Lexmark C935 Service Manual
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Lexmark C935 Service Manual

Lexmark C935 Service Manual

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Table of Contents

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See also: Troubleshooting Manual , Maintenance Manual
Revision: February 21, 2012
™
Lexmark
C93x Printer
5057-XXX
• 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.

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Summary of Contents for Lexmark C935

  • Page 1 ™ Lexmark C93x Printer 5057-XXX • 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.
  • Page 2 Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PCL® is a registered trademark of the Hewlett-Packard Company.

  • Page 3: Table Of Contents

    5057-XXX Notices and safety information ......... xvii Previous Laser notice .
  • Page 4 5057-XXX Printhead assembly ............. 1-13 Previous Printhead shutter .
  • Page 5 5057-XXX Media transport path ............1-35 Previous Functions of main components .
  • Page 6 5057-XXX Media feed lift motor ............1-52 Previous Switch (media size) .
  • Page 7 5057-XXX 849.00 Hard drive/configuration ID mismatch ........2-60 Previous 900.xx System software error .
  • Page 8 5057-XXX 930.03 Yellow toner RFID communication failure ........2-111 Previous 940.00 MPF tray 5 size sensing error .
  • Page 9 5057-XXX Solid black ............. . . 2-151 Previous Vertical lines and bands (process direction) .
  • Page 10 5057-XXX Fuser Temp Fail Clear ............3-19 Previous ATC SENSOR FAILURE CLEAR .
  • Page 11 5057-XXX Media out actuator removal ............4-22 Previous Sensor (media level) removal .
  • Page 12 5057-XXX Rear lower cooling fan assembly ..........4-99 Previous CMY developer drive motor assembly .
  • Page 13 5057-XXX 2000-sheet dual input (TTM)—feed roll one-way clutch removal ..... . . 4-152 Previous 2000-sheet dual input (TTM)—one-way 22 tooth removal ......4-153 2000-sheet dual input (TTM)—separation roll one-way friction clutch removal .
  • Page 14 5057-XXX 1X 500-sheet drawer (1TM)—one-way 22 tooth removal ....... 4-203 Previous 1X 500-sheet drawer (1TM)—separation roll one-way friction clutch removal .
  • Page 15 5057-XXX Assembly 28: Cooling fans ............7-31 Previous Assembly 29: Electrical 1.
  • Page 16 5057-XXX Previous Next Go Back Printer Service Manual...

  • Page 17: Laser Notice

    5057-XXX Notices and safety information Previous The following laser notice labels may be affixed to this printer. Next Laser notice Go Back The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 18 5057-XXX Previous Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Next Clase I (1).
  • Page 19 5057-XXX Previous Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) - lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Next Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
  • Page 20 5057-XXX Previous Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
  • Page 21 5057-XXX Previous Next Go Back Notices and safety information...
  • Page 22 5057-XXX Previous Next Go Back xxii Printer Service Manual...
  • Page 23 5057-XXX Previous Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. Next •...
  • Page 24 5057-XXX Previous Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Next • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 25 5057-XXX Previous Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 26: Connector Locations

    5057-XXX Preface Previous This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
  • Page 27 5057-XXX Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements: CAUTION Go Back A caution identifies something that might cause a servicer harm. CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working.
  • Page 28 5057-XXX Previous Next Go Back xxviii Printer Service Manual...

  • Page 29: General Information

    5057-XXX 1. General information Previous The Lexmark™ C935 is color laser printer. All information in this service manual pertains to both models unless explicitly noted. Next Printer technology • Color laser Go Back Processor • 1.25 GHz Memory • Standard: 512 MB •...

  • Page 30: Printer Overview

    5057-XXX Previous Printer overview CAUTION: Do not set up this product or make any electrical or cabling connections, such as the power cord or options and features, during a lightning storm. Next Basic model Go Back The following illustration shows a printer with its base features. Operator panel Duplex unit...

  • Page 31: Configured Model

    5057-XXX Configured model Previous The following illustration shows a fully configured printer. Items denoted with an asterisk (*) are options. Operator panel Next Go Back Duplex unit Bridge unit* (Used in conjunction with finisher) Multipurpose feeder (MPF) Finisher* Tray 3 and tray 4 850+1150 sheet dual input tray (TTM) Tray 1 and tray 2...

  • Page 32: Printer Theory

    5057-XXX Previous Printer theory Media transport Media transport path Next Media is supplied from the MPF, tray 1, 2, 3 or 4, and is transported to the printer along the media transport path shown below. Go Back Tray 1 Tray 2 Tray 3 Tray 4 MPF pick roll...

  • Page 33: Sfp Paper Path Rolls

    5057-XXX SFP paper path rolls Previous Upper media transport roll assembly Finisher media entrance roll assembly Bridge unit assembly Upper media exit (included with finisher) roll assembly Standard media exit roll assembly Bridge unit bin exit Next roll assembly Buffer roll assembly Fuser exit Media eject roll assembly...

  • Page 34: Sfp Sensors

    5057-XXX SFP sensors Previous Sensor (diverter gate) Sensor (finisher Sensor (bridge unit Sensor (bridge media entrance) Sensor (upper media exit) media bin exit) unit media exit) Sensor (upper Sensor (standard media bin full) Next bin media full) Sensor (lower media exit) Sensor (fuser exit) Go Back Sensor (media on belt)

  • Page 35: Rear Media Guide

    5057-XXX Rear media guide Previous The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear. The rear guide come into contact with the media and hold it in position. End guide Next The media tray assembly is designed so it can adapt to the media length in the media feed direction by moving...

  • Page 36: Media Feed/Lift Motor

    5057-XXX Media feed/lift motor Previous This motor is activated to feed media and to lift the bottom plate. When feeding media, it rotates forward to drive the pick roll. When lifting the bottom plate, it rotates reversely to drive the tray module gears to lift the lift up shaft. Switch (media size) Next This switch (media size) sets the size of media supplied from each media tray assembly.

  • Page 37: Multi-Purpose Feeder (Mpf)

    MPF pick solenoid MPF pick rolls Sensor (MPF media width) Sensor (MPF media out) Media size The following table details the standard paper and envelope sizes supported by the Lexmark C935, and options. Media Width Length 210 mm 297 mm...

  • Page 38: Registration

    5057-XXX Previous Media Width Length Folio 8.5 inches 13 inches Statement 5.5 inches 8.5 inches Universal 140 to 297 mm 98.4 to 432 mm Next 5.5 to 11.7 inches 3.9 to 17 inches MPF only 105 to 305 mm 148 to 482 mm 4.1 to 12 inches 5.8 to 19 inches Go Back...

  • Page 39: Transfer

    5057-XXX The registration roll assembly feeds the media at the precise moment to ensure that printed images are Previous precisely placed. The registration roll assembly feeds media from all trays to the transfer belt. Registration clutch Sensor (transparency detect) Next Sensor (registration) Go Back...

  • Page 40: Transfer Belt Unit Assembly

    5057-XXX Transfer belt unit assembly Previous The transfer belt unit assembly contains the four 1st transfer rolls; these 1st transfer rolls are referred to as the CMYK transfer rolls. The CMYK transfer rolls are positively charged to remove the developed toner image from the four drums.

  • Page 41: Sensor (2Nd Transfer Roll Hp)

    5057-XXX Sensor (2nd transfer roll HP) Previous The sensor (2nd transfer roll HP) is used to detect the home position of the 2nd transfer roll assembly. Next Go Back Transfer belt Sensor (2nd transfer roll retract HP) 2nd transfer roll assembly 2nd transfer roll retract motor Printhead assembly...
  • Page 42 5057-XXX Conceptual diagram of an image created by scanning Previous Next Go Back Printhead 1-14 Printer Service Manual...
  • Page 43 5057-XXX Previous Y Laser Path Y drum Next Go Back Sensor (Y start of scan) Polygon Mirror M Laser Path M drum Polygon Mirror Sensor (M start of scan) 1-15 General information...

