cable in connector JBLW1 for proper connection to the system board for pinch points and any other damage to the cable or connector and reseat the cable Did the error clear Problem resolved Go to step 2 2 Measure the continuity across all of the fuses on the system board Are any of the fuses blown Replace the system board See System board removal on page 4 163 Go ...

Page 157: ...nection to the system board the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the HVPS cable See High voltage power supply HVPS cable removal on page 4 125 Go to step 3 3 Disconnect JHVPS1 from system board and HVPS Check for the following continuity Go to step 4 Replace the HVPS cable See High voltage power supply HVPS cable removal on page 4 ...

Page 158: ...1 and magenta2 or black1 and black2 on the transfer contact assembly Go to step 5 Replace the transfer contact assembly Is continuity present 5 Replace the HVPS See High voltage power supply HVPS removal on page 4 123 Does the error clear Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes No yellow2 cyan2 magenta2 black2 yellow1 cyan1 magent...

Page 159: ...the top access cover assembly been replaced recently Replace the top access cover assembly with a new and not previously installed operator panel assembly See Top access cover assembly removal on page 4 54 Go to step 3 3 Has the system board been replaced recently Replace the system board with a new and not previously installed system board See System board removal on page 4 163 Go to step 4 4 Tur...

Page 160: ...message still displayed Replace the system board See System board removal on page 4 163 Problem resolved Step Questions actions Yes No 1 Turn the printer off and remove the rear frame cover See Rear frame cover removal on page 4 47 Check the cable in connector J49 for proper connection to the system board Is the cable seated correctly Replace the system board See System board removal on page 4 163...

Page 161: ...oints and for any other damage to the cable or connector Is the cable damaged Replace the 5 V interlock switch See 5 V interlock switch cable removal on page 4 61 Go to step 3 3 1 Disconnect the cable in connector JINT1 2 Connect the new 5 V interlock switch to JINT1 3 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Activate t...

Page 162: ...for any other damage to the cable or connector Is the cable damaged Replace the 24 V interlock switch See 24 V interlock switch removal on page 4 63 Go to step 3 3 1 Disconnect the cable in connector JCVR1 2 Connect the new 24 V interlock switch to the connector JCVR1 3 Bring the printer up in Diagnostics Menu turn off the printer press and hold buttons 3 and 6 then turn on the printer 4 Activate ...

Page 163: ...e to the cable or connector Is the cable damaged Replace the fuser DC cable See Fuser DC cable removal on page 4 121 Note Make sure to verify if the new cable is working properly first Route the cables properly only when you have verified that the cables are working properly Go to step 3 3 Place a voltmeter between the fuser DC autoconnect pin 3 and ground pin 6 Does the voltage meter read 5 V dc ...

Page 164: ...e printer press and hold buttons 3 and 6 then turn on the printer 3 Navigate to SENSOR TESTS Dynamic Sensors Bubble 4 Open the front door 5 Activate the bubble sensor Did the bubble sensor change from Open to Closed Problem resolved Replace the system board See System board removal on page 4 163 Step Questions actions Yes No ...

Page 165: ...he line voltage correct Go to step 2 Inform the customer 2 Is the AC line cord damaged Replace the line cord Go to step 3 3 Check the system board for 5 V dc between JLVPS2 pin 1 and ground Is the voltage correct Replace the system board See System board removal on page 4 163 Go to step 4 4 Is the JLVPS2 cable correctly installed at JLVPS2 on the system board Go to step 5 Reseat the JLVPS2 cable 5...

Page 166: ...e LAN use DHCP Note A printer should use a static IP address on a network Go to step 7 Go to step 9 7 Are the first two segments if the IP address 169 254 Go to step 8 Go to step 9 8 POR the printer Is the problem resolved Problem resolved Go to step 10 9 Reset the address on the printer to match the IP address on the driver Did this resolve the issue Problem fixed Go to step 10 10 Have the networ...

Page 167: ...nicating properly Go to step 18 Contact the network administrator 18 Verify that the ISP wireless card cable is properly seated in their connectors Is the wireless card seated correctly Go to step 20 Go to step 19 19 Properly reseat the ISP cables Did this fix the problem Problem resolved Go to step 20 20 Replace the ISP wireless card See Installing an Internal Solutions Port ISP Did this fix the ...

Page 168: ...he operator panel assembly cable from JOPP1 on the system board and then measure the voltage on pin 6 and ground Does the voltage measure approximately 3 3 V dc Replace the operator panel assembly See Operator panel assembly removal C746 on page 4 34 If this does not fix the problem replace the top cover access assembly See Top access cover assembly removal on page 4 54 Replace the system board Se...

Page 169: ...Connect a new top access cover assembly from outside of the machine for verification Does the problem persist Return to the Old Top access cover assembly then go to step 6 Return to the Old Top access cover assembly then go to step 3 3 1 Open the top access cover assembly Refer to Top access cover assembly removal on page 4 54 2 Reseat the operator panel cable on both ends 3 Check for any damage o...

Page 170: ...e print from what is expected An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Measure all voltages from the connector to the printer ground Print quality background Service tip Some background problems can be caused by rough papers non Lexmark toner cartridges or if the media texture is set to th...

Page 171: ...thead removal installation and adjustment on page 4 153 Step Questions actions Yes No 1 Is all the packing material for the photoconductor unit in question removed Go to step 2 Remove the packing material 2 Replace the photoconductor unit for the color in question Does this fix the problem Problem resolved Go to step 3 3 1 Enter the Diagnostics mode turn off the printer press and hold buttons 3 an...

Page 172: ...act assembly Go to step 5 5 Turn off the printer and check the continuity of the HVPS cable Go to step 6 Replace the cable assembly Is there continuity 6 Replace the HVPS See High voltage power supply HVPS removal on page 4 123 Did this fix the problem Problem resolved Go to step 7 7 Replace the printhead See Printhead removal installation and adjustment on page 4 153 Did this fix the problem Prob...

Page 173: ...rint quality insufficient fusing Print quality missing image at edge Reseat the developer cartridge Print quality mottle 2 5mm speckles Keep running prints through and the problem normally clears up If the problem persists replace the developer cartridge Print quality narrow vertical line Step Questions actions Yes No 1 Measure the distance between repeating bands Is the distance between bands eit...

Page 174: ...ocess resulting in toner development on the entire photoconductor drum Step Questions actions Yes No 1 Is there any loose or foreign material on the photoconductor unit Replace the photoconductor unit See Photoconductor unit removal on page 4 150 Go to step 2 2 Is there any loose or foreign material on the cartridge roll Replace the print cartridge Go to step 3 3 Is there any loose or foreign mate...

Page 175: ...nd for removal procedures Are the spring s defective Replace the transfer contact assembly Go to step 3 3 Turn the printer off and then check the continuity of the HVPS cable Go to step 4 Replace the cable assembly Is there continuity 4 Replace the HVPS See High voltage power supply HVPS removal on page 4 123 Did this solve the problem Problem resolved Replace the system board See System board rem...

Page 176: ...e High voltage power supply HVPS cable removal on page 4 125 Go to step 4 4 1 Check the metal contact on the left of the transfer module for any damage 2 Check for any contamination and clear any contaminants with a piece of cloth Are the transfer module contacts damaged Replace the transfer module See Transfer module removal on page 4 179 Go to step 5 5 1 Open the front cover 2 Check the spring c...

Page 177: ...r Jtray1 and JFDPCK on the system board then check for any damage on the connectors Are the flag and cable connectors free of damage Go to step 4 Replace the paper pick assembly See Paper pick mechanism assembly removal on page 4 145 4 1 Disconnect the cable in JTRAY1 and connect the cable from the new paper pick mechanism 2 Bring the printer up in the Diagnostics menu turn off the printer press a...

Page 178: ...inked Step Questions actions Yes No 1 Load the same size and type of paper in each tray Move the paper guides to the correct positions for the paper size loaded in each tray Does tray linking work properly Problem resolved Go to step 2 2 Print a menu settings page from the Admin Menu and compare the settings for each tray Are the settings for each tray to be linked the same for paper type and pape...

Page 179: ...the printer See Diagnostics menu on page 3 2 for more information Configuration menu 1 Turn off the printer 2 Press and hold buttons 2 and 6 3 Turn on the printer 4 Release the buttons when the progress bar displays The Configuration menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used ...

Page 180: ...e tests display on the operator panel in the order shown REGISTRATION Top Margin See Registration on page 3 5 Bottom Margin Left Margin Right Margin Skew See Skew on page 3 5 Quick Test See Quick Test on page 3 8 ALIGNMENT MENU Cyan See Alignment on page 3 8 Magenta Yellow Factory Scanner A summary page for all the color alignment settings Can be used in place of alignment pages for each individua...

Page 181: ... the PCI slot 1 See Serial 1 Wrap on page 3 14 USB HS Test Mode See USB HS Test Mode on page 3 16 DUPLEX TESTS if installed Quick Test See Quick Test duplex on page 3 16 Print Test See Print Test duplex on page 3 17 Top Margin See Top Margin duplex on page 3 18 Left Margin See Left Margin duplex on page 3 18 Skew See Skew duplex on page 3 18 SENSOR TESTS Static Sensors See Sensor Test on page 3 19...

Page 182: ...See Configuration ID on page 3 23 Reset Color Cal See Reset color calibration Reset Color Cal on page 3 24 Par 1 Strobe Adj See Parallel 1 strobe adjustment Par 1 Strobe Adj on page 3 24 Motor Calibration See Motor Calibration on page 3 24 EP SETUP EP Defaults See EP Defaults on page 3 24 Fuser Temp See Fuser temperature Fuser Temp on page 3 24 DC Charge Adjust See DC Charge Adjust Dev Bias Adj Tr...

Page 183: ...argin Bottom Margin Left Margin Right Margin Skew and Quick Test Skew One printhead houses the four color planes The black plane is aligned to the printer and the color planes are internally aligned to black Adjust the skew mechanically by moving the printhead with a printhead adjustment screw See Printhead mechanical alignment C746 on page 4 8 for instructions on setting printhead alignment Elect...

Page 184: ...se or to increase the offset values 5 The message Submitting changes displays and the original REGISTRATION screen appears Description Value Direction of change Skew 50 to 50 Each increment corresponds to 1 1200 of an inch Skew settings should be between 5 and 5 If not readjust the skew with the printhead mechanical setting See Printhead alignment on page 4 8 Top margin 25 to 25 Each increment cor...

Page 185: ...change moves the image down the page and increases the top margin A negative change moves the image up and decreases the top margin Note Make sure media selection size matches the media size in tray 1 Bottom margin 25 to 25 Each increment causes approximately 0 55 mm shift in the bottom margin A positive offset moves text up the page and widens the bottom margin A negative offset moves text down t...

Page 186: ...owing information is meant to explain the uses for the menu items Alignment is part of the process of adjusting the printhead and the color planes to the black plane and to each other Before you start perform the black alignment Registration See Printhead alignment on page 4 8 If you are replacing a new printhead see Printhead removal installation and adjustment on page 4 153 Alignment C746x To pe...

Page 187: ...gn Go to each submenu and use and to zero out all settings Note It is important to zero out all settings to make the adjustment easier 2 Scroll and touch Quick Test in the same color menu Two pages print 3 On the pages make sure all the Current Values are set to zero If not go back two steps and repeat 4 Look at the coarse and fine adjustments on the top left of the page and enter the best number ...

Page 188: ... offered Forward or Reverse or other setting for that test Press or to stop the motor and end the test The following tests have special setup before running the test Motor diagnostic setup Motor Setup requirements Notes Top cover position Front door position Tray 1 N A Closed Ok Picks paper use empty or remove tray Open Ok Align N A Closed Ok Open defeat 25 V switch Ok View align mechanism Duplex ...

Page 189: ...g edge Function not supported Duplex Forward Push media down toward input Will run continuously View with front cover split Reverse Pick from MPF MPF test Will pick continuously View empty or pull tray Belt stepper Forward only Gear turns counter clockwise View with front cover open No forward menu Reverse N A Only used to clear cleaner nip Cartridge K 3 Forward only Gear turns counter clockwise V...

Page 190: ... the media source Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multi Purpose Feeder if installed 3 Select Single or Continuous If Single is selected a single page is printed If Continuous is selected printing continues until is pressed to cancel the test Cam Forward Engage motor couplings Runs to stall position Locks door Enables print operations Reverse N...

Page 191: ...s of five pages Pages one and two contain a mixture of graphics and text The remainder of the pages only contain graphics The test prints on the media in the default tray This test may be printed from either Configuration Menu or the Diagnostics mode To run the print quality pages from the Diagnostics mode select PRINT TESTS and Print Quality Pages from the menu Once the test is started it cannot ...

Page 192: ... the display lights up 3 Press or touch Back to end the test DRAM Test This test checks the validity of DRAM both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test navigate to Diagnostics Menu HATDWARE TEST DRAM Test The power indicator blinks indicating the test is in progress Note If you need to exi...

Page 193: ...0 is displayed The maximum pass count is 999 999 F represents the number of times the serial port hardware has failed Initially 0000 is displayed The maximum fall count is 999 999 Any of the following explanations for failure may display Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Err...

Page 194: ...st restart the printer Duplex Tests Quick Test duplex Note Before you set the duplex top margin be sure to set the skew and alignment See Printhead alignment on page 4 8 This test prints a duplex version of the Quick Test that can be used to verify the correct placement of the top margin on the back side of a duplex page You can run one duplexed page Single or continue printing duplexed pages Cont...

Page 195: ...st continues until you press Print Test duplex This test provides service personnel with a way to verify the function of the printer s duplex hardware After the user selects this test the device automatically executes a continuous print test that generates a duplexed color output page To stop the test the user must press While this test executes the power indicator light blinks green and the panel...

Page 196: ...justments are made to the image that is face down in the output tray Therefore be sure to set the top margin in REGISTRATION before setting the duplex top margin See Registration on page 3 5 To set the Top Margin duplex 1 Select DUPLEX TESTS from the Diagnostics Menu 2 Select Quick Test 3 Select Single The test page prints 4 Hold the page to the light to see whether the top margin of the back alig...

Page 197: ...sensors tests static sensors and dynamic sensors To run the Sensor Test 1 Select Sensor Tests from the Diagnostics Menu 2 Select Static Sensors or Dynamic Sensors For static sensors view the current status Exit menus and re enter to change state For dynamic sensors view the current status and toggle the state to test the sensor 3 Select the particular sensor you need to test Touch Back or press to...

Page 198: ...nd pushing up to sensor The sensor should change state K Toner Open Closed Remove the black toner cartridge Shine a flashlight on the toner level sensor The sensor should change state M Toner Open Closed Remove the magenta toner cartridge Shine a flashlight on the toner level sensor The sensor should change state C Toner Open Closed Remove the cyan toner cartridge Shine a flashlight on the toner l...

Page 199: ... the saved data is written back to the disk To run the Quick Disk Test 1 Select DEVICE TESTS from the Diagnostics Menu 2 Select Quick Disk Test The power indicator blinks while the test is in progress Quick Disk Test Test Passed is displayed if the test passes and the power indicator turns on solid Quick Disk Test Test Failed is displayed if the test failed and the power indicator turns on solid Y...

Page 200: ...icates the number of usable blocks xxxx Bad Blocks Replace Disk is displayed if more than 2000 bad blocks are detected The disk cannot be recovered because too many bad blocks exist on the disk 5 Touch Back or press to return to DEVICE TESTS Flash Test This test causes the file system to write and read data on the flash to test the flash Warning This test destroys all data on the flash because the...

Page 201: ... the factory when the printer is manufactured However the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever the system board is replaced The IDs consist of eight digits The first seven digits in each ID are hexadecimal numbers while the last digit is a checksum of the preceding seven digits Each ID can contain a combination of the digits 0 through 9 and A through F Note ...

Page 202: ...creased by 1 the strobe is sampled 50 ns less often When the value of this setting is 0 the factory default is used to determine the length of time the strobe is sampled If the servicer for example decreased the value from 0 to 3 the strobe will be sampled for 150 ns longer than the factory setting Motor Calibration This test is run to calibrate the leading edge of the paper to each transfer stati...

Page 203: ...e is a list of DIAGNOSTICS settings with the current value Event Log Display Log The event log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is discarded Identica...

Page 204: ...l of support for verification or diagnosis To print the event log 1 Select EVENT LOG from the Diagnostics Menu 2 Select Print Log Touch Back or press to return to EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Select EVENT LOG from the Diagnostics Menu 2 Select Clear Log 3 Select YES to clear t...

Page 205: ...lor Adj State See Color Adj State on page 3 31 Enforce Color Order See Enforce Color Order on page 3 31 Color Alignment See Color Alignment on page 3 31 Motor Calibration See Motor Calibration on page 3 32 Paper Prompts See Paper Prompts on page 3 32 Envelope Prompts See Envelope Prompts on page 3 32 Action for Prompts See Action for Prompts on page 3 32 Jobs on Disk if hard disk is installed See ...

Page 206: ...g menu or power off and on again Note If On is selected and the color supplies are left installed when the printer is returned to normal mode the printer displays Remove All Color Supplies Remove all the color supplies and press or touch If Off is selected then at step 3 install all color supplies If the supplies are not installed when the printer returns to normal mode the printer displays 31 Mis...

Page 207: ...on top of a colored background If so rather than remove the color from beneath the black content the printer leaves the color around the edge of the text or line The hole in the colored region is reduced in size which prevents the characteristic white gap that is caused by mis registration This menu item applies to PCL 5e emulation PCL XL PDF and PostScript Selections are Off and the values 1 thro...

Page 208: ...Warning This selection cannot be reversed so this operation should only be used as a last resort to fix any printer problem When factory default settings are restored All downloaded resources fonts macros symbol sets in the printer memory RAM are deleted All menu settings return to the factory default setting except The Display Language setting in the Setup Menu All settings in the Parallel Menu S...

Page 209: ...djustments Eventually the user will have to manually correct alignment and color on the printer Color Adj State These settings allow you to select when color calibrations occur Selecting Busy indicates the color calibrations will complete queued jobs but refuse to add new jobs to the queue When calibration is complete jobs are again accepted Selecting Idle allows calibrations only when the printer...

Page 210: ...f the envelope requested and not by the envelope type Selections include Auto Multi Purpose Feeder and Manual Envelope Note Multi Purpose Feeder is only available on some printer models Note If the Configure MP setting is changed to Manual and a power on reset is performed and the value of the Envelope Prompts menu item before the power on reset was Multi Purpose Feeder then when the printer resta...

Page 211: ...ss it is absolutely unavoidable for example disk corruption or unless the printer can remain offline for several hours without inconveniencing users Warning A user should not initiate either type of wipe from the Configuration Menu if the hard disk contains downloaded fonts macros held jobs and so forth that should not be erased This setting initiates either a single pass wipe or a multiple pass w...

Page 212: ...ting allows external developers to measure the stability of their applications by performing their own automated testing against the device Selections include Enable and Disable default When Enable is selected the machine creates a file called ENABLE_UI_AUTOMATION in the var fs shared directory As long as this file exists the device permits automated testing by external users When Disable is selec...

Page 213: ...IR that appears on the operator panel will display the option to return to the Home screen without clearing it Once the device returns to the Home screen though any existing IR again will appear after the device remains inactive on the Home screen for a length of time equal to the Screen Timeout setting Note SFPs and MFPs use a different default value for this setting in order to preserve their le...

Page 214: ...e place However if the printer is turned off or has an error while the front door is locked for example while printing or calibrating the front door may not unlock If this happens turn the printer off and restart it Once it goes through POR it may unlock itself If this does not work use the following procedure to unlock the front door 1 Remove the two screws A from the rear upper cover and remove ...

Page 215: ...ack Previous Next 3 Press the waste toner release latch C swing the front of the waste toner assembly away from the printer and remove 4 Remove the two screws D on the bottom and one screw higher up E 5 Press the locking tab F D E F ...

Page 216: ...t 6 Lift the rear of the left cover out and rotate it out of position Note It will not come completely off with the front cover locked 7 With a flatblade screwdriver turn the camshaft counterclockwise until the door unlocks 8 Open the front cover ...

Page 217: ...rify that the printhead is the failing FRU by following this procedure 1 Turn the printer off and remove the power cord from the outlet Remove all cords and cables from the printer before beginning 2 Locate the printer on a corner of a work area so the front and back can be accessed ...

Page 218: ...ual 5026 Go Back Previous Next 3 Remove the rear frame cover a Loosen the eight screws on the rear frame cover A Note Do not remove the screws b Lift up on the rear frame cover to remove it from the back of the printer ...

Page 219: ...he Diagnostics menu press and hold buttons 3 and 6 turn on the printer and release the buttons when the progress bar displays 7 Perform the Mirror Motor Test a Select PRINTHEAD TESTS b Select Mirror Motor Test The panel displays Motor Running At the end of the test the panel displays either Pass or Fail If the test fails replace the system board If the test passes perform the Servo Laser Test in s...

Page 220: ...ice Manual 5026 Go Back Previous Next Paper Jams Error jam locations The following illustration shows the location and error codes generated for specific paper jams and the corresponding locations of these jams ...

Page 221: ...refer to the Card Stock Label Guide available on the Lexmark Web site at www lexmark com publications Do not load too much paper Make sure the stack height does not exceed the indicated maximum height Do not load wrinkled creased damp or curled paper Flex fan and straighten paper before loading it Do not use paper that has been cut or trimmed by hand Do not mix paper sizes weights or types in the ...

Page 222: ...t from behind the toner cartridge area Note Make sure all paper fragments are removed 3 Close the front door 4 Press or touch 200 or 201 paper jam If paper jams under the photoconductor units 200 xx Paper jam or 201 xx Paper jam may appear 1 Open the front door Note To avoid overexposing the photoconductor units do not leave the front door open longer than 10 minutes 2 Pull the paper forward if it...

Page 223: ...paper is jammed under the fuser or the top cover 201 xx Paper jam appears 1 Open the front door and then open the top cover Warning Potential Damage To avoid overexposing the photoconductor units do not leave the front door open longer than 10 minutes 2 Determine where the jam is located a If paper is visible under the fuser grasp it on each side and pull it forward b If paper is not visible turn ...

Page 224: ...rely 3 Close the top cover and then close the front door 4 Press or touch 202 paper jam If paper is jammed both under the fuser unit and in the slot behind the fuser unit 202 xx Paper jam appears 1 If the paper is visible in the standard exit bin grasp the paper and pull it away from the bin 2 Open the front door and then open the top cover 3 Grasp the paper on each side and pull it forward ...

Page 225: ...ews on the fuser unit to the left b Lift the unit and pull to remove it c Pull the paper gently out of the printer or up toward the standard exit bin to remove it d Place the fuser unit back into the printer and turn the screws to the right to fasten the fuser unit securely 4 Close the top cover and then close the front door 5 Press or touch ...

Page 226: ...ull it away from the bin 2 Open the front door and then open the top cover 3 Grasp the paper on each side and pull it out gently 4 Close the top cover and then close the front door 5 Press or touch 230 paper jam If paper is jammed between the front door and tray 1 230 xx Paper jam appears 1 Remove tray 1 2 Open the front door 3 Pull straight up to remove the jammed paper 4 Close the front door 5 R...

Page 227: ...2 If the jam is located in front of the tray pull the jammed pages up and out 3 After removing the tray the front door may need to be opened to access the jam 4 Close tray 1 5 Press or touch If the jammed pages are located in one of the optional trays follow the appropriate steps below to remove the pages from an optional tray 1 Open the specified optional tray and pull the jammed pages out as ill...

Page 228: ...Next 250 paper jam If paper is jammed in the multipurpose tray 250 xx Paper jam appears 1 Press the paper release lever and then remove the jammed pages from the multipurpose tray 2 Load new paper into the multipurpose tray 3 Press or touch 1 2 ...

Page 229: ...Diagnostic aids 3 51 5026 Go Back Previous Next Theory of operation Paper path ...

Page 230: ...ia onto the transfer belt and corrects any media skew as it comes out of the paper trays or MPF Transfer belt The transfer rolls located inside the transfer belt unit are an integral part of the electrophotographic process and the transfer belt advances the print media through the printer Fuser The fuser bonds toner to the print media and advances the print media through the last portion of the pa...

Page 231: ...ted by a sensor located in the paper pick mechanism It does not matter where the media comes from Tray 1 Tray 2 or the MPF it will enter the electrophotographic process at the bump aligner drive The bump aligner motor drives the bump aligner roll which feeds the paper to the transfer belt 500 sheet assembly pick tire Bump aligner roll MPF pick tire Pick tire Backup aligner roll ...

Page 232: ...ual 5026 Go Back Previous Next Once the paper is fed onto the transfer belt the photoconductor drums in conjunction with the transfer belt pull the print media through the paper path Photoconductor drums Transfer belt ...

Page 233: ...n and pull the print media through the paper path until it reaches the exit drive roll The exit drive roll pulls the print media from the fuser rollers and delivers it to the fuser output drive roll Once the print media reaches the fuser output drive roll the roller pushes the print media into the output bin Fuser output drive roll Fuser exit drive roll Paper exit flag Fuser backup roll Fuser exit...