  • Page 44: Printhead Shutter

    5057-XXX Previous C drum C Laser Path Next Sensor Go Back (C start of scan) Polygon Mirror K drum K Laser Path Sensor (K start of scan) Polygon Mirror Printhead shutter The printhead shutter tightly covers the slit glass through which laser beams from the printhead pass to write the four drums.

  • Page 45: Fuser

    5057-XXX Fuser Previous Next Go Back Fuser cooling fan Heat roll Sensor (fuser exit) Pressure belt Thumb screws Heat roll The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media.

  • Page 46: Pressure Belt

    5057-XXX Pressure belt Previous The pressure belt is used to apply pressure to the media surface for fusing. Pressure is applied to the media between the pressure belt and heat roll, pressing the melted toner against the media. Next Heater lamps Rear thermister Go Back...

  • Page 47: Standard Media Exit Roll Assembly

    5057-XXX Standard media exit roll assembly Previous The media exit roll assembly feeds printed media from the fuser to the standard bin. Sensor (standard bin full) Next The sensor (standard bin full) detects whether the standard bin is full by moving the actuator up and down. Standard media exit shift motor Go Back The standard media exit shift motor allows the standard media exit roll assembly to shift back and forth to...

  • Page 48: Cmyk Pc Cartridge Drive Motor Assembly

    5057-XXX The MPF/transport drive motor is a stepper motor that drives the MPF unit assembly and media transport roll. Previous K developer/transport Next drive motor assembly Go Back MPF/transport drive motor CMYK PC cartridge drive motor assembly The CMYK PC cartridge drive motor assembly uses dual DC brushless motors that drive the four drums in the four PC cartridges.

  • Page 49: Cmy Developer Drive Motor Assembly

    5057-XXX CMY developer drive motor assembly Previous The CMY developer drive motor assembly uses a DC brushless motor to drive the three color developer unit assemblies. K developer clutch Next This clutch is used to engage the K developer unit assembly and is driven by the K-developer/transfer drive motor assembly.

  • Page 50: Waste Toner Agitator Motor Assembly

    5057-XXX The CMYK toner add motor assembly consists of 4 separate DC motors. Each color of toner has its own motor Previous that is used to rotate the toner auger inside the toner cartridge and drive the auger inside the toner add assembly.

  • Page 51: Fuser Cooling Fan

    5057-XXX Fuser cooling fan Previous The fuser cooling fan discharges air from the printer to prevent excessive temperature increase. AC drive card assembly Next The AC drive card assembly accepts the main source voltage and distributes it to secondary power supplies and circuit boards.

  • Page 52: Upper Printer Engine Card Assembly

    5057-XXX Upper printer engine card assembly Previous The upper printer engine card assembly controls printing operation based on the communication with the RIP card assembly and optional peripherals. It also controls toner dispense, erase lamps and fuser control. Lower printer engine card assembly Next The lower printer engine card assembly controls printing operation based on the communication with the RIP card assembly and on sensor/switch information.

  • Page 53: Media Size Control

    5057-XXX Previous Control Media size control Media tray assembly feeding Next The following table gives the states (on/off) of the switches on the switch (media size), corresponding to the media sizes of the media tray assembly. Go Back Note: The switches on the switch (media size) are denoted by “S/W2”, “S/W4”, “S/W3”, “S/W5”, and “S/W1” respectively from the left side.

  • Page 54: Determination Of Printhead Ready

    5057-XXX Determination of printhead ready Previous The printhead goes into ready state after the specified period passes since the reception of the printhead MPA start signal and the SOS cycle exceeds the reference value. Printhead reference value Next Printhead reference value Description Go Back Ready reference value...

  • Page 55: Xerographic Process During A Print Cycle

    5057-XXX Xerographic process during a print cycle Previous K toner C toner M toner Y toner Fuser Transfer belt Next Transfer belt Cleaning roll K transfer roll C transfer roll M transfer roll cleaning Y transfer roll Go Back assembly 2nd transfer roll assembly Registration roll...

  • Page 56: Charge

    5057-XXX Charge Previous The Charge Roll places a uniform negative electrostatic charge on the surface of the drum. The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness. Light striking the drum discharges the surface charge.

  • Page 57: Exposure

    5057-XXX Exposure Previous The Printhead generates a beam of laser light. Image data received from the RIP card assembly modulates this beam, turning it on and off according to image information that is received from the host computer and software. Through the use of a series of rotating and stationary mirrors within the Printhead, the beam scans the negative Next charged drum surface.

  • Page 58: Transfer

    5057-XXX The toner adhering to the Magnet Roll is always in contact with the drum surface. When a less negative point on Previous the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet Roll, toner transfers from the Magnet Roll to that point on the drum.

  • Page 59: Cleaning

    5057-XXX is now stuck to the transfer belt due to the relative electrical differences between the negative electrical charge Previous of the inner conductive layer of the drum and the positive electrical charge of the paper. Next Go Back HVPS -VDC DRUM -VDC...

  • Page 60: Auto Density Sensing

    5057-XXX At the beginning of each individual printer cycle, the Printhead scans the surface of the drum, further discharging Previous any residual DC charge that may be left on the drum. Erase lamp LED array Next Go Back DRUM Ground Auto density sensing Image density sensor assembly...

  • Page 61: Ttm Theory

    5057-XXX Previous TTM theory Next Go Back 1-33 General information...

  • Page 62: Media Transport

    5057-XXX Media transport Previous Media transport path Media is supplied from tray 2, tray 3, or tray 4, and is transported to the printer along the media transport path shown below. Next Tray 2 Tray 3 Tray 4 Go Back Pick roll Pick roll Pick roll...

  • Page 63: Functions Of Main Components

    5057-XXX Media transport path Previous The following is a cross section of the printer and the tandem tray module, showing the main components directly associated with the media path and transport. Upper media transport roll assembly Finisher media entrance Next roll assembly Bridge unit assembly Upper media exit...

  • Page 64: Bottom Plate

    5057-XXX Bottom plate Previous The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to come in contact with the pick roll.
  • Page 65 5057-XXX Tray 3 or 4 media tray assembly Previous Rear lift cables Rear media guide Next Go Back Bottom plate F/R lift cable F/L lift cable 1-37 General information...

  • Page 66: Ttm Media Feed Units

    5057-XXX TTM media feed units Previous Media feed unit assembly Since the tray 3 and tray 4 are functionally equivalent in terms of the switch (TTM media size), sensor (media out), sensor (media level) and sensor (pre-feed), only the components of one tray are described here. Next The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer.

  • Page 67: Main Components

    5057-XXX Previous Media feed lift motor Next Go Back Sensor (media level) Sensor (media out) Switch (TTM media size) Media feed unit assembly Front Main components Switch (tray module left door interlock) The switch (tray module left door interlock) detects open/close of the tray module left door assembly. Sensor (tray 2 feed-out) The sensor (tray 2 feed-out) detects media fed from trays 2, 3, or 4.

  • Page 68: Tray Module Drive Motor

    5057-XXX Tray module drive motor Previous This motor is used to drive the media transport mechanism in the tray module. TTM tray 4 media transport motor Next This motor is used in the TTM to transport media from the tray 4 towards the tray module left door assembly. TTM controller card assembly Go Back The TTM controller card assembly, which contains a CPU, controls media feed in the tandem tray module upon...