Page 234: ...ath until it reaches the bump aligner roll Once in this position it enters the EP path for the second time The paper exit flag serves two purposes When it triggers the paper exit sensor it serves as a one way gate for the media when it is exiting the printer to the output bin and also serves as a one way gate when the media is entering back into the printer for a duplex print In other words it div...

Page 235: ...g paragraphs Paper pick mechanism drive When printing from Tray 1 or Tray 2 the paper pick motor drives the paper pick gears which causes the pick roller to turn During an MPF print the paper pick motor drives the swing arm assembly for the MPF and causes the MPF paper pick roller to turn Swing arm bracket C52x MPF swing arm assembly Paper pick mechanism gears Paper pick motor Paper pick mechanism...

Page 236: ...from the bump aligner motor The motor drives a set of bump aligner gears which causes the bump aligner roll to turn Note If this motor is stalling or causing waste toner box full messages the vertical auger mechanism might be causing the problem Bump aligner roll Bump aligner gears Bump aligner gears Bump aligner motor ...

Page 237: ...ly provides drive to the top two photoconductor units and toner cartridges yellow and cyan Likewise the bottom cartridge motor 2 drives the two bottom photoconductor units and toner cartridges When the printer s top access door is open the couplers for the toner cartridges and photoconductor units disengage Toner cartridge couplers Inside Photoconductor couplers Fuser motor Cartridge motor1 Cartri...

Page 238: ...it receives drive from a motor located on the EP drive assembly When the top access door is open the coupler for the transfer belt disengages Fuser drive The fuser drive motor is built into the fuser assembly and drives the fuser rollers to turn Inside Coupler Transfer belt motor Outside ...

Page 239: ...ectrophotographic process There are two paper flags one at the bottom of the machine paper pick to detect input paper including duplex second side from all sources and one at the top paper exit to detect paper movement beyond the fuser The flags are similar in design in that a mechanical arm is moved by the media to interrupt an optical sensor both are normally blocked when no media is present The...

Page 240: ...retracted from the exit tray back into the duplex path Each sheet must be driven past the fuser exit flag and allowed to fall before being turned around and starting the duplex path If the print media activates the paper exit flag for too long or the print media doesn t reach the paper exit flag within a given time a paper jam error will be posted Paper exit duplex entry flag Paper exit duplex ent...

Page 241: ...uring the print process an image is sent from a computer to the system board The raster image processor RIP portion of the system card converts the data into a raster image and feeds this data along with control information to the printhead Fuser Printhead High voltage power supply Developer toner cartridge Transfer belt Photoconductor belt System board ...

Page 242: ...ctrostatic image Photoconductor unit The photoconductor unit consists primarily of a charge roll and the photoconductor drum The charge roll charges the surface of the photoconductor drum to prepare it for the latent image drawn by the laser Once the photoconductor drum has been written to by the laser it is responsible for picking up toner from the cartridge developer roller and then transferring...

Page 243: ...the HVPS to the charge roll contact on the photoconductor unit It is essential that the contact springs are properly touching to provide a good flow If not print quality problems will occur Photoconductor unit photoconductor drum The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the photoconductor drum contact on the photoconductor unit It ...

Page 244: ...s three parts that are provided high voltage from the HVPS These three parts are the doctor blade the developer roll and the toner adder roll TAR It is essential that the contact springs are properly touching to provide a good flow If not print quality problems will occur Toner add roll high voltage contact path Developer roll high voltage contact path High voltage power supply Cleaner blade high ...

Page 245: ...nductor drum to the print media The transfer belt receives its high voltage charge through spring contacts located on the transfer contact assembly as shown in the following illustration For the sake of simplicity only one of the roller s high voltage paths is shown This path is typical for the other three rollers as well Transfer belt high voltage path ...

Page 246: ...l data path for a single color exposure Data is received from a computer into a port on the system card The system card s RIP function converts this data into raster information which is fed to the printhead along with other control data The data is converted by the printhead laser into light energy data that is directed to the light sensitive photoconductor unit System card Printhead Photoconduct...

Page 247: ...s to the electrically charged toner adder roll The toner on the toner adder roll is then electrically attracted to the developer roll because of the difference in electrical charge between the toner adder roll and the developer roll The toner uniformly coats the developer roll with help from the doctor blade and is introduced to the electrostatic image on the photoconductor drum The toner then tra...

Page 248: ...elt and is carried along the belt underneath each photoconductor unit The charged transfer roll s located inside the transfer belt pulls the image from the photoconductor drum to the print media This is a direct transfer method The main function of the transfer belt is to provide transport for the print media Toner is not transferred directly to the belt during the print process Photoconductor uni...

Page 249: ... the image has been transferred onto the print media it is ready for fusing The print media is transported into the fuser where the hot roll and backup roll use a combination of high heat and pressure to melt and press the toner to the media Backup roll Hot roll ...

Page 250: ...ates past a cleaning blade and shaft located inside the transfer belt assembly Any waste toner that is scraped off of the belt is collected in the waste toner container located next to the belt inside the transfer belt unit The photoconductor drum is cleaned by the cleaning blade Transfer belt cleaning blade Photoconductor drum cleaning blade Transfer belt cleaning shaft Transfer belt waste toner ...

Page 251: ...he 24 V interlock switch and cuts the 24 V supply to the system board HVPS motors and fuser Closing the front door triggers a switch that initializes the motor When the 24 V switch opens the normally open side of the switch is activated which signals the system board to disable a 24 V power supply output turning off all high voltage supplies the bump align motor the duplex motor and the fuser moto...

Page 252: ...3 74 Service Manual 5026 Go Back Previous Next ...

Page 253: ...n volatile memory This device may utilize two forms of non volatile memory EEPROM and NAND flash memory Both types are used to store the operating system device settings network information scanner and bookmark settings and embedded solutions Hard disk memory Some devices have a hard disk drive installed The printer hard disk is designed for device specific functionality and cannot be used for lon...

Page 254: ... be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install printer covers when you are not working on the printer and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is u...

Page 255: ...g fan to top cover 2 1126828 E clip M3 LR overcenter bell crank to side frame 1 1126829 E ring M4 MP feeder gears to right side frame studs 2 18B0832 Taptite M3 L6 panhead 5 V interlock switch to right frame 1 Card support plate to upper plate 2 Card support plate to lower plate 3 Card support plate and printhead ground to left frame 5 Card support plate to right frame 4 Cartridge left guide assem...

Page 256: ...ly to laser support plate 2 Right frame assembly to lower plate 3 System board to RIP plate 9 Top cover assembly to printer frame 5 Upper plate to right frame assembly 3 Upper plate to left frame assembly 3 Upper plate to laser support plate 3 18B0939 Plastite M3x6 flathead Gearbox plate assembly to frame 4 18B2302 Machine M2 6 L3 3 5 MP feeder duplex drive motor to rightside plate 2 18B2315 Machi...

Page 257: ... to left plate 1 27S2839 Taptite M3 L6 Taptite slotted hex black Rear cover frame to frame 8 88A0003 Machine M3X0 5 6G 8L Printhead 3 88A0095 M2 5x10 Machine 5 V interlock switch actuator assembly 1 24 V interlock switch and shield to right frame 1 88A0212 Taptite M3 5x0 6 PAN Fuser AC cable s ground wire to left plate 1 88A0232 Taptite M3 L6 PANHD Cartridge right guide assembly to rightside plate...

Page 258: ...r frame support to lower left frame assembly 2 Operator panel card to top access door cover CBM 3 Option locator to rightside plate 1 88A0313 Plastite M2 9 L8 PAN Contacts assembly to leftside cartridge guide 1 Cover bracket to front access door cover 2 Cover pivot to swingout frame 3 HVPS to transfer contact assembly 3 HVPS to leftside cartridge guide assembly 2 Interior screws attaching cover br...

Page 259: ...ious Next 88A0412 M2 9x5 2 Plastite GS COD bell cranks to guide 3 NGS COD bell cranks to guide 3 Top access door assembly to fuser retract link 1 Top cover left link to cover 1 Screw identification table continued P N Screw type Location Qty ...

Page 260: ... adjusted The first step in aligning the printhead is to loosen the printhead mounting screws and to set the skew for black Note If you need to replace the printhead see Printhead removal installation and adjustment on page 4 153 Printhead mechanical alignment C746 Skew black 1 Turn off the printer 2 Disconnect the power cord from the electrical outlet 3 Remove the transfer module and photoconduct...

Page 261: ... printhead alignment screw cover E 6 Reinstall the transfer module with the photoconductor units still attached 7 Reconnect the transfer module cable 8 Replace the toner cartridges 9 Close the top access door 10 Close the front access door 11 Plug the electrical cord into the printer 12 Plug the electrical cord into the outlet D2 D3 D1 E ...

Page 262: ...he printer press and hold buttons 3 and 6 turn on the printer and release the buttons when the clock graphic displays b Select REGISTRATION from the DIAGNOSTICS menu and select Settings c Select Skew and press d Use or to set the Skew to zero and press e Scroll down to Quick Test and press A page similar to this one prints ...

Page 263: ...unterclockwise a full revolution and print the Quick Test page Repeat adjusting the screw and printing the Quick Test until the top alignment marks are the same distance from the top of the media Note One rotation of the printhead alignment screw equals approximately 0 5 millimeter movement of the top edge print alignment marks g When the top right and top left alignment marks are both showing and...

Page 264: ...two tabs on either side of the transfer module and lift out the transfer module with the photoconductor units in place e Remove all of the toner cartridges f Tighten the printhead mounting screws in the following order H1 H2 and H3 15 Replace the printhead alignment screw cover 16 Replace the toner cartridges 17 Reinstall the transfer module and the photoconductor units 18 Connect the transfer mod...

Page 265: ...g the value moves the top alignment marks down on the page Decreasing the value moves the top alignment marks up on the page 7 Press to save the value 8 Print the Quick Test page and check the top alignment marks Repeat adjustment of the top margin and printing of the Quick Test page until top margin is set Bottom Margin 1 Select Bottom Margin and press 2 Adjust the bottom margin until the points ...

Page 266: ...l the points of the left alignment marks touch the edge of the page Increasing the value moves the right alignment marks away from the edge of the page Decreasing the value moves the right alignment marks toward the edge of the page 3 Press to save the value 4 Print the Quick Test page and check the results Repeat if necessary 5 When the registration is complete proceed to the color alignment Alig...

Page 267: ...ext 7 Select Quick Test in the Cyan menu and press Two pages print You may have to print these pages several times until you get T Top Margin and Z Skew aligned Do not go to step 2 until T and Z are aligned The first page is similar to the following ...

Page 268: ...er the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the T value The current value is automatically entered on the sheet At this point it should be zero 10 Enter the New Cyan T value on the operator panel using the left and right arrows and press to save the value 11 Reprint the Quick Test and evaluate whether you are at zero changes 1...

Page 269: ...le is shown below 13 Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin T the Skew Z and on the second page of the Quick Test page the Left Margin L Right Margin R and Bow P 14 Repeat steps 1 through 13 for yellow and magenta Note Start each color group by setting the Top Margin Left Margin Right Margin Bottom Margin Skew and Bow to zero 18 18 18 14 4 ...

Page 270: ... two tabs C on either side of the transfer module and lift out the transfer module Note Leave the photoconductor units on the transport belt when removing To avoid damaging the photoconductor drum place the transfer module with the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time You can place a clean dry cloth over the transfer ...

Page 271: ...Close the top access door 10 Close the front access door 11 Plug the electrical cord into the printer 12 Plug the electrical cord into the outlet 13 Align the printhead skew for black a Enter the Diagnostic menu turn off the printer press and hold buttons 3 and 6 turn on the printer and release the buttons when the clock graphic displays b Touch REGISTRATION from the DIAGNOSTICS menu and then touc...

Page 272: ...4 20 Service Manual 5026 Go Back Previous Next e Scroll down and touch Quick Test A page similar to this one prints ...

Page 273: ...unterclockwise a full revolution and print the Quick Test page Repeat adjusting the screw and printing the Quick Test until the top alignment marks are the same distance from the top of the media Note One rotation of the printhead alignment screw equals approximately 0 5 millimeter movement of the top edge print alignment marks g When the top right and top left alignment marks are both showing and...

Page 274: ...two tabs on either side of the transfer module and lift out the transfer module with the photoconductor units in place e Remove all of the toner cartridges f Tighten the printhead mounting screws in the following order H1 H2 and H3 15 Replace the printhead alignment screw cover 16 Replace the toner cartridges 17 Reinstall the transfer module and the photoconductor units 18 Connect the transfer mod...