  • Page 69: Switch (Ttm Media Size)

    5057-XXX Switch (TTM media size) Previous The following table gives on/off states of the switches on the switch (TTM media size), corresponding to the media sizes of the media tray assembly. Note: The switches (TTM media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Next Analog switch Media Size...

  • Page 70: Tm Theory

    5057-XXX Previous 3TM theory Next Go Back 1-42 Printer Service Manual...

  • Page 71: Media Transport

    5057-XXX Media transport Previous Media transport path Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown below. Next Tray 2 Tray 3 Tray 4 Go Back Pick roll Pick roll Pick roll Separation roll...

  • Page 72: Media Transport Path

    5057-XXX Media transport path Previous The following is a cross section of the printer and the tandem tray module, showing the main components directly associated with the media path and transport. Upper media transport roll assembly Next Finisher media entrance roll assembly Bridge unit assembly Upper media exit...

  • Page 73: Bottom Plate

    5057-XXX Bottom plate Previous The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to come in contact with the pick roll.

  • Page 74: Main Components

    5057-XXX This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of Previous the actuator leaves the sensor (media level) sensing area, the sensor detects that the media has been lifted. Next Go Back Main components...

  • Page 75: Tray Module Media Transport Roll Assembly

    5057-XXX Tray module media transport roll assembly Previous The tray module transport roll assembly feeds media from the tray 3 or tray 4 to the printer. Tray module drive motor Next This motor is used to drive the media transport mechanism in the tray module. 3TM controller card assembly Go Back The 3TM controller card assembly, which contains a CPU, controls media feed in the tandem tray module upon...

  • Page 76: Switch (Media Size)

    5057-XXX Switch (media size) Previous The following table gives on/off states of the switches on the switch (media size), corresponding to the media sizes of the media tray assembly. Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Next Analog switch Media Size...

  • Page 77: Tm Theory

    5057-XXX Previous 1TM theory Next Go Back 1-49 General information...

  • Page 78: Media Transport

    5057-XXX Media transport Previous Media transport path Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown below. Next Tray 2 Tray 3 Tray 4 Go Back Pick roll Pick roll Pick roll Separation roll...

  • Page 79: Media Transport Path

    5057-XXX Media transport path Previous The following is a cross section of the printer and the 1TM, showing the main components directly associated with the media path and transport. Upper media transport roll assembly Next Finisher media entrance roll assembly Bridge unit assembly Upper media exit (included with finisher)

  • Page 80: Bottom Plate

    5057-XXX Bottom plate Previous The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to come in contact with the pick roll.

  • Page 81: Switch (Media Size)

    5057-XXX Switch (media size) Previous The switch (media size) switches the setting of the size of media supplied from each media tray assembly. A signal indicating the set size is transmitted as a voltage to the printer engine card assembly. Sensor (media out) Next If there is no media in the media tray assembly, the media out actuator lowers and the flag of the media out...

  • Page 82: Tray Module Media Transport Roll Assembly

    5057-XXX Sensor (tray 2 feed-out) Previous The sensor (tray 2 feed-out) detects media fed from the tray 2. Tray module media transport roll assembly Next The tray module transport roll assembly feeds media from the tray 2. Tray module drive motor Go Back This motor is used to drive the media transport mechanism in the tray module.

  • Page 83: Switch (Media Size)

    5057-XXX Switch (media size) Previous The following table gives on/off states of the switches on the switch (media size), corresponding to the media sizes of the media tray assembly. Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Next Analog switch Media Size...

  • Page 84: Duplex

    5057-XXX Previous Duplex Next Go Back 1-56 Printer Service Manual...

  • Page 85: Layout Of Media Transport Path

    5057-XXX Layout of media transport path Previous The main components associated with the media path and transport with the duplex installed. Inverter forward Standard media clutch Inverter exit roll assembly Next reverse clutch Standard Go Back media bin Sensor Exit duplex diverter gate (fuser exit) Fuser unit assembly Fuser...

  • Page 86: Duplex Controller Card Assembly

    5057-XXX Duplex controller card assembly Previous The duplex controller card assembly that contains a CPU controls media feed in the duplex upon receiving a command from the upper printer engine card assembly and sensor/switch information. Duplex drive motor Next The duplex drive motor transmits driving force to the two duplex media transport roll assemblies and the duplex media center transport roll assembly middle that feeds media.

  • Page 87: Tools Required For Service

    5057-XXX Previous Tools required for service Flat-blade screwdriver #1 Phillips screwdriver, magnetic Next #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle nose pliers Go Back Diagonal side cutters Spring hook Analog or digital multi meter Parallel wrap plug 1319128 Twinax/serial debug cable (#1381963) Coax/serial debug cable (#1381964) 5.5 mm hexdriver (magnetic)

  • Page 88: Acronyms

    5057-XXX Previous Acronyms 1 Tray Module 3 Tray Module Alternating Current Next Automatic Document Feeder Automatic Paper Size ASIC Application Specific Integrated Circuit Go Back Automatic Toner Control Customer Replaceable Unit Customer Setup Counterclockwise Clockwise Direct Current DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out...
  • Page 89 5057-XXX SRAM Static Random Access Memory Previous Tandem Tray Module TVOC Total Volatile Organic Compound Used Parts Return Volts V ac Volts alternating current Next V dc Volts direct current Go Back 1-61 General information...
  • Page 90 5057-XXX Previous Next Go Back 1-62 Printer Service Manual...
  • Page 91 5057-XXX Previous Next Go Back 1-63 General information...
  • Page 92 5057-XXX Previous Next Go Back 1-64 Printer Service Manual...

  • Page 93: Diagnostic Information

    5057-XXX 2. Diagnostic information Previous Start Next CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable Go Back electronic board or assembly. CAUTION If the printer is kept on, never touch the conductive parts if not specifically required. The power switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while the power supply is cut off.

  • Page 94: Confirm The Installation Status

    The following is an example of the events that occur during the POR sequence: Turn the machine on. The Lexmark splash screen appears with a progress bar in the center until the code is loaded. The scanner exposure lamp flashes several times.

  • Page 95: Error Code Table

    5057-XXX Previous Error code table Error code or Error contents Description/Action message Next 200.00 Sensor (registration) late jam The media is late reaching the sensor (registration) within the specified time after being fed from any Paper jam given media tray. Go Back Go to “200.00 Sensor (registration) late jam”...
  • Page 96 5057-XXX Previous Error code or Error contents Description/Action message 242.00 Sensor (tray 2 feed-out) late The media is late reaching the sensor (tray 2 feed- jam. out) within the specified time after the tray 2 media Paper jam feed lift motor is turned on. Next Go to “242.00 Sensor (tray 2 feed-out) late jam”...
  • Page 97 5057-XXX Previous Error code or Error contents Description/Action message 281.00 Sensor (bridge unit media The media is late reaching the sensor (bridge unit exit) late jam media exit) within the specified time after reaching Paper jam the sensor (bridge unit media entrance). Next Refer to the Finisher Service Manual.
  • Page 98 5057-XXX Previous Error code or Error contents Description/Action message 287.00 Sensor (upper media exit) The media is late reaching the sensor (upper media late jam exit) within the specified time after reaching the Paper jam sensor (finisher media entrance). Next Refer to the Finisher Service Manual.
  • Page 99 5057-XXX Previous Error code or Error contents Description/Action message <Color> toner cartridge The <Color> toner cartridge is defective or not detection error installed. Missing or defective Go to “<Color> toner cartridge detection error” Next <color> on page 2-52. cartridge Incorrect black toner cartridge A black toner cartridge of an incorrect specification Go Back error.
  • Page 100 5057-XXX Previous Error code or Error contents Description/Action message 100K maintenance required Service is required to maintain printer performance. Scheduled Go to “100K maintenance required” on maintenance page 2-136. Next 100K kit 600K maintenance required Service is required to maintain printer performance. Go Back Scheduled Go to...
  • Page 101 5057-XXX Previous Error code or Error contents Description/Action message (Color) toner cartridge nearly The (color) toner cartridge is nearing the empty replacement interval. (Color) toner Go to “(Color) toner cartridge nearly empty” on Next page 2-143. (Color) toner cartridge empty The (color) toner cartridge requires replacing.
  • Page 102 5057-XXX Previous Error code or Error contents Description/Action message 903.00 K developer/transport drive K developer/transport drive motor error does not motor error rotate at the specified speed. Service motor error Go to “903.00 K developer/transport drive Next assembly motor error” on page 2-71.
  • Page 103 5057-XXX Previous Error code or Error contents Description/Action message 904.05 Sensor (CMY transfer roll The sensing area of the sensor (CMY transfer roll retract HP) late error retract HP) is not interrupted within the specified Service time when the CMY transfer rolls is moving to the transfer belt Next home position.
  • Page 104 5057-XXX Previous Error code or Error contents Description/Action message 907.03 C laser SOS internal error The interval of the printhead start of scan C signals exceed the specified value. Printhead error Go to “907.03 M laser SOS internal error” on Next page 2-97.
  • Page 105 5057-XXX Previous Error code or Error contents Description/Action message 920.02 Fuser sub lamp overheat The rear thermistor detected an abnormal high error temperature. Service fuser error This error must be reset inside diagnostic mode Next before troubleshooting or machine operation can occur.
  • Page 106 5057-XXX Previous Error code or Error contents Description/Action message 925.00 Sensor (Y ATC) Outputs of the sensor (Y ATC) are not in the specified range. Service PC cartridge This error must be reset inside diagnostic mode Next before troubleshooting or machine operation can occur.
  • Page 107 5057-XXX Previous Error code or Error contents Description/Action message 941.01 sensor (media level) late The sensing area of the sensor (media level) in the error (tray 1) media tray 1 is not interrupted within the specified Service tray 1 time after the lift tray has risen to operating level. failure Next Go to...
  • Page 108 5057-XXX Previous Error code or Error contents Description/Action message 950.00 through EPROM mismatch failure This error code indicates a mismatch between the 950.29 operator panel assembly and the interconnect card assembly. Service Next NVRAM Warning: In the event of replacement of any one of mismatch the following components: •...
  • Page 109 5057-XXX Previous Error code or Error contents Description/Action message 953.XX Operator panel assembly NVRAM chip failure with operator panel assembly NVRAM failure (mirror). Service NVRAM failure Go to Go to “953.XX Operator panel assembly Next NVRAM failure” on page 2-122. 954.XX Interconnect card assembly NVRAM chip failure with interconnect card...
  • Page 110 5057-XXX Previous Error code or Error contents Description/Action message 981.01 Stacker bin upper limit error The sensing area of the sensor (stacker bin upper limit) is not interrupted when the stacker bin raises Service finisher to its uppermost limit. error Next Refer to the Finisher Service Manual.
  • Page 111 5057-XXX Previous Error code or Error contents Description/Action message 986.01 Sensor (media eject clamp The sensing area of the sensor (media eject clamp HP) lag error HP) remains interrupted within the specified time Service finisher after the eject clamp starts moving from the home error Next position.
  • Page 112 5057-XXX Previous Error code or Error contents Description/Action message 991.03 Sensor (booklet rear tamper The sensing area of the sensor (booklet rear tamper HP) lag error HP) remains interrupted within the specified time Service finisher after the rear booklet tamper starts moving from the error Next home position.
  • Page 113 5057-XXX Previous Error code or Error contents Description/Action message 992.00 Sensor (de-curler clutch HP) The sensing area of the sensor (de-curler cam HP) late error is not interrupted within the specified time after the Service finisher de-curler roll assembly (nip) starts moving to the error Next home position.
  • Page 114 5057-XXX Previous Error code or Error contents Description/Action message Remove paper Finisher upper media bin full. Stacker set over count from bin 1 The upper media bin has reached maximum capacity. Next Refer to the Finisher Service Manual. Remove paper Stacker media bin full (no The stacker media bin has reached maximum Go Back...

  • Page 115: Service Checks

    5057-XXX Previous Service checks 200.00 Sensor (registration) late jam Next Step Check Check the media position. Remove the Go to step 2. Go Back media. Does the media touch the sensor (registration)? Check the registration/transport roll assembly. Go to step 3. Clean or replace the registration / Is the above component free of excess wear and...

  • Page 116: Sensor (Registration) Lag Jam

    5057-XXX Previous Step Check Check the Replace the K developer/transport drive motor Go to step 9. Go to step 8. assembly for proper operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.
  • Page 117 5057-XXX Previous Step Check Check the sensor (registration) for proper operation. Go to step 6. Go to step 5. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TEST. 3. Select Media Path. 4. Select Registration. Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection.

  • Page 118: Sensor Static Jam

    5057-XXX Previous Step Check Check the Replace the K developer/transport drive motor Go to step 12. Go to step 11. assembly for proper operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.

  • Page 119: Sensor (Media On Belt) Late Jam

    5057-XXX Previous Step Check POR the machine. Replace the lower Problem solved. printer engine card Does the error continue? assembly. Next Go to “Lower printer engine card assembly removal” on Go Back page 4-93. 200.03 Sensor (media on belt) late jam Step Check Check the media condition.

  • Page 120: Sensor (Fuser Exit) Late Jam

    5057-XXX 201.00 Sensor (fuser exit) late jam Previous Step Check Check the media position. Remove the Go to step 2. Next media. Does the media touch the sensor (fuser exit)? Check the fuser exit actuator. Replace the Go to step 3. Go Back sensor (fuser exit) Does the fuser exit actuator attached to the sensor (fuser...
  • Page 121 5057-XXX Previous Step Check Check the duplex diverter gate solenoid for proper Replace the Replace the connection. duplex media connection. inverter assembly. Is the above component properly connected? Next Go to “Duplex media inverter assembly removal” on Go Back page 4-9.

  • Page 122: Sensor (Fuser Exit) Lag Jam

    5057-XXX Previous Step Check Perform a print test. Replace the lower Problem solved. printer engine card Does the error continue? assembly. Next Go to “Lower printer engine card assembly removal” on Go Back page 4-93. 202.00 Sensor (fuser exit) lag jam Step Check Check the media position.

  • Page 123: Sensor (Duplex Wait) Late Jam (Duplex Media Feed)

    5057-XXX Previous Step Check Check the Replace the K developer/transport drive motor Go to step 8. Go to step 7. assembly for proper operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.
  • Page 124 5057-XXX Previous Step Check Check the sensor (duplex wait) for proper connection. Replace the sensor Replace the (duplex wait). connection. Is the above component properly connected? Go to “Sensor Next (duplex wait) removal” on page 4-11. Go Back Check the duplex diverter gate solenoid for proper Go to step 7.

  • Page 125: Sensor (Registration) Late Jam (Duplex Feed)

    5057-XXX Previous Step Check Check the duplex media inverter clutch for proper Go to step 11. Go to step 10. operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1. Enter the Diagnostics Menu. 2.
  • Page 126 5057-XXX Previous Step Check Check the sensor (registration) for proper operation. Go to step 5. Go to step 4. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection.