Page 275: ... moves the top alignment marks down on the page Decreasing the value moves the top alignment marks up on the page 7 Touch to save the value 8 Print the Quick Test page and check the top alignment marks Repeat adjustment of the top margin and printing of the Quick Test page until top margin is set Bottom Margin 1 Touch Bottom Margin 2 Adjust the bottom margin until the points of the bottom margin a...

Page 276: ...the points of the left alignment marks touch the edge of the page Increasing the value moves the right alignment marks away from the edge of the page Decreasing the value moves the right alignment marks toward the edge of the page 2 Touch to save the value 3 Print the Quick Test page and check the results Repeat if necessary 4 When the registration is complete proceed to the color alignment Alignm...

Page 277: ...ous Next 7 Touch Quick Test in the Cyan menu Two pages print You may have to print these pages several times until you get T Top Margin and Z Skew aligned Do not go to step 2 until T and Z are aligned The first page is similar to the following ...

Page 278: ...ent scales 9 Enter the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the T value The current value is automatically entered on the sheet At this point it should be zero 10 Enter the New Cyan T value on the operator panel and touch to save the value 11 Reprint the Quick Test and evaluate whether you are at zero changes 18 18 ...

Page 279: ...le is shown below 13 Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin T the Skew Z and on the second page of the Quick Test page the Left Margin L Right Margin R and Bow P 14 Repeat steps 1 through 13 for yellow and magenta Note Start each color group by setting the Top Margin Left Margin Right Margin Bottom Margin Skew and Bow to zero 18 18 18 14 4 ...

Page 280: ...nplug the power cable from the outlet prior to starting removals or checks 2 Prior to starting any repairs read and understand the warnings in this manual High temperature High voltage Laser radiation 3 Confirm the direction of all parts and screw lengths during removal replacement 4 Utilize the proper cleaning procedures solvents during maintenance 5 Confirm that all parts and covers are properly...

Page 281: ...t access door cover assembly 4 Press the two tabs C on either side of the transfer module and lift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a pr...

Page 282: ...Back Previous Next 5 Looking down at the keyed end of the restraint D twist the end clockwise slide the restraint upward through the slit E and slip the end of the restraint through the keyed hole F Repeat for the other side D F E ...

Page 283: ...move the bracket H 9 Remove the front access cover assembly Left cover removal See Left cover on page 7 3 for the part number 1 Remove the paper tray 2 Remove the waste toner assembly See Waste toner assembly removal on page 4 184 3 Open the front access door 4 Open the top access door 5 Remove the two screws A on the bottom and one screw higher up B 6 Press the locking tab C G H A B C ...

Page 284: ...e left cover and rear left cover together Note Because the paper tray dust cover is loose at this point set it aside Note If you are removing the left cover to access another part leave the left cover and the rear left cover attached and you are done If you need to replace the left cover FRU continue with the next step to remove the separate rear left cover FRU ...

Page 285: ...Repair information 4 33 5026 Go Back Previous Next 9 Separate the left cover and rear left cover by sliding the left rear cover as shown to disengage the latch E ...

Page 286: ...p the part they must sign a confirmation of memory device retention form Warning When replacing any one of the following components Operator panel assembly System board Top access cover assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inopera...

Page 287: ... 4 Pull open the UICC connector and disconnect the UICC cable Installation note Make sure the contact pins on the cable are facing up when reconnecting the operator panel cable to the connector 5 Flip open the LCD connector and disconnect the LCD cable ...

Page 288: ...xt 6 Remove the six screws B securing the operator panel card then remove the operator panel card 7 Remove the three screws C securing the LCD bracket then remove the LCD bracket 8 Remove the operator panel LCD together with the LCD protector B C ...

Page 289: ... this part return it to your next level of support so any data can be removed If the customer requests to keep the part they must sign a confirmation of memory device retention form Warning When replacing any one of the following components Operator panel assembly System board Top access cover assembly Only replace one component at a time Replace the required component and perform a POR before rep...

Page 290: ...ight screws A securing the position guide cover 4 Pull open the operator panel connector and disconnect the operator panel cable Installation note Make sure the contact pins on the cable are facing up when reconnecting the operator panel cable to the connector A ...

Page 291: ...air information 4 39 5026 Go Back Previous Next 5 Flip open the LCD connector and disconnect the LCD cable 6 Remove the five screws B securing the operator panel card then remove the operator panel card B ...

Page 292: ...4 40 Service Manual 5026 Go Back Previous Next 7 Remove the four screws C securing the LCD bracket 8 Remove the LCD bracket and ground connector 9 Remove the operator panel LCD C ...

Page 293: ...art number 1 Open the front cover 2 Pry the bezel using a flat head screw driver to remove Operator panel buttons removal C746 1 Remove the top access door cover assembly See Top access cover assembly removal on page 4 54 2 Turn the top access cover assembly over 3 Remove the eight screws A securing the position guide cover A ...

Page 294: ...2 Service Manual 5026 Go Back Previous Next 4 Remove the six screws B securing the operator panel card then remove the operator panel card 5 Unsnap the small latches securing the buttons then remove them B ...

Page 295: ...ove the top access door cover assembly See Top access cover assembly removal on page 4 54 2 Turn the top access cover assembly over 3 Remove the eight screws A securing the position guide cover 4 Remove the five screws B securing the operator panel card then remove the operator panel card A B ...

Page 296: ...4 44 Service Manual 5026 Go Back Previous Next 5 Unsnap the small latches securing the buttons then remove them ...

Page 297: ...cover removal See Output bin extension cover on page 7 3 for the part number 1 Turn the printer around so the back is toward you 2 Rotate the output bin extension cover toward the front of the printer 3 Use a flathead screwdriver to ease the posts from the holes on one side ...

Page 298: ... the paper tray dust cover assembly Installation notes 1 Place the paper tray dust cover into position 2 Slide the left cover down until it locks into place Note Be sure the post in the left cover engages the hole in the left cover and that the post in the paper tray dust cover engages the hole in the left cover properly 3 Replace the three screws on the left cover Note Verify that the paper tray ...

Page 299: ...ar frame cover removal See Rear frame cover on page 7 3 for the part number 1 Remove paper tray 2 Loosen the eight screws A on the rear frame cover Note Do not remove the screws 3 Lift up on the rear frame cover to remove it from the back of the printer A ...

Page 300: ...5026 Go Back Previous Next Rear left cover removal 1 Remove the left cover See Left cover removal on page 4 31 2 Separate the left cover and rear left cover by sliding the left rear cover as shown to disengage the latch A ...

Page 301: ...ck Previous Next Rear right cover removal See Rear right cover on page 7 3 for the part number 1 Remove the right cover See Right cover removal on page 4 51 2 Press the two tabs A to separate the right cover from the rear right cover A ...

Page 302: ...he rear upper cover Note If you are removing the rear upper cover to access another part leave the cooling fan filter attached and you are done If you need to replace the rear upper cover FRU continue with the next step to remove the cooling fan filter FRU 3 Remove the cooling fan filter See Cooling fan filter removal on page 4 94 ...

Page 303: ...r the part number 1 Remove the power cord from the printer 2 Remove the paper tray 3 Remove the rear upper cover See Rear upper cover removal on page 4 50 4 Open the front cover 5 Open the top access cover 6 Remove the two screws A on the inside front 7 Remove the plastic screw B on the inside front B ...

Page 304: ...over D When you reinstall be sure to verify that the top access cover opens correctly and that the paper tray dust cover swings properly 10 Remove the paper tray dust cover E Note If you are removing the right cover to access another part leave the right cover and the rear right cover attached and you are done If you need to replace the right cover FRU continue with the next step to remove the sep...

Page 305: ...Repair information 4 53 5026 Go Back Previous Next 11 Press the two tabs F to separate the right cover from the rear right cover F ...

Page 306: ...nent and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the rear frame cover See Rear frame cover removal on page 4 47 2 Disconnect the cable connectors at operator panel connector A JFMUSB1 B and JBIN1 C on the system board 3 Remove the rear upper cover See Rear upper cover removal on page 4 50 4 Op...

Page 307: ...Repair information 4 55 5026 Go Back Previous Next 6 Disconnect the JOPP1 and JFMUSB1 cables E from their connectors 7 Take out the JOPP1 and JFMUSB1 cables F E F ...

Page 308: ... Manual 5026 Go Back Previous Next 8 Raise the top access cover assembly 9 Push down on the rear right side of the top cover G then pull out the right cover H lightly to release the top cover from the hinge I I G H ...

Page 309: ...leave the operator panel bezel attached and you are done If you are replacing the top access cover assembly FRU then remove the separate operator panel bezel FRU See Operator panel bezel removal on page 4 41 Installation note When reinstalling the top access cover assembly guide the speaker and bin full sensor cables through the two holes J on the rear of the top cover first J ...

Page 310: ...n page 4 127 2 Remove the top access cover assembly See Top access cover assembly removal on page 4 54 3 Disconnect the connectors in JBLW1 A JFUSER1 B JFAN1 C on the system board Note If you are removing the top cover assembly of the C748x model make sure to remove the speaker connector D 4 Pull the cables through the openings Note Be sure to observe the routing for the cables C B A D ...

Page 311: ...Repair information 4 59 5026 Go Back Previous Next 5 Remove the fuser AC cable from the cable restraint D 6 Remove the five screws E E E ...

Page 312: ...mbly of the C748x model remove the two screws F to detach the speaker mount The speaker mount is not included as part of the top access cover assembly FRU 7 Lift and remove the top cover assembly Installation note Make sure to push down on the cam after reinstalling the top cover assembly F ...

Page 313: ...ter removals 5 V interlock switch cable removal See 5 V interlock switch on page 7 9 for the part number 1 Remove the EP drive assembly See Electrophotographic EP drive assembly removal on page 4 98 2 Disconnect the connector at JINT1 A on the system board ...

Page 314: ...4 62 Service Manual 5026 Go Back Previous Next 3 Open the front access door cover and remove the screw B 4 Remove the cable from the two cable retainers C B ...

Page 315: ...e printer 6 Remove the screw D and remove the 5 V interlock switch cable from the bracket 24 V interlock switch removal See 24 V interlock switch on page 7 9 for the part number 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 127 2 Disconnect the connector at JCVR1 A at system board ...

Page 316: ...4 64 Service Manual 5026 Go Back Previous Next 3 Remove the screw B and the bracket separates from the 24 V interlock switch Installation notes Observe the routing of the 24 V interlock switch cable C ...

Page 317: ...r over and use a flatblade screwdriver to carefully remove the flag A Bin full sensor removal See Bin full sensor with cable on page 7 3 for the part number 1 Remove the top access cover assembly See Top access cover assembly removal on page 4 54 2 Turn the top access cover over and press the side of the bin full sensor A to snap it loose from the cover 3 Remove the bin full sensor and cable A A ...

Page 318: ...nual 5026 Go Back Previous Next Cartridge cooling fan removal 1 Remove the top cover See Top cover assembly removal on page 4 58 2 Turn the top cover over and remove the two screws A 3 Remove the cartridge cooling fan ...

Page 319: ...idge guide wheel Note Only replace defective cartridge guide wheel s 1 For yellow cyan or magenta a Remove the two screws A from the cartridge guide b Gently pull the cartridge guide then remove the cartridge guide wheel B CAUTION Do not pull too hard on the cartridge guide to avoid damage A B ...

Page 320: ...liers to hold the cartridge guide wheel in place when installing a new cartridge wheel Installation note Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide 2 For black a Remove the screw C from the lower most cartridge guide 1 2 C ...

Page 321: ...cartridge guide to avoid damage Installation note Gently pull the cartridge guide then use a long nosed pliers to hold the cartridge guide wheel in place when installing a new cartridge guide wheel Installation note Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide D 1 2 ...

Page 322: ...a a Remove the two screws A from the cartridge guide b Gently pull the cartridge guide then remove the front B or rear C cartridge guide wheel CAUTION Do not pull too hard on the cartridge guide to avoid damage Note When replacing either the front or rear cartridge guide wheel be careful to not let the non defective cartridge guide wheel fall off A B C ...

Page 323: ...formation 4 71 5026 Go Back Previous Next Installation note Gently pull the cartridge guide then use a long nosed pliers to hold the cartridge guide wheel in place when installing a new rear cartridge wheel 1 2 ...

Page 324: ...rly align the pins to their proper slot when reinstalling the cartridge guide wheel Be careful not to damage or bend the pins Installation note Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide ...

Page 325: ...ious Next 2 For black a Remove the screw D from the lower most cartridge guide b Gently pull the cartridge guide then remove the front E or rear F cartridge guide wheel CAUTION Do not pull too hard on the cartridge guide to avoid damage D E F ...

Page 326: ...uide wheel fall off Installation note Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide Cartridge motor 1 fuser cable removal 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 127 2 Disconnect the connectors in JCARTP1 A and JCARTS1 B on the system board ...