  • Page 127: Sensor (Registration) Late Jam (Duplex Media Feed)

    5057-XXX Previous Step Check Check the duplex media inverter clutch for proper Go to step 11. Go to step 10. operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1. Enter the Diagnostics Menu. 2.
  • Page 128 5057-XXX Previous Step Check Check the sensor (registration) for proper operation. Go to step 5. Go to step 4. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection.

  • Page 129: Sensor (Tray 1 Feed-Out) Late Jam

    5057-XXX Previous Step Check Check the duplex media inverter clutch for proper Go to step 11. Go to step 10. operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1. Enter the Diagnostics Menu. 2.
  • Page 130 5057-XXX Previous Step Check Check the feed roll, separation roll, and pick roll for media Go to step 4. Clean or replace tray 1. the feed roll, separating roll, or Are the above components free of excess wear and Next pick roll.

  • Page 131: Sensor (Tray 2 Feed-Out) Late Jam

    5057-XXX Previous Step Check Perform a print test. Replace the lower Problem solved. printer engine card Does the error continue? assembly. Next Go to “Lower printer engine card assembly removal” on Go Back page 4-93. 242.00 Sensor (tray 2 feed-out) late jam Step Check Check the media condition.

  • Page 132: Sensor (Tray 1 Feed-Out) Late Jam (Feeding From Tray 2)

    5057-XXX Previous Step Check Check the media feed lift motor in media tray 2 for proper Go to step 9. Skip to step 8. operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.

  • Page 133: Sensor (Tray 3 Feed-Out) Late Jam

    5057-XXX Previous Step Check Check the sensor (tray 2 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. Next 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 2. 5.
  • Page 134 5057-XXX Previous Step Check Check the feed roll, separation roll, and pick roll for Go to step 4. Clean or replace the media tray 3. feed roll, separating roll, or pick roll. Are the above components free of excess wear and Next Go to “Feed roll...

  • Page 135: Sensor (Tray 2 Feed-Out) Late Jam (Feeding From Tray 3)

    5057-XXX Previous Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM Next controller card assembly or the TTM controller card assembly. Go Back Go to “1X 500- sheet drawer (1TM)—1TM controller card assembly removal”...
  • Page 136 5057-XXX Previous Step Check Check the sensor (tray 3 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. Next 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 3. 5.

  • Page 137: Sensor (Tray 4 Feed-Out) Late Jam

    5057-XXX Previous Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM Next controller card assembly or the TTM controller card assembly. Go Back Go to “1X 500- sheet drawer (1TM)—1TM controller card assembly removal”...
  • Page 138 5057-XXX Previous Step Check Check the sensor (tray 4 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. Next 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 4. 5.

  • Page 139: Sensor (Tray 3 Feed-Out) On Jam (Feeding From Tray 4)

    5057-XXX Previous Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM Next controller card assembly or the TTM controller card assembly. Go Back Go to “1X 500- sheet drawer (1TM)—1TM controller card assembly removal”...
  • Page 140 5057-XXX Previous Step Check Check the sensor (tray 4 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. Next 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 4. 5.

  • Page 141: Sensor (Registration) Late Jam (Feeding From The Mpf)

    5057-XXX Previous Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM Next controller card assembly or the TTM controller card assembly. Go Back Go to “1X 500- sheet drawer (1TM)—1TM controller card assembly removal”...
  • Page 142 5057-XXX Previous Step Check Check the sensor (registration) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TEST. 3. Select Media Path. 4. Select Registration. Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection...

  • Page 143: Black Toner Cartridge Detection Error

    5057-XXX Previous Step Check Check the MPF/transport drive motor for proper connection. Replace the MPF/ Replace the transport drive connection. Is the above component properly connected? motor . Next Go to “MPF / transport drive motor assembly removal” on Go Back page 4-114.

  • Page 144: Color> Toner Cartridge Detection Error

    5057-XXX <Color> toner cartridge detection error Previous Step Check Check the <color> toner cartridge for proper installation. Go to step 3. Reinstall the Next <color> toner Is the above component properly installed? cartridge. Replace the <color> toner cartridge. Got to step 3. Problem solved.

  • Page 145: Tray 1 Media Size Mismatch Error

    5057-XXX Tray 1 media size mismatch error Previous Step Check Check the media tray assembly 1 side guide. Go to step 2. Properly set the Next media tray Is the above component set properly? assembly side guide. Go Back Check the media tray assembly 1 end guide. Go to step 3.

  • Page 146: Tray 3 Media Size Mismatch Error

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error remain when the power is turned off/on? assembly. Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90. Perform a POR.

  • Page 147: Tray 4 Media Size Mismatch Error

    5057-XXX Tray 4 media size mismatch error Previous Step Check Check the media tray assembly 4 side guide. Go to step 2. Properly set the Next media tray Is the above component set properly? assembly side guide. Go Back Check the media tray assembly 4 end guide. Go to step 3.

  • Page 148: Tray 2 Media Type Mismatch Error

    5057-XXX Previous Step Check Check the sensor (transparency detect) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TESTS. 3. Select Media path. 4. Select Transparency detect Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 149: Tray 3 Media Type Mismatch Error

    5057-XXX Previous Step Check Check the sensor (transparency detect) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TESTS. 3. Select Media path. 4. Select Transparency detect Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 150: Tray 4 Media Type Mismatch Error

    5057-XXX Previous Step Check Check the sensor (transparency detect) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TESTS. 3. Select Media path. 4. Select Transparency detect Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 151: Image Pipeline Asic Error

    5057-XXX Previous Step Check Check the sensor (transparency detect) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. Next 2. Select BASE SENSOR TESTS. 3. Select Media path. 4. Select Transparency detect Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 152: Xx System Software Error

    Note: Before troubleshooting, determine the operating system used when the error occured. If possible determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device. Step Action and questions POR the device.
  • Page 153 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.
  • Page 154 5057-XXX Previous Step Action and questions Replace the modem. Restart the device. Go to step 31. Problem resolved. Does the 900.xx error reoccur? Run a fax job. Go to step 31. Go to step 21. Next Does the 900.xx error reoccur? Are there any ISP (internal solutions port) options Go to step 22.

  • Page 155: Xx Rip Card Assembly Software Error

    5057-XXX 901.xx RIP card assembly software error Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2.

  • Page 156: General Upper Engine Error Fuse #2

    5057-XXX Previous Step Check Check the fuser cooling fan cables and any associated Go to step 5. Repair or replace cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? Next or replace the fuser cooling fan.

  • Page 157: General Upper Engine Error Fuse #3

    5057-XXX Previous Step Check Check the erase lamp cable assemblies and any other Go to step 3. Repair or replace associated cables for damage. the appropriate cable assemblies. Are the above components free from crimps and damage? Next Check the image density sensor assembly cables for Go to step 4.

  • Page 158: General Lower Engine Error Fuse #2

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90. 902.03 General lower engine error fuse #1 Step Check...

  • Page 159: General Lower Engine Error Fuse #3

    5057-XXX Previous Step Check Check the transfer belt drive motor assembly cables and Go to step 3. Repair or replace any associated cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? Next or replace the transfer belt drive motor assembly.
  • Page 160 5057-XXX Previous Step Check Perform a POR. Replace the lower Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Next Go to “Lower printer engine card assembly removal” on Go Back page 4-93. 902.06 General lower engine error fuse #4 Step Check...

  • Page 161: General Lower Engine Error Fuse #5

    5057-XXX Previous Step Check Check the developer/transfer roll HVPS card assembly Go to step 6. Repair or replace cables and any associated cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? Next or replace the developer/transfer roll HVPS card assembly.
  • Page 162 5057-XXX Previous Step Check Check the MPF pick solenoid cables and any associated Go to step 5. Repair or replace cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? Next or replace the MPF feed unit assembly.

  • Page 163: K Developer/Transport Drive Assembly Motor Error

    5057-XXX Previous Step Check Perform a POR. Replace the lower Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Next Go to “Lower printer engine card assembly removal” on Go Back page 4-93. 903.00 K developer/transport drive assembly motor error Step Check...

  • Page 164: K Pc Drive Motor Error

    5057-XXX 903.01 K PC drive motor error Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2.

  • Page 165: Developer Drive Motor Error

    5057-XXX Previous Step Check Check the CMYK PC cartridge drive motor assembly for Go to step 4. Go to step 3. proper operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.

  • Page 166: Sensor (Transfer Belt Hp) Late Error

    5057-XXX Previous Step Check Check the CMY developer drive motor assembly for proper Replace the CMY Replace the connection. developer drive connection. motor assembly. Is the above component properly connected? Next Go to “CMY developer drive motor assembly” on page 4-100.
  • Page 167 5057-XXX Previous Step Check Are the PC cartridge units correctly installed? Go to the next Remove and step. reinstall the PC Refer to the following images. Note that the far left PC cartridge units cartridge unit is tilted in the first image. Next correctly.
  • Page 168 5057-XXX Previous Step Check Check that the transfer belt steering mechanism lock Remove any Go to the next packaging was fully removed. If not removed before the packaging step. transfer belt lever is lowered, the transfer belt steering remnants. Next mechanism lock might break and remain inside the machine If the problem in the area, as showing in the following image (A).
  • Page 169 5057-XXX Previous Step Check Check the transfer belt cleaning assembly for proper Replace the Go to the next installation or damage. transfer belt step. cleaning Remove the transfer belt cleaning assembly. See Next assembly. See “Transfer belt cleaning assembly removal” on “Transfer belt page 4-17.

  • Page 170: Transfer Belt Position Failure

    5057-XXX Previous Step Check Check the transfer belt drive motor assembly drive gear for Replace the Contact the next damage. transfer belt drive level of support. motor assembly. 1. Remove the transfer belt unit assembly. Go to Next “Transfer belt unit assembly removal” on page 4-16.
  • Page 171 5057-XXX Previous Step Check Is the transfer belt torn, damaged, or missing? Replace the Go to the next transfer belt. step. Check to ensure that the transfer belt lift mechanism is Go to the next The problem is Next functioning properly. See “Transfer belt lift mechanism step.
  • Page 172 5057-XXX Previous Step Check Are the PC cartridge units correctly installed? Go to the next Remove and step. reinstall the PC Refer to the following images. Note that the far left PC cartridge units cartridge unit is tilted in the first image. Next correctly.
  • Page 173 5057-XXX Previous Step Check Check that the transfer belt steering mechanism lock Remove any Go to the next packaging was fully removed. If not removed before the packaging step. transfer belt lever is lowered, the transfer belt steering remnants. Next mechanism lock might break and remain inside the machine in the area, as showing in the following image (A).
  • Page 174 5057-XXX Previous Step Check Check the transfer belt cleaning assembly for proper Replace the Go to the next installation or damage. transfer belt step. cleaning Remove the transfer belt cleaning assembly. See Next assembly. See “Transfer belt cleaning assembly removal” on “Transfer belt page 4-17.

  • Page 175: Sensor (Transfer Belt Edge) Failure

    5057-XXX Previous Step Check Check the transfer belt drive motor assembly drive gear for Replace the Contact the next damage. transfer belt drive level of support. motor assembly. 1. Remove the transfer belt unit assembly. Go to Next “Transfer belt unit assembly removal” on page 4-16.
  • Page 176 5057-XXX Previous Step Check Did the error occur following a developer unit replacement? Verify the Go to the next developers are step. installed correctly. Next “Developer unit assembly removal” on page 4-53. Go Back Check to ensure that the transfer belt lift mechanism is Go to the next The problem is functioning properly.
  • Page 177 5057-XXX Previous Step Check Do the PC units easily slide in and out of the machine? Go to the next Replace any step. damaged PC units or any damaged Next erase lamp assembly. See “PC cartridge unit removal” on Go Back page 4-43, “K...

  • Page 178: Sensor (2Nd Transfer Roll Retract Hp) Late Error

    5057-XXX Previous Step Check Check the transfer belt steering motor assembly for proper Go to step 5. Go to step 4. operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.

  • Page 179: Sensor (2Nd Transfer Roll Retract Hp) Lag Error

    5057-XXX Previous Step Check Check the 2nd transfer roll retract motor for proper Go to step 6. Skip to step 5. operation. 1. Enter the Diagnostics Menu. Next 2. Touch BASE SENSOR TESTS. 3. Touch Media Path. 4. Touch 2nd transfer roll retract HP. Go Back Does the above component operate properly? Check the 2nd transfer roll retract motor for proper...

  • Page 180: Sensor (Cmy Transfer Roll Retract Hp) Late Error

    5057-XXX Previous Step Check Check the sensor (2nd transfer roll HP) for proper Replace the Replace the connection. sensor (2nd connection. transfer roll retract Is the above component properly connected? Next HP) . Go to “Sensor (2nd transfer roll retract HP) Go Back removal”...
  • Page 181 5057-XXX Previous Step Check Did the error occur following a developer unit replacement? Verify the Go to the next developers are step. installed correctly. Next “Developer unit assembly removal” on page 4-53 Go Back Check to ensure that the transfer belt lift mechanism is The problem is Contact the next functioning properly.
  • Page 182 5057-XXX Previous Step Check Do the PC units easily slide in and out of the machine? Go to the next Replace any step. damaged PC units or any damaged Next erase lamp assembly. See “PC cartridge unit removal” on Go Back page 4-43, “K...

  • Page 183: Sensor (Cmy Transfer Roll Retract Hp) Lag Error

    5057-XXX 904.06 Sensor (CMY transfer roll retract HP) lag error Previous Step Check Check the transfer belt unit assembly. To to step 2 Properly reinstall Next the transfer belt Is the above component properly installed? unit assembly. Perform a POR. Go to step 3.
  • Page 184 5057-XXX Previous Step Check Are the PC cartridge units correctly installed? Go to the next Remove and step. reinstall the PC Refer to the following images. Note that the far left PC cartridge units cartridge unit is tilted in the first image. Next correctly.

  • Page 185: Cmy Transfer Roll Retract Motor Time Out

    5057-XXX Previous Step Check Check that the transfer belt steering mechanism lock Remove any Contact the next packaging was fully removed. If not removed before the packaging level of support. transfer belt lever is lowered, the transfer belt steering remnants. Next mechanism lock might break and remain inside the machine in the area, as showing in the following image (A).

  • Page 186: Nvm Read/Write Cannot Be Executed Error

    5057-XXX Previous Step Check Replace the transfer belt unit assembly. Go to “Transfer Replace the lower Problem solved. belt unit assembly removal” on page 4-16. printer engine card assembly. Does the error remain? Next Go to “Lower printer engine card assembly removal”...

  • Page 187: Marking Device Xerographics Error

    5057-XXX 905.02 Marking device Xerographics error Previous Step Check Perform a POR. Replace the upper Problem solved. Next printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Upper Go Back printer engine card assembly removal”...