Page 327: ...formation 4 75 5026 Go Back Previous Next 3 Disconnect the connectors from the cartridge motor 1 C and the fuser motor D 4 Disconnect the camshaft cable connector E from the motor card and unwind the two cables ...

Page 328: ... from the six retainers F Installation notes Make sure you wrap the camshaft cable around the cartridge motor 1 fuser cable as shown to prevent the cables from interfering with the motors and damaging the cables Note the routing of the cables and the cable retainers ...

Page 329: ...idge motor 2 3 cable removal 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 127 2 Disconnect the connectors in JCARTP2 A and JCARTS2 B on the system board 3 Disconnect the connectors from the cartridge motor 2 C and cartridge motor 3 D ...

Page 330: ...y attention to the routing of the cables and the cable retainers Color on demand assembly removal 1 Remove the fuser See Fuser removal on page 4 118 2 Remove the print cartridges 3 Remove the top cover assembly See Top cover assembly removal on page 4 58 4 Disconnect the connector at JBOR1 A on the system board ...

Page 331: ...Repair information 4 79 5026 Go Back Previous Next 5 Remove the five screws B 6 Remove the COD assembly ...

Page 332: ...ation notes 1 Push the actuators A all the way down 2 Turn the printer around and verify the actuators are in the correct location by looking inside the front of the printer The actuators B should be visible in the triangular holes in the frame as shown A ...

Page 333: ...Repair information 4 81 5026 Go Back Previous Next 3 Rotate the large COD gear until the stop C on the gear is against the housing 4 Engage the gears on the left side of the COD C ...

Page 334: ... screws E 7 Verify the actuators can be seen by looking inside the printer at the triangular holes as in step 2 8 Check to make sure you can rotate the large COD gear from stop to stop 9 Reconnect the cable connector to JBOR1 connector on the system board 10 Reinstall the top cover assembly the fuser and the covers ...

Page 335: ...move the LVPS See Low voltage power supply LVPS removal on page 4 127 2 Remove the printhead See Printhead removal installation and adjustment on page 4 153 3 Remove contact spring cables from the cable restraints A Note Pay attention to the routing of the cartridge contact cables and the appropriate slots where each cartridge contact is installed A ...

Page 336: ...4 84 Service Manual 5026 Go Back Previous Next 4 Remove the three screws B securing the top three bell crank links 5 Remove the bell crank link C together with its bell crank spring D B C D ...

Page 337: ... the bell crank link and the other end onto the boss rest on the bell crank F b Make sure the locator pin on the bell crank rests on the locator hole of the bell crank link G 6 Use a prying tool to remove the bell crank Note The bell crank must be replaced due to the damage that can occur to the retention features of this bell crank 7 Perform steps 5 and 6 to the other bell crank links and bell cr...

Page 338: ...crank I 9 Using a spring compression tool J align its opening to the rib on the cartridge guide as shown then push and hold the spring compression tool into the cartridge contact spring Note Make sure to properly align the opening on the spring compression tool to the rib on the cartridge guide H I J ...

Page 339: ...t side of the machine then release the spring compression tool Note Pay attention to the color coding of the cartridge contact cables and the appropriate slots where each cartridge contact is installed Installation notes a Insert the cartridge contact spring into the slot on the cartridge guide 1 2 ...

Page 340: ...he cartridge guide then push and hold the spring compression tool into the cartridge contact spring Note Make sure to properly align the opening on the spring compression tool to the rib on the cartridge guide c Insert the cartridge contact on the right side of the machine 11 Perform steps 9 and10 to remove all the cartridge contacts K 1 2 ...

Page 341: ...ove the HVPS See High voltage power supply HVPS removal on page 4 123 2 Remove the charge roll contact springs A Be sure to push the springs under the retainers that hold them in place Installation note Make sure the springs are behind the retainers when installing the new springs A Retainer ...

Page 342: ...wer supply HVPS removal on page 4 123 2 Pull out the spring that will be replaced HVPS DB contact spring A HVPS DR contact spring B HVPS TAR contact spring C Installation note Refer below for the location of the HVPS DR Contact spring and HVPS DB contact spring C A B 27S1997 HVPS DR Contact 27S1998 HVPS DB Contact ...

Page 343: ...us Next Torsion spring removal 1 Open the front access door and remove all the toner cartridges 2 Remove the screw A and the spring cap B of the appropriate contact spring 3 Press the lower half C D of the springs and remove the springs B A D C ...

Page 344: ...n notes When installing make sure the top half E of the spring is under the straight spring F This is typical for both types of springs Also make sure the bottom half D G of both springs are compressed and locked by the appropriate locking tabs H I G F E H D I ...

Page 345: ...us Next Cooling fan removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 50 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Disconnect JFAN1 A 4 Remove the two screws B 5 Remove the cooling fan B ...

Page 346: ...al 5026 Go Back Previous Next Cooling fan filter removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 50 2 Turn the cover over 3 Squeeze the right side of the filter and remove it from the tabs A ...

Page 347: ... C on either side of the transfer module and lift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photocondu...

Page 348: ... Looking down at the keyed end of the restraint D twist the end clockwise slide the restraint upward through the slit E and slip the end of the restraint through the keyed hole F Repeat for the other side 6 Close the front access door assembly D F E ...

Page 349: ...tion 4 97 5026 Go Back Previous Next 7 Remove the two screws on the duplex aligner G and then remove the screw H securing the duplex reference edge guide assembly 8 Remove the duplex reference edge guide assembly G H ...

Page 350: ...ve the paper tray 2 Remove the transport belt module and the developer units See Transfer module removal on page 4 179 3 Remove the cartridges 4 Remove the low voltage power supply LVPS See Low voltage power supply LVPS removal on page 4 127 5 Disconnect the cartridge 1 fuser motor cable two connectors A and remove the cables from the cable retainers B ...

Page 351: ...connector C and remove the cable from the cable clamps D 7 Unwind the camshaft transport cable and the cartridge 1 fuser cables E Note Be sure to rewind the camshaft transport cable around the other cables with about four twists to keep them from interfering with or being damaged by the motors ...

Page 352: ...e 3 motor cable two connectors F and remove the cable from the cable clamps G 9 Disconnect the motor drive cable connector H and remove the cable from the cable clamps J 10 Remove the two screws K to remove the motor driver card assembly 11 Remove the two screws L on the inside K J J H ...

Page 353: ...Repair information 4 101 5026 Go Back Previous Next 12 Remove the three screws M on the front L M ...

Page 354: ...4 102 Service Manual 5026 Go Back Previous Next 13 Remove the seven screws N securing the EP drive N N First N N ...

Page 355: ... Previous Next 14 Remove the 5 V interlock switch cable from the restraint N on the backside of the EP drive 15 Remove the EP drive Installation notes 1 Push the actuator rack all the way to the right A 2 Pull the link all the way up B A B ...

Page 356: ...iner C on the bottom of the EP drive 4 Align the gear so the first gear tooth D of the top cover camshaft meshes with the first two gear teeth E after the flat area in the EP drive actuator rack and then seat the right side of the top cover camshaft into the boss F on the EP drive E D Flat area gap F ...

Page 357: ...Repair information 4 105 5026 Go Back Previous Next 5 Hold the drive in place while replacing the first of the seven screws then continue replacing the rest of the screws G ...

Page 358: ...eplace the three screws J on front 8 Wind the camshaft cable K around the cartridge 1 fuser cables about four times to make sure they do not interfere with or are damaged by the fuser motor 9 Connect the cartridge 1 fuser motor cable two connectors L and place the cables in the cable retainers M ...

Page 359: ...or driver card in place and reinstall the two screws P to secure the motor driver card 12 Connect the three connectors Q and secure the cables in the cable clamps R 13 Reinstall the low voltage power supply LVPS 14 Replace the right and rear covers 15 Replace the transport belt module and developer units 16 Replace the cartridges and the fuser 17 Replace the paper tray O N O R R Q P ...

Page 360: ...he front access cover assembly See Front access cover assembly removal on page 4 29 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Remove the LVPS See Low voltage power supply LVPS removal on page 4 127 4 Disconnect the JTPS1 cable A from the system board 5 Release the left and right front door assembly cable springs B from the front door assembly B B ...

Page 361: ...rmation 4 109 5026 Go Back Previous Next 6 Open the front door assembly 7 Unwrap and remove the cable from the left and right pulleys C 8 Close the front door assembly and remove the mounting screw D and the cap E ...

Page 362: ...e right and remove You need to press firmly to slide the front door assembly to the right Installation note See Front door assembly front cable left removal on page 4 111 and The longer cable installs on the left side of the printer on page 4 114 for proper installation of the cable restraints ...

Page 363: ... C on either side of the transfer module and lift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photocondu...

Page 364: ...Back Previous Next 5 Looking down at the keyed end of the restraint D twist the end clockwise slide the restraint upward through the slit E and slip the end of the restraint through the keyed hole F Repeat for the other side D F E ...

Page 365: ...val on page 4 118 7 Push down on both of the front door locking mechanism simultaneously to close the camshaft 8 Close the front access door assembly 9 Release the cable spring H from the front door assembly Note In order to access the springs make sure the top access cover is closed H ...

Page 366: ...o Back Previous Next 10 Remove the end of the cable J from the frame Installation notes The longer cable installs on the left side of the printer Push down on the lever to raise front door locking mechanism and open the camshaft ...

Page 367: ...s C on either side of the transfer module and lift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photocond...

Page 368: ...Back Previous Next 5 Looking down at the keyed end of the restraint D twist the end clockwise slide the restraint upward through the slit E and slip the end of the restraint through the keyed hole F Repeat for the other side D F E ...

Page 369: ...ight cover removal on page 4 51 7 Close the front access door assembly 8 Release the spring G from the front door assembly Note In order to access the springs make sure the top access cover is closed 9 Remove the end of the cable H from the frame 10 Remove the right restraint cable G ...

Page 370: ...of post for two full turns Fuser removal See Fuser assembly 115 V on page 7 7 Fuser assembly 230 V on page 7 7 or Fuser assembly 100 V on page 7 7 for the part number 1 Turn off the printer 2 Open the front access door 3 Open the top access door 4 Rotate the fuser thumbscrews A counterclockwise until loosened CAUTION The fuser can be extremely hot Use care when handling to avoid burns ...

Page 371: ...n To reset the counter and run the calibration 1 Enter the Configuration Menu Turn off the printer press and hold buttons 2 and 6 turn on the printer and release the buttons when the progress bar displays 2 Press for the Reset value Resetting Fuser Count Value appears 3 Select Motor Calibration from the CONFIG MENU Calibrating displays and the printer prints several blank pages and then returns to...

Page 372: ...ve the top cover assembly See Top cover assembly removal on page 4 58 2 Turn the top cover assembly over 3 Lift the locking latch A on the connector slide the connector down and remove the connector from the keyed hole 4 Remove the cable from the cable openings B Note Observe the routing of the cable for reinstallation ...

Page 373: ...e the top cover assembly See Top cover assembly removal on page 4 58 2 Turn the top cover assembly over 3 Remove the connector A from the top cover assembly Warning You will damage the old connector in the process Be careful not to damage the top cover assembly 4 Pull the cable through the hole B in the top cover assembly and the notch C ...

Page 374: ...it to your next level of support so any data can be removed If the customer requests to keep the part they must sign a confirmation of memory device retention form 1 Remove the rear frame cover See Rear frame cover removal on page 4 47 2 Remove the two screws A and squeeze the connector to disconnect the hard disk from the system board B 3 Pull the hard disk straight out to pop the hard drive stan...

Page 375: ...ltage power supply HVPS removal See High voltage power supply on page 7 13 for the part number 1 Remove the left cover See Left cover removal on page 4 31 2 Remove the six mounting screws A 3 Release the locking tab B from the front lower corner of the HVPS A B ...

Page 376: ...ct the five connectors C from the HVPS Installation notes Make sure to replace the spring when replacing the HVPS There are two types of spring forces on the cartridge contacts Make sure to put the springs in their appropriate slots and are oriented properly C ...

Page 377: ...able removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 50 2 Disconnect the cable connector at JHVPS1 on the system board 3 Disconnect the cable connector B from the HVPS 4 Remove the cable from the hole through the frame C and from the two cable restraints D ...

Page 378: ...evious Next Left bell crank assembly removal See Left bellcrank assembly with spring on page 7 7 for the part number 1 Remove the left cover See Left cover removal on page 4 31 2 Remove the C clip A 3 Remove the left bell crank assembly A ...

Page 379: ... page 7 9 for the part number 1 Remove the right cover See Right cover removal on page 4 51 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Disconnect the connector at JLVPS1 connector A on the system board 4 Remove the five LVPS mounting screws B 5 Disconnect the AC fuser cable C from the LVPS A ...