  • Page 188: Printhead Polygon Mirror Motor Error

    5057-XXX 907.00 Printhead polygon mirror motor error Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2.

  • Page 189: M Laser Sos Internal Error

    5057-XXX Previous Step Check Perform a POR. Replace the Problem solved. printhead Does the error occur when the power is turned off/on? assembly. Next Go to “Printhead assembly removal” on page 4-104. Go Back 907.03 M laser SOS internal error Step Check Perform a POR.

  • Page 190: Printhead Control Error

    5057-XXX 907.05 Printhead control error Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2. Turn the printer off for 60 seconds.

  • Page 191: V Lvps Cooling Fan Error

    5057-XXX 911.00 24V LVPS cooling fan error Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2.

  • Page 192: Fuser Cooling Fan Lock Error

    5057-XXX 911.02 Fuser cooling fan lock error Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2.

  • Page 193: Fuser Main Lamp Overheat Error

    5057-XXX 920.00 Fuser main lamp overheat error Previous Step Check Reset the fuser overheat failure lock out condition. Go to step 2. Go to step 5. Next 1. Enter the Diagnostics Menu. 2. Select Fuser temp fail clear. 3. Select Fuser temp fail clear. Go Back Perform a POR.

  • Page 194: Fuser Sub Lamp Overheat Error

    5057-XXX Previous Step Check Perform a POR. Replace the fuser Problem solved. unit assembly. Does the error occur when the power is turned off/on? Go to “Fuser unit Next assembly removal” on page 4-15. Go Back 920.02 Fuser sub lamp overheat error Step Check Reset the fuser overheat failure lock out condition.

  • Page 195: Main Lamp Warm Up Error

    5057-XXX Previous Step Check Check the fuser unit assembly for proper installation. Go to step 3. Install the fuser unit assembly Is the fuser unit assembly installed properly? properly. Next Check the fuser unit assembly for proper connection. Go to step 4. Repair the connection.

  • Page 196: Main Lamp On-Time Error

    5057-XXX 920.05 Main lamp on-time error Previous Step Check Check the fuser unit assembly for a media jam. Remove the Go to step 2. Next media. Is there a media jam in the fuser unit assembly? Check the fuser unit assembly for proper installation. Go to step 3.

  • Page 197: Sub Lamp On-Time Error

    5057-XXX Previous Step Check Perform a POR. Replace the AC Problem solved. drive card bracket Does the error occur when the power is turned off/on? assembly. Next Go to “AC drive card bracket assembly removal” on Go Back page 4-109. 920.07 Sub lamp on-time error Step Check...

  • Page 198: Magenta Pc Smartchip Communication Error

    5057-XXX Previous Step Check Check the appropriate smartchip socket, located on the Go to step 5. Replace the developer interlock plate assembly for wear or damage. developer interlock plate Is the above component free from damage? Next assembly. Go to Go to “Developer interlock plate...

  • Page 199: Cyan Pc Smartchip Communication Error

    5057-XXX 924.02 Cyan PC smartchip communication error Previous Step Check Check the C PC cartridge for proper installation. Go to step 2. Reinstall the C PC Next drum. Is the above component properly installed? Install the C PC drum in one of the other three PC locations. Replace the Go to step 3.

  • Page 200: Sensor (Y Atc)

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90 925.00 Sensor (Y ATC) Step...

  • Page 201: Sensor (C Atc)

    5057-XXX Previous Step Check Check the sensor (M ATC) for proper connection. Replace the M Replace the Developer unit connection. Is the above component properly connected? assembly. Next Go to “Developer unit assembly removal” on page 4-53. Go Back Perform a very large print test. Replace the upper Problem solved.

  • Page 202: Sensor (K Atc)

    5057-XXX 925.03 Sensor (K ATC) Previous Step Check Reset the K ATC failure lock out condition. Go to step 2. Problem solved. Next 1. Enter diagnostic mode 2. Touch ATC sensor failure clear Go Back 3. Touch K channel (925.03) Perform a very large print test.

  • Page 203: Cyan Toner Rfid Communication Failure

    5057-XXX 930.01 Cyan toner RFID communication failure Previous Step Check Check the C toner cartridge. Go to step 2. Reinstall the C Next toner cartridge. Is the C toner cartridge properly installed? Check the sensor (C toner RFID) for proper connection. Replace the Replace the Go Back...

  • Page 204: Mpf Tray 5 Size Sensing Error

    5057-XXX Previous Step Check Check the sensor (Y toner RFID) for proper connection. Replace the Replace the CMYK toner add connection. Is the above component properly connected? motor assembly. Next Go to “CMYK toner add motor assembly removal” on Go Back page 4-103.

  • Page 205: Sensor (Media Level) Late Error (Tray 1)

    5057-XXX Previous Step Check Check the tray 1 switch (media size) for proper operation. Go to step 5. Go to step 4. 1. Enter the Diagnostics Menu. Next 2. Select INPUT TRAY TESTS. 3. Select Sensor Test. 4. Select Tray 1. 5.

  • Page 206: Switch (Media Size) Size Sensing Error (Tray 2)

    5057-XXX Previous Step Check Check the media feed/lift motor (tray 1) for proper Go to step 6. Go to step 5. operation. Caution: When performing motor tests, Next ensure that all cover and door interlock switches are overridden. Go Back 1.

  • Page 207: Sensor (Media Level) Late Error (Tray 2)

    5057-XXX Previous Step Check Check the tray 2 switch (media size) for proper connection. Replace the switch Replace the (media size). connection. Is the above component properly connected? Go to “Switch Next (media size) removal” on page 4-121. Go Back Perform a POR.
  • Page 208 5057-XXX Previous Step Check Check the media feed/lift motor (tray 2) for proper Replace the media Replace the connection. feed/lift motor. connection. Is the above component properly connected? Go to “Media feed Next lift motor removal” on page 4-120. Go Back Perform a POR.

  • Page 209: Sensor (Media Level) Late Error (Tray 3)

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error continue when the power is turned off/ assembly. Next Go to “Upper printer engine card assembly removal” on page 4-90. Go Back 943.01 Sensor (media level) late error (tray 3) Step Check...

  • Page 210: Switch (Media Size) Size Sensing Error (Tray 4)

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error continue when the power is turned off/on? assembly. Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90. 944.00 Switch (media size) size sensing error (tray 4) Step Check...
  • Page 211 5057-XXX 944.01 Sensor (media level) late error (tray 4) Previous Step Check Check the media. Go to step 2. Load media Next properly. Is media loaded in tray 4 properly? Check the sensor (media level) (tray 4) for proper operation. Go to step 4.

  • Page 212: Through 950.29 Eprom Mismatch Failure

    5057-XXX 950.00 through 950.29 EPROM mismatch failure Previous Warning: In the event of replacement of any one of the following components: • RIP card assembly • Interconnect card assembly Next Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.

  • Page 213: Xx Rip Card Assembly Nvram Failure

    5057-XXX Check the interconnect card assembly. Go to step 3. Go to step 2. Previous Was the interconnect card assembly recently replaced? Check the RIP card assembly. Go to step 4. Contact next level of support. Was the RIP card assembly recently replaced? Replace the current interconnect card assembly with the Go to step 5 Problem solved.

  • Page 214: Xx Operator Panel Assembly Nvram Failure

    5057-XXX Previous Step Check Turn the printer off for 60 seconds. Replace the Problem solved. interconnect card Does the error occur when the power is turned off/on again? assembly. Next Go to “Interconnect card assembly removal” on Go Back page 4-88.