Page 380: ...alue 115 V or 230 V depending on the country Note Not all LVPS FRUs have a switch Others are switched automatically Install the LVPS and make sure the AC fuser cable is in the cable guides and not behind the LVPS Reconnect the AC fuser cable to the LVPS Replace the five LVPS mounting screws Reconnect the cable in connector JLVPS1 on the system board ...

Page 381: ...tion 4 129 5026 Go Back Previous Next Motor driver card removal 1 Remove the right cover See Right cover removal on page 4 51 2 Disconnect the three cables A 3 Remove the two screws B and remove the motor driver card ...

Page 382: ...tage power supply LVPS removal on page 4 127 2 Disconnect the connector in JDVR1 A on the system board 3 Disconnect the connector on the motor driver card B 4 Remove the cable from the cable from the four cable retainers C Installation note Pay attention to the routing of the cable and the cable retainers ...

Page 383: ...ousing removal See the multipurpose feeder duplex gear and housing kit for the part number 1 Remove the paper pick mechanism assembly See Paper pick mechanism assembly removal on page 4 145 2 Remove the two E clips A from the gears 3 Remove the three screws B 4 Slide the front gear C off A B C ...

Page 384: ...4 132 Service Manual 5026 Go Back Previous Next 5 Slide a flathead screwdriver up and under the front cover 6 Slide the remaining two gears and housings off ...

Page 385: ...ower supply LVPS removal on page 4 127 2 Remove the multipurpose feeder duplex gear and housing See Multipurpose feeder MPF duplex gear and housing removal on page 4 131 3 Remove the two multipurpose feeder duplex motor mounting screws A 4 Remove the multipurpose duplex motor from the printer 5 Push in the prongs B of the housing to remove the cable tie C 6 Slide the motor out of the housing 7 Dis...

Page 386: ...4 134 Service Manual 5026 Go Back Previous Next Installation notes 1 Connect the cable A at the motor 2 Slide the cable tie B onto the motor 3 Insert the motor into the frame ...

Page 387: ...135 5026 Go Back Previous Next 4 Replace the screws C 5 Slide the housing onto the motor making sure the four tabs of the housing slide under the cable tie 6 Replace the multipurpose feeder duplex gear and housing assembly ...

Page 388: ... feeder MPF duplex motor cable removal 1 Remove the multipurpose feeder duplex motor See Multipurpose feeder MPF duplex motor assembly removal on page 4 133 2 Disconnect the connector from JDX1 A on the system board 3 Remove the cable from the cable retainers B ...

Page 389: ... 3 Remove the rear frame cover See Rear frame cover removal on page 4 47 4 Remove the Low voltage power supply LVPS See Low voltage power supply LVPS removal on page 4 127 5 Remove the three screws A securing the tray rail that contains the paper present sensor 6 Remove the JMPFPP1 connector B from the system board then remove the cable Installation note Pay attention to the routing of the cable A...

Page 390: ...us Next 7 Remove the MPF paper sensor bracket from the machine 8 Pry the sensor off the bracket then disconnect the sensor C from the cable D 9 Remove the cable from the bracket Installation note Pay attention to the routing of the cable C D ...

Page 391: ...Repair information 4 139 5026 Go Back Previous Next MPF pick removal 1 Open the MPF door 2 Press the latch on the MPF pick then pull to the left to remove 1 1 2 ...

Page 392: ...y over 3 Remove the eight screws A and remove the position guide cover 4 Pull open the operator panel connector B and disconnect the operator panel cable from the operator panel card 5 Remove the operator panel cable from the toroid C and the two cable retainers D Installation note Make sure the contact pins on the cable are facing up when reconnecting the operator panel cable to the connector A D...

Page 393: ... access cover assembly over 3 Remove the eight screws A securing the position guide cover 4 Disconnect the operator panel ground cable from the operator panel ground pin B 5 Remove the screw C securing the operator panel ground cable to the operator panel card 6 Remove the operator panel ground cable from its retainers Installation note Pay attention to the routing of the ground cable A B C ...

Page 394: ...sembly removal on page 4 54 2 Turn the top access cover assembly over 3 Remove the eight screws A securing the position guide cover 4 Disconnect the USB ground cable B and detach the USB cable connector C from the USB slot 5 Remove the USB cable and ground cable from its retainers Installation note Make sure to observe the routing of the USB cable A B C ...

Page 395: ... removal 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 127 2 Disconnect the cable connector at JOPT1 A on the system board 3 Replace the rear frame cover to protect the system board 4 Position the printer on its back 5 Remove the two screws B ...

Page 396: ...4 144 Service Manual 5026 Go Back Previous Next 6 Press the tabs together to remove the option cable connector Note Be sure to note the cable routing for reinstallation ...

Page 397: ...t number 1 Remove the paper tray 2 Remove the waste toner assembly See Waste toner assembly removal on page 4 184 3 Remove the rear frame cover See Rear frame cover removal on page 4 47 4 Disconnect the connector in JFDPCK1 A and JTRAY1 B on the system board 5 Push the cables through the hole in the frame C 6 Open the front access cover ...

Page 398: ... lift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum place the transfer module with the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time Place a clean dry cloth over the transfer module and photoconductor units until they are requir...

Page 399: ...he paper pick mechanism and remove through the front of the printer Note Make sure the JTRAY1 and JTRAY2 connectors do not bind when passing through the frame access hole Installation notes 1 Remove the waste toner assembly See Waste toner assembly removal on page 4 184 2 Replace the rear frame cover to protect the system board 3 Turn the printer on its back 4 Slide the paper pick assembly toward ...

Page 400: ...4 148 Service Manual 5026 Go Back Previous Next 5 Engage the gear B ...

Page 401: ...Secure the remaining three screws D 9 Remove the rear frame cover 10 Route the cables through the hole in the frame and connect them to JFDPCK1 E and JTRAY1 F 11 Replace the rear frame cover 12 Replace the waste toner assembly 13 Replace the toner cartridges 14 Replace the transfer module with the photoconductor units 15 Close the front access cover 16 Replace the paper tray ...

Page 402: ...new photoconductor unit is installed reset the life count value in the printer memory If a message appears on the operator panel 1 When 84 color PC Unit Life Warning or 84 Replace color PC Unit appears select Supply Replaced and then press Replace Supply displays 2 Select Cyan PC Unit Magenta PC Unit Yellow PC Unit or Black PC Unit based on the photoconductor unit that was just replaced and then p...

Page 403: ...ns If you have additional input options and you are having problems with media picking replace these tires also Always replace the pick arm rolls in pairs The rolls come in a package of two Warning Remove only the rubber tires and not the pick tire assembly to avoid losing small parts 1 Remove the paper tray 2 Pull the paper pick arm A down 3 Remove the pick arm roll B from the pick arm roll assem...

Page 404: ...urns properly in the direction shown Printer pad removal 1 Slide the corner of the printer containing the damaged pad over the corner of the table 2 Remove the side cover that corresponds to the damaged pad so you can see if the pad fully seats in the installation holes 3 Pull the pad tabs A from the bottom of the printer Installation note Verify that the pad fully seats in the installation holes ...

Page 405: ... properly so the system board is probably the failing component Printhead removal 1 Turn the printer off 2 Disconnect the power cord from the electrical outlet and from the printer 3 Remove the paper tray 4 Open the front access door 5 Open the top access door 6 Remove the fuser 7 Remove the transfer module and photoconductor units a Disconnect the transfer module cable A b Press the two tabs B to...

Page 406: ...clean dry cloth over the transfer module and photoconductor units until they are required 8 Remove all of the toner cartridges 9 Remove the right cover and the right side cover attached See Right cover removal on page 4 51 10 Remove the LVPS See Low voltage power supply LVPS removal on page 4 127 11 Remove the system board support shield See System board support shield removal on page 4 168 12 Pus...

Page 407: ...Repair information 4 155 5026 Go Back Previous Next 13 Remove the three printhead mounting screws D ...

Page 408: ...stalling the printhead it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer The printer parts are installed with the printhead mounting screws loose so you can print the pages that will be used to align the black plane to the printer frame This also allows the black skew adjustment to be adjusted with the ...

Page 409: ...xt 2 Loosely attach the three printhead mounting screws B Warning Do not fully tighten the printhead mounting screws until skew has been adjusted 3 Lightly tighten the alignment screw C 4 Feed the ground cable through the hole in bottom leftside frame ...

Page 410: ...he edges of the frame c Replace the remaining system board support shield screws in the following order Replace the four screws E1 from the inner right side of the support shield Tighten the two mounting screws E2 to the top of the support shield Replace the three screws E3 from the bottom of the support shield and two screws from the top Replace the five mounting screws E4 E5 to the outer left si...

Page 411: ...the following order Loosely attach the four corners F1 in a clockwise order beginning with the left top corner Replace the USB connector screw F2 Loosely attach the left center side top center and right center side F3 Tighten the top left corner and top right corner Replace the two screws on the center bottom F4 Tighten the bottom left and bottom right corners F1 c Route the cables through the acc...

Page 412: ...ect all the cables to the system board Use the diagram below as a guideline Warning Be careful in reconnecting the printhead ribbon cable J It can be damaged and should be handled carefully A flat ribbon cable can easily be damaged and should be connected gently by hand f Install the hard disk if appropriate 7 Replace the LVPS a Install the LVPS and make sure the cable is in the cable guides and n...

Page 413: ...d just enough to hold the printhead in the printer There is one printhead that houses the four color planes The black plane is aligned to the printer and the color planes are internally aligned to black Electrical alignment is done to fine tune the alignment of the color planes to the black plane after the printhead is installed and black skew is adjusted using the alignment screw 1 Plug the elect...

Page 414: ...ous Next Right bell crank assembly removal See Right bellcrank assembly with spring on page 7 7 for the part number 1 Remove the right cover See Right cover removal on page 4 51 2 Remove the C clip A 3 Remove the right bell crank assembly A ...

Page 415: ...er removing this part return it to your next level of support so any data can be removed If the customer requests to keep the part they must sign a confirmation of memory device retention form Warning When replacing any one of the following components Operator panel assembly System board Top access cover assembly Only replace one component at a time Replace the required component and perform a POR...

Page 416: ...n page 4 31 2 Remove the rear frame cover See Rear frame cover removal on page 4 47 3 Remove the hard disk if one is installed See Hard drive assembly removal on page 4 122 4 Remove all the screws A from the left side of the printer so you can remove the system board including USB port connector 1 screw Ethernet port connector 1 screws Modem shield 1 screws Hard disk shield 2 screws Ground screw 1...

Page 417: ...isconnect all the cables from the system board Warning Do not use tools to remove the printhead ribbon cable B A flat ribbon cable can be damaged and should be removed gently by hand 6 Remove the nine screws C from the system board 7 Remove the system board ...

Page 418: ...the following order Loosely attach the four corners A1 in a clockwise order beginning with the left top corner Replace the USB connector screw A2 Replace the top center right center side and left center side A3 Tighten the top left corner and top right corner Replace the two screws on the center bottom A4 Tighten the bottom right and bottom left corners A1 3 Route the cables through the access hol...

Page 419: ...Note Be sure to attach the ground wire C to the ground screw 5 Reconnect all the cables to the system board Use the diagram below as a guideline Warning Be careful reconnecting the printhead ribbon cable D It can be damaged and should be handled carefully A flat ribbon cable can easily be damaged and should be connected gently by hand 6 Install the hard disk if appropriate 7 Replace the rear frame...

Page 420: ...3 2 Remove the right cover See Right cover removal on page 4 51 3 Pull the cables through the access holes on the right side of the printer 4 Remove the five mounting screws A from the outer left side of the printer Note Make a note of the attachment of the printhead ground cable B to the fourth screw from the top for later installation 5 Remove the four screws C from the inner right side of the s...

Page 421: ...oles in the system board support shield 7 Lower and remove the support shield Be careful not to damage the ribbon cable that routes through the bottom frame of the printer Installation notes 1 Loosely attach the two mounting screws A 2 Set the system board support shield in place Note Check that the ribbon mirror motor cable white and the printhead cable bottom do not rub against the edges of the ...

Page 422: ... the inner right side of the support shield Tighten the two mounting screws A to the top of the support shield Replace the three screws C from the bottom of the support shield and two screws from the top Replace the five mounting screws D to the outer left side of the printer Note Be sure to connect the printhead ground cable E to the fourth screw from the top ...

Page 423: ...See Toner level sensor on page 7 13 for the part number Note the locations of the toner sensors 1 Remove the HVPS See High voltage power supply HVPS removal on page 4 123 2 For the upper two sensors These sensors are more difficult to reach because the toner is difficult to reach ...

Page 424: ... the sensor on that side Press the other locking tab B and remove the sensor Note Use a slight pressure on the cable to keep the first locking tab from relatching while you disconnect the second locking tab For the lower two sensors Using a spring hook press the locking tab C and disengage the sensor on that side Press the other locking tab D and remove the sensor ...

Page 425: ...ft assembly on page 7 14 for the part number 1 Open the front cover access door cover 2 Open the top access cover 3 Remove the two screws A from the links on either side and disengage the links 4 Rotate the top access cover back and place a screwdriver in the cable hole in the frame to hold the cover in place ...

Page 426: ...vice Manual 5026 Go Back Previous Next 5 Remove the fuser See Fuser removal on page 4 118 6 Remove the top screw B and loosen the other screw C This will allow you to flex the EP drive 7 Remove the two screws D ...

Page 427: ...us Next 8 Rotate the camshaft up using the camshaft actuator handles E so you can access the other two screws F and remove them 9 Flex the EP drive assembly to remove the right side of the camshaft from the boss G and lift to remove the camshaft ...

Page 428: ...Manual 5026 Go Back Previous Next Installation notes 1 On the left side align the mark on the idler gear A with the mark on the camshaft gear B and slide the camshaft into place meshing the gears on the left side A B ...

Page 429: ... the first gear tooth of the camshaft aligns with the first two gear teeth of the EP drive actuator rack D Note Make sure the actuator rack on the EP drive is all the way back 3 Flex the EP drive on the right to seat the end of the shaft into the boss E on the EP drive 4 Make sure the left and right camshaft brackets are fully seated and replace the two screws F ...

Page 430: ...e camshaft actuator handle and replace the two screws G 6 Replace the screw in the EP drive that allowed you to flex the EP drive and tighten the other screw see step 6 of the removal 7 Replace the top access cover assembly 8 Replace the fuser the cartridges and close the covers ...

Page 431: ...bs C on either side of the transfer module and lift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum place the transfer module with the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time Place a clean dry cloth over the transfer module ...

Page 432: ...eleased from the holding pin E Installation note Place the photoconductor units on the new transport belt and reinstall Perform the Color Alignment in the Configuration Menu 1 Enter Config Menu turn off the printer press and hold buttons 3 and 6 turn the printer on and release the buttons when the clock graphic displays 2 Select Color Alignment from the Configuration Menu 3 Select Print Alignment ...

Page 433: ...the transport belt assembly Leave the photoconductor units in place See Transfer module removal on page 4 179 3 Disconnect the transport cable from the system board at JTPS1 connector A Note The cable connector on the system board end of the cable is smaller than the connector on the front access door and it may be easier to get that end through the openings ...

Page 434: ...ough the opening in the frame to the right side of the printer B 5 Remove the cable from the five cable restraints C 6 Remove the cable from the three openings in the cable channel D on the right side of the front access door 7 Remove the six screws E from the cable shield ...

Page 435: ...ove the cable through the cable channel F Transport motor cable removal 1 Remove the right cover See Right cover removal on page 4 51 2 Disconnect the cable from the transport motor drive A 3 Disconnect the cable from the transport motor B 4 Remove the cable ...

Page 436: ...184 Service Manual 5026 Go Back Previous Next Waste toner assembly removal Not a FRU 1 Press the waste toner release latch A 2 Swing the front of the waste toner assembly away from the printer and remove ...

Page 437: ...ift out the transfer module Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum place the transfer module with the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time Place a clean dry cloth over the transfer module and photoconductor units until they are required...

Page 438: ...4 186 Service Manual 5026 Go Back Previous Next 5 Remove the six mounting screws D holding the HVPS in place 6 Release the locking tab E from the front lower corner of the HVPS D E ...

Page 439: ...Repair information 4 187 5026 Go Back Previous Next 7 Lay the board to the left 8 Disconnect the three top toner level sensor cables F from the HVPS F ...

Page 440: ...4 188 Service Manual 5026 Go Back Previous Next 9 Remove the two screws G G 18B1236 ...

Page 441: ...Repair information 4 189 5026 Go Back Previous Next 10 Remove the cleaner shutter actuator H from the waste toner HV contact assembly H ...

Page 442: ...90 Service Manual 5026 Go Back Previous Next 11 Remove the four screws J the two screws K and the screw L Tilt the Waste toner HV contact assembly forward and up to remove it J 18B0832 K 88A0313 L 27S2838 ...

Page 443: ...s when re installing the waste tone HV contact assembly 1 Remove the fuser 2 Remove all four toner cartridges 3 Remove the four sets of torsion springs Remove the screw A and the spring cap B of the appropriate contact spring 4 Press the lower half C D of the springs and remove the springs B A D C ...

Page 444: ...tall the waste toner HV contact assembly into place Route the toner level sensor cables E through the holes in the waste toner HV contact assembly while positioning the assembly Make sure the aligner shaft worm gear is aligned as shown E Ribs aligned Rib ...

Page 445: ...Repair information 4 193 5026 Go Back Previous Next 6 Install the seven screws in the order shown below Install 1 18B0832 st Install 2 88A0313 nd Install 4 18B0832 th Install 3 rd 27S2838 ...

Page 446: ...194 Service Manual 5026 Go Back Previous Next 7 Use two screws F to attach the cleaner shutter actuator to the Waste toner HV contact assembly Make sure the gear aligns as shown F 27S2838 Rib Ribs aligned ...

Page 447: ...Repair information 4 195 5026 Go Back Previous Next 8 Attach the eight springs G to the Waste toner HV contact assembly as shown Make sure the springs are behind the retainers G Retainer ...

Page 448: ... When installing each contact spring make sure the top half H of the spring is under the straight spring J This is typical for both types of springs Also make sure that the bottom half K L of both springs are compressed and locked by the appropriate locking tabs M N L K J M H N ...

Page 449: ...ormation 4 197 5026 Go Back Previous Next 10 Connect the three top toner level sensor cables to the HVPS making sure the cables O are attached properly to the retainers P 11 Reassemble the rest of the printer P O ...

Page 450: ...move the wireless network card see Wireless network card removal on page 4 199 2 Disconnect the wireless network antenna cable A from the wireless network card 3 With pliers squeeze the inner tabs B and pull the antenna out 4 Pull the cable through and remove the antenna with the cable ...

Page 451: ...ss network card removal 1 Remove the rear frame cover See Rear frame cover removal on page 4 47 2 Disconnect the wireless cable from the system board at J5 A by squeezing the tabs at either end together 3 Remove the two screws B that secure the card into place ...

Page 452: ...e removing the wireless network card to access another part leave the antenna attached to the card and you are done If you need to replace the wireless network card FRU continue with the next step to remove the separate wireless network antenna FRU 5 Remove the wireless network antenna See Wireless network antenna removal on page 4 198 ...

Page 453: ...he high capacity input tray HCIT media tray assembly it is not necessary to remove it from the base machine and the caster base 1 Open the HCIT media tray assembly A until it reaches a stop 2 Press the latches B on the left and right side of the HCIT tray slides 3 Slide the HCIT media tray assembly out of the drawer B B A ...

Page 454: ...T front tray cover it is not necessary to remove the HCIT media tray assembly from the base machine and the caster base 1 Remove the HCIT media tray assembly See HCIT media tray assembly removal on page 4 201 2 Remove the six screws A securing the HCIT front tray cover to the media tray assembly 3 Remove the HCIT front tray cover ...

Page 455: ...Repair information 4 203 5026 Go Back Previous Next HCIT rear cover removal 1 Remove the four screws A securing the HCIT rear cover to the drawer 2 Remove the HCIT rear cover ...

Page 456: ...he high capacity input tray HCIT and remove the HCIT from the caster base 2 Remove the HCIT media tray assembly See HCIT media tray assembly removal on page 4 201 3 Remove the HCIT rear cover See HCIT rear cover removal on page 4 203 4 Remove the six screws A securing the HCIT right cover to the drawer 5 Remove the HCIT right cover A A ...

Page 457: ... the high capacity input tray HCIT and remove the HCIT from the caster base 2 Remove the HCIT media tray assembly See HCIT media tray assembly removal on page 4 201 3 Remove the HCIT rear cover See HCIT rear cover removal on page 4 203 4 Remove the six screws A securing the HCIT left cover to the drawer 5 Remove the HCIT left cover A A ...

Page 458: ... Top plate assembly removal on page 4 214 2 Remove the four screws A securing the pass thru sensor bracket to the top plate assembly Note The bushing may come off when removing the pass thru sensor bracket 3 Remove the screw B securing the 46T gear C to the top plate assembly 4 Remove the 46T gear 5 Snap loose the feed roller D and remove A B D C ...

Page 459: ...T right cover See HCIT right cover removal on page 4 204 2 Disconnect the seven connectors A from the HCIT controller board 3 Remove the ground screw B from the HCIT controller board 4 Remove the two screws C securing the HCIT controller board to the card mount option 5 Remove the HCIT controller board A B C ...

Page 460: ...slide but removing the right slide is similar 1 Remove the HCIT media tray assembly See HCIT media tray assembly removal on page 4 201 2 Remove the three screws A securing the HCIT drawer slide to the side frame 3 Remove the HCIT drawer slide HCIT elevator motor with sensor removal 1 Remove the HCIT right cover See HCIT right cover removal on page 4 204 2 Disconnect the connector A from the HCIT c...

Page 461: ...curing the pass thru sensor to the top plate assembly 4 Remove the pass thru sensor from the top plate assembly 5 Release the harness from the clamps C 6 Remove the eight screws D securing the elevator motor with sensor to the side frame 7 Remove the elevator motor with sensor ...

Page 462: ...y assembly removal on page 4 201 2 Pull the auto compensator pick arm A down 3 Remove the pick arm roll B from the pick roll assembly C 4 Repeat for the other pick arm roll D Note Always replace the pick arm rolls as pairs Installation notes See Pick arm roll removal and replacement on page 4 151 to make sure the pick arm roll is oriented correctly A B C D ...

Page 463: ...ard assembly removal on page 4 207 2 Disconnect the two springs A from the frame Note Leave the springs attached to the cam size sensing plate B and the actuator switch 3 Slide the cam size sensing plate B through the access hole in the rear side frame 4 Remove the media size actuator from the card mount option C 5 Snap loose the actuator switch D and remove ...

Page 464: ...ation note 1 Place the card mount option into position and secure it with the four screws 2 Reinstall the media size actuator to the card mount option 3 Reinstall the actuator switch with spring through the inside of the drawer 4 Reinstall the cam size sensing plate with spring through the access hole in the rear side 5 Reattach the two springs to the frame ...

Page 465: ...l on page 4 204 2 Disconnect the photo interrupter sensor cable connector A from the HCIT controller board 3 Turn the drawer rear side down and use 4 0 mm wrench to remove the four Allen screws B securing the counterweight to the rear frame Warning Do not remove the screws without turning the drawer rear side down first The counterweight is very heavy it might fall and cause damage A B ...

Page 466: ...Note Remove the cable from the restraint and observe the routing for reinstallation 5 Remove the photo interrupter sensor with cable assembly Top plate assembly removal 1 Remove the high capacity input tray HCIT right cover See HCIT right cover removal on page 4 204 2 Disconnect the five connectors A from the HCIT controller board C D A ...

Page 467: ...5 5026 Go Back Previous Next 3 Release the hooks B securing the pass thru sensor from the top plate assembly 4 Remove the fourteen screws C securing the top plate assembly to the frame 5 Remove the top plate assembly B C C C ...

Page 468: ...4 216 Service Manual 5026 Go Back Previous Next ...

Page 469: ...Connector locations 5 1 5026 Go Back Previous Next 5 Connector locations Locations ...

Page 470: ...xt Connectors System board diagram JSB1 JBIN1 JFAN1 JFUSER1 JBOR1 JHVPS1 JMIRR1 JBLW1 JCVR1 JLVPS2 JCARTP1 JCARTS1 JCARTS2 JCARTP2 JDVR1 JTPS 19 JOX1 JFDS1 JINT1 JFDPCK1 JTRAY1 JSEC1 JMPFPP1 J7 J19 JT 9 JPH1 JFMUSB1 J2 J2 F5 F7 F8 F9 F10 F11 F14 ...

Page 471: ...C motor lower JCVR1 25V Cover Open Switch Connector JDVR1 Daughter card motor driver JDX1 Duplex MFP BDC motor drive JFAN1 System fan JFDPCK1 Feed and pick motor connector JFDS1 Feed thru sensor connector JFMUSB1 USB device port JFUSER1 Fuser motor connector JHVPS1 High voltage power supply JINT1 Interlock switch 5v JLVPS2 Low voltage power supply JMIRR Mirror motor connector JMPFPP1 MPF sensor JO...

Page 472: ...5 4 Service Manual 5026 Go Back Previous Next ...

Page 473: ...IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Use Nyogel type 774 to lubricate the Fuser Drive Assembly and Nyogel 744 to lubricate the ITU and Cartridge Drive assemblies Maintaining the printer Periodically certain tasks are required to maintai...

Page 474: ...s 4 Clean the lenses using a can of compressed air Warning Potential Damage Do not touch the printhead lenses 5 Reinstall the four toner cartridges 6 Close the front door Moving the printer Follow these guidelines to avoid personal injury or printer damage Always use at least two people to lift the printer Always turn off the printer using the power switch before moving it Disconnect all cords and...

Page 475: ...ription Abbreviation used Machine type and model Printer name Description 310 5026 310 Lexmark C746n Network ready 330 5026 330 Lexmark C746dn Network ready with duplex 330 5026 330 Lexmark C746dtn Network ready with duplex and 550 sheet tray 510 5026 510 Lexmark C748e Network ready with etask touch screen 530 5026 530 Lexmark C748de Network ready with etask touch screen and duplex 530 5026 530 Le...

Page 476: ...7 2 Service Manual 5026 Go Back Previous Next Assembly 1 Covers C746 1 2 3 4 5 16 17 17 13 14 15 6 7 8 9 10 11 12 18 ...

Page 477: ...ng Bin full flag Operator panel display bracket 6 40X5106 1 1 Output bin extension cover 7 40X5103 1 1 Rear upper cover 8 40X5993 1 1 Top cover assembly 9 40X5287 1 1 Cooling fan filter 10 40X5145 1 1 Rear frame cover 11 40X5105 1 1 Rear right cover 12 40X5153 1 1 Dust cover assembly 13 40X5104 1 1 Rear left cover 14 40X5994 1 1 Right cover 15 40X7661 1 1 Front access door cover assembly 16 40X510...

Page 478: ...7 4 Service Manual 5026 Go Back Previous Next Assembly 2 Covers C748 1 2 3 6 19 18 18 17 15 16 7 8 9 11 12 14 13 20 4 5 10 ...

Page 479: ...0X5106 1 1 Output bin extension cover 8 40X5103 1 1 Rear upper cover 9 40X5993 1 1 Top cover assembly 10 40X7703 1 1 Speaker 11 40X5287 1 1 Cooling fan filter 12 40X5145 1 1 Rear frame cover 13 40X5153 1 1 Dust cover assembly 14 40X5105 1 1 Rear right cover 15 40X5994 1 1 Right cover 16 40X7661 1 1 Front access door cover assembly 17 40X5104 1 1 Rear left cover 18 40X5119 1 1 Top access cover link...

Page 480: ...7 6 Service Manual 5026 Go Back Previous Next Assembly 3 Front 1 2 3 4 7 12 11 13 14 10 A B D E C G F F 5 6 8 9 ...

Page 481: ...ction gear MP feeder duplex reduction gear MP feeder drive cover 5 40X6319 1 1 Cranklift spring and metal clip 6 40X8308 1 1 Paper pick assembly 7 40X5152 2 2 Pick arm roll 8 40X5999 1 1 Paper tray assembly 550 sheet 9 40X6496 1 1 MPF pick arm assembly 10 40X5111 1 1 Front door parts packet Includes the following A Front access door cap 1 B Right cable assembly 1 C Front access cover pivot 1 D Lef...

Page 482: ...7 8 Service Manual 5026 Go Back Previous Next Assembly 4 Right ...

Page 483: ...Units FRU Description 4 1 40X5290 1 1 EP drive assembly 2 40X5991 1 1 Low voltage power supply 3 40X5126 1 1 Motor driver card 4 40X8309 1 1 MP feeder duplex motor 5 40X5128 1 1 24 V interlock switch 6 40X5127 1 1 5 V interlock switch 7 40X5998 1 1 MPF paper present sensor with cable ...

Page 484: ...7 10 Service Manual 5026 Go Back Previous Next Assembly 5 Rear ...

Page 485: ... Austria Belgium Catalan Czechoslovakia Finland France Germany Greece Hungary Ireland Italy Netherlands Norway Paraguay Poland Portugal Russia Spain Sweden Turkey United Kingdom NS 40X0271 1 1 Power cord 8 ft United Kingdom NS 40X4596 1 1 Power cord 8 ft Brazil NS 40X0273 1 1 Power cord 8 ft Chile Uruguay NS 40X0303 1 1 Power cord 8 ft China NS 40X1774 1 1 Power cord 8 ft Denmark Finland Norway Sw...

Page 486: ...7 12 Service Manual 5026 Go Back Previous Next Assembly 6 Left 4 places 1B 4 places 4 places 1A 1C 4 places 4 places 3 8 places 4 places 1G 1E 1F 5 1D 2 6 4 ...

Page 487: ...t spring B Torsion CR contact spring C Contact spring cap D Charge roll contact spring E HVPS TAR contact spring F HVPS doctor developer contact spring G HVPS Db contact spring Screw 2 40X7159 1 1 Auger shaft and gear parts pack 3 40X5307 1 1 Waste toner HV contact assembly 4 40X5129 1 1 High voltage power supply 5 40X1416 4 1 Toner level sensor 6 40X8373 1 1 Toner cartridge contacts ...

Page 488: ...Back Previous Next Assembly 7 Top Index P N Units mach Units FRU Description 7 1 40X5122 1 1 Color On Demand assembly 2 40X5109 1 1 Cooling fan 3 40X5130 1 1 Top cover camshaft assembly 4 40X5108 1 1 Cartridge cooling fan 3 4 1 2 ...

Page 489: ... cable Fuser AC cable Fuser DC cable HVPS cable Transport cable Fuser and cartridge 1 motor cable Cartridge 2 and 3 motor cable USB A cable 550 option cable Transport motor cable Speaker cable UICC cable for single function UICC cable for multi function Operator panel ground cable for single function Operator panel ground cable for multi function NS 40X6351 1 1 Motor driver cable ...

Page 490: ...xt Assembly 9 Optional 550 sheet media drawer and tray Index P N Units opt Units FRU Description 9 1 40X5140 1 1 550 sheet tray option drawer and tray assembly 2 40X5168 2 2 Pick arm roll 550 sheet tray 3 40X5141 1 1 550 sheet tray assembly 3 2 1 ...

Page 491: ...Next Assembly 10 Optional special media tray assembly Index P N Units opt Units FRU Description 10 1 40X5142 1 1 Special media assembly including tray 2 40X5152 2 2 Pick arm roll 550 sheet drawer 3 40X5143 1 1 Special media tray assembly 1 3 2 ...

Page 492: ...7 18 Service Manual 5026 Go Back Previous Next Assembly 11 Optional high capacity input option HCIT 4 2 1 6 5 7 8 11 12 10 13 14 3 9 ...

Page 493: ...ng 4 40X5149 1 1 HCIT rear cover 5 40X4585 2 1 Tray latch with spring 6 40X5159 1 1 HCIT controller card assembly 7 40X4587 1 1 Slide assembly with springs 8 40X5147 1 1 HCIT right cover 9 40X5155 1 1 Elevator motor with sensor 10 40X5158 1 1 Photointerrupter sensor with cable assembly 11 40X4593 2 1 HCIT drawer slide assembly 12 40X5146 1 1 HCIT front tray cover 13 40X5144 1 1 HCIT paper drawer t...

Page 494: ...120 10 1000 NS 40X4827 1 1 MarkNet N8130 10 100 fiber NS 40X4823 1 1 Parallel 1284 B interface card adapter NS 40X4819 1 1 Serial interface card adapter NS 40X7058 1 1 160 GB hard drive assembly NS 7377200 1 1 Option drawer relocation kit NS 40X5281 1 1 High capacity input tray HCIT relocation kit NS 40X5316 1 1 14 pin JST cable assembly for ISP interface cable NS 40X8332 1 1 C74x relocation kit N...

Page 495: ...HVPS cable 4 125 motor driver cable 4 130 MP feeder duplex motor 4 136 operator panel 4 140 operator panel usb coonector cable 4 142 option cable 4 143 transport cable 4 181 transport motor cable 4 183 cables parts catalog 7 15 cartridge cooling fan parts catalog 7 14 removal 4 66 service check 2 118 cartridge motor service check 2 109 2 110 2 113 cartridge motor 1 fuser cable 4 74 cartridge motor...

Page 496: ...24 Print Tests input source tests 3 12 Prt Quality Pgs 3 13 Printer Setup Configuration ID 3 23 Defaults 3 22 Engine Setting 1 4 3 23 Model Name 3 23 Page Counts 3 23 Reset Color Calibration 3 24 Serial Number 3 23 Printhead Tests Mirror Motor Test 3 20 Servo Laser Test 3 20 Registration 3 5 Bottom Margin 3 6 3 7 Left Margin 3 6 3 7 Quick Test 3 8 Right Margin 3 6 3 7 Skew 3 5 Top Margin 3 6 3 7 R...

Page 497: ...4 202 left cover 4 205 media tray assembly 4 201 photointerrupter sensor with cable assembly 4 213 pick arm roll 4 210 rear cover 4 203 right cover 4 204 slide assembly with spring 4 211 top plate assembly 4 214 high voltage power supply HVPS cable removal 4 125 parts catalog 7 12 removal 4 123 I input sensor service check 2 101 J jams clearing jams 3 43 common messages diagram 3 42 paper jam mess...

Page 498: ...or 3 61 paper support output bin extension cover 4 45 paper tray dust cover removal 4 46 Par 1 Strobe Adj 3 24 parts catalog cable parts packet 7 15 front 7 6 left 7 12 rear 7 10 right 7 8 top 7 14 Perm Page Count 3 23 photoconductor unit 4 2 handling 4 2 installation 4 150 parts not to be touched 4 2 removal 4 150 transportation storage 4 2 Pick arm roll replacement 4 151 power cords 7 11 power o...

Page 499: ... HCIT front tray cover 4 202 HCIT left cover 4 205 HCIT media tray assembly 4 201 HCIT photointerrupter sensor with cable assembly 4 213 HCIT pick arm roll 4 210 HCIT rear cover 4 203 HCIT right cover 4 204 HCIT slide assembly with spring 4 211 HCIT top plate assembly 4 214 paper pick mechanism assembly 4 145 photoconductor unit 4 150 pick roll rubber tires 4 151 precautions 4 28 printer pad 4 152...

Page 500: ...tem board parts catalog 7 10 removal 4 163 service check 2 122 system board support shield parts catalog 7 10 removal 4 168 T test pages print quality test pages 3 13 3 28 Quick Test 3 8 quick test duplex 3 16 theory electrical interlock 24 V interlock switch 3 73 5 V interlock switch 3 73 electrophotographic EP process charging 3 65 cleaning 3 72 developing 3 69 exposing 3 68 fusing 3 71 main com...

Page 501: ...y Paraguay Poland Portugal Russia Spain Sweden Turkey United Kingdom 7 11 40X3609 Power cord 8 ft Japan 7 11 40X4585 Tray latch with spring 7 19 40X4587 Slide assembly with springs 7 19 40X4593 HCIT drawer slide assembly 7 19 40X4596 Power cord 8 ft Brazil 7 11 40X4819 Serial interface card adapter 7 20 40X4823 Parallel 1284 B interface card adapter 7 20 40X4826 MarkNet N8120 10 1000 7 20 40X4827 ...

Page 502: ...M 7 20 40X5307 Waste toner HV contact assembly 7 13 40X5315 Wireless ISP thumbscrew 7 20 40X5316 14 pin JST cable assembly for ISP interface cable 7 20 40X5317 Parts packet ISP thumbscrew and standoff 7 20 40X5318 ISP thumbscrew 7 20 40X5704 256 MB flash card 7 20 40X5969 Korean font card 7 20 40X5970 Simplified Chinese font card 7 20 40X5971 Traditional Chinese font card 7 20 40X5972 Japanese fon...

Page 503: ...8111 Fuser assembly 230 V 7 7 40X8112 Fuser assembly 100 V 7 7 40X8259 Operator panel bezel 510 7 5 40X8308 Paper pick assembly 7 7 40X8309 MP feeder duplex motor 7 9 40X8317 Operator panel bezel C74x blank logo 7 3 7 5 40X8321 C746x forms barcode 7 20 40X8322 C748x forms barcode 7 20 40X8324 C746x IPDS SCS TNe card 7 20 40X8325 C748x IPDS SCS TNe card 7 20 40X8327 C746x Prescribe card 7 20 40X832...

Page 504: ...I 10 Service Manual 5026 Go Back Previous Next ...

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