  • Page 215: Xx Rip Card Assembly Nand Crc Failure

    5057-XXX Previous Step Check Turn the printer off for 60 seconds. Replace the inner Problem solved. connect card Does the error occur when the power is turned off/on again? assembly. Next Go to “Interconnect card assembly removal” on Go Back page 4-88.

  • Page 216: Rip Card Assembly Processor Over Temperature Failure

    5057-XXX 956.01 RIP card assembly processor over temperature failure Previous Step Check Perform a POR. Go to step 2. Perform several Next print tests. Does the error occur when the power is turned off/on? If the problem remains, go to Go Back step 2.

  • Page 217: Communication Error With 1Tm, 3Tm, Or Ttm Assembly

    5057-XXX 980.00 Communication error with 1TM, 3TM, or TTM assembly Previous Step Check Check the 1TM, 2TM or TTM controller card assembly Go to step 2. Replace the Next and the printer engine card assembly for proper connection. connection. Is the above component properly connected? Go Back Perform a POR.

  • Page 218: Communication Error Between Printer And Rip Card Assembly

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error continue when the power is turned off/on? assembly. Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90. 980.02 Communication error between printer and RIP card assembly Step Check...

  • Page 219: Tm, 3Tm Or Ttm Left Door Assembly Open

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error continue when the power is turned off/on? assembly. Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90. 1TM, 3TM or TTM left door assembly open Step Check...

  • Page 220: Duplex Left Door Assembly Open

    5057-XXX Previous Step Check Perform a POR. Replace the 1TM, Problem solved. 3TM, or TTM Does the error continue when the power is turned off/ controller card Next assembly. Go to “1X 500- sheet drawer (1TM)—1TM Go Back controller card assembly removal”...

  • Page 221: Media Size Mismatch In Width

    5057-XXX Previous Step Check Perform a POR. Replace the duplex Problem solved. controller card Does the error continue when the power is turned off/ assembly. Next Go to “Duplex controller card assembly removal” on page 4-14. Go Back Go to step 5. Perform a POR.

  • Page 222: Media Size Mismatch In Width

    5057-XXX Media size mismatch in width Previous Step Check Check the media. Go to step 2. Load media Next properly. Pull out the tray, and visually check it. Is the media loaded in tray properly? Go Back Check the media. Go to step 3.

  • Page 223: No Media In The Selected Media Tray

    5057-XXX Previous Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error remain? assembly. Next Go to “Upper printer engine card assembly removal” on page 4-90. Go Back No media in the selected media tray Step Check Check the media.

  • Page 224: Paper Is Installed (Short Edge) In The Media Paper Tray

    5057-XXX Previous Step Check Check the sensor (media out) connection for proper Replace the Replace the connection on the appropriate media tray. appropriate sensor connection. (media out). Is the above component connected properly? Next Go to “1X 500- sheet drawer (1TM)—sensor (media out) Go Back...

  • Page 225: Pc Cartridge End Of Life

    5057-XXX PC cartridge end of life Previous Step Check Check the appropriate PC cartridge for proper installation. Go to step 2. Install the Next appropriate PC Is the appropriate PC cartridge installed properly? cartridge properly. Check the appropriate PC cartridge for damage. Replace the Go to step 3.

  • Page 226: Printer Left Door Open

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error continue when the power is turned off/on? assembly. Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90. Printer left door open Step Check...

  • Page 227: Transfer Belt Access Door Open

    5057-XXX Previous Step Check Check the switch (printer left door interlock) for proper Replace the switch Replace the connection. (printer left door connection. interlock). Is the above component properly connected? Next Go to “Switch (printer left door interlock) removal” on Go Back page 4-19.

  • Page 228: Printer Left Lower Door Assembly Open

    5057-XXX Printer left lower door assembly open Previous Step Check Check the printer left lower door for proper operation. Go to step 2. Replace the Next printer left lower Does the above component open and close properly? door assembly. Go to “Printer left Go Back lower door...

  • Page 229: K Maintenance Required

    5057-XXX 600K maintenance required Previous Step Check Install the 600K maintenance kit. Reset the 600K Problem solved. Next maintenance Does the message still occur? counter. Go to “Scheduled Go Back maintenance” on page 6-2. ADF maintenance required Step Check Install the ADF maintenance kit. Reset the ADF Problem solved.

  • Page 230: Toner Cartridge Error

    5057-XXX Toner cartridge error Previous Step Check Check the toner cartridge installation. Go to step 2. Install the correct Next toner cartridge Is the correct toner cartridge properly installed? properly. Checking the sensor (RFID toner cartridge) for proper Go to step 3. Install the sensor Go Back installation.

  • Page 231: Waste Toner Cartridge Full

    5057-XXX Waste toner cartridge full Previous Step Check Check the waste toner cartridge. Go to step 2. Reinstall the waste Next toner cartridge. Is the above component properly installed? Check the sensor (waste toner cartridge full) for proper Go to step 5. Go to step 3.

  • Page 232: Waste Toner Cartridge Nearly Full

    5057-XXX Previous Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error remain when the power is turned off/on assembly. again? Next Go to “Upper printer engine card assembly removal” on Go Back page 4-90.

  • Page 233: Color) Pc Cartridge Not Detected

    5057-XXX (Color) PC cartridge not detected Previous Step Check Check the appropriate PC cartridge. Go to step 2. Reinstall the Next appropriate PC Is the above component properly installed? cartridge. Go to “PC Go Back cartridge unit removal” on page 4-43.

  • Page 234: Cmy Pc Cartridges Nearly Exhausted

    5057-XXX CMY PC cartridges nearly exhausted Previous Step Check Check the CMY PC cartridges. Go to step 2. Reinstall the CMY Next PC cartridges. Is the above component properly installed? Go to “PC cartridge unit Go Back removal” on page 4-43.

  • Page 235: K Pc Cartridge Exhausted

    5057-XXX Previous Step Check Replace the K PC cartridge. Go to step 3. Problem solved. Does the error remain? Next Perform a POR. Replace the upper Problem solved. printer engine card Does the error remain when the power is turned off/on assembly.

  • Page 236: Color) Toner Cartridge Empty

    5057-XXX Previous Step Check Check the appropriate toner add assembly chute for Go to step 5. Clean any clogging. obstructions. Is the chute, located at the lower part of the above Next component, free of clogs and obstructions? Check the appropriate segment of the CMYK toner add Go to step 7.
  • Page 237 5057-XXX Previous Step Check Check the appropriate toner add assembly chute for Go to step 5. Clean any clogging. obstructions. Is the chute, located at the lower part of the above Next component, free of clogs and obstructions? Check the appropriate segment of the CMYK toner add Go to step 7.

  • Page 238: Printer Related Troubleshooting

    5057-XXX Previous Image quality trouble Printer Related Troubleshooting Note: First, get a printout as a base, and follow the symptom table to identify the possible failing FRU’s. Next Image quality symptoms Go Back • Faint print (low contrast)— “Faint print (Low contrast)” on page 2-147.

  • Page 239: Image Quality

    5057-XXX Image Quality Previous Faint print (Low contrast) Leading edge Next Go Back Trailing edge Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path. Step Check Check the media condition. Problem solved.
  • Page 240 5057-XXX Previous Step Check Check the toner add motor assembly. Go to step 7. Problem solved. Replace the toner add motor assembly. Next Go to “CMYK toner add motor assembly removal” on page 4-103. Does the error continue. Go Back Check the developer/transfer roll HVPS card assembly.

  • Page 241: Blank Print (No Print)

    5057-XXX Blank print (no print) Previous Next Go Back Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the four toner cartridges. Problem solved. Replace any empty toner Re-print the defective image. cartridges.
  • Page 242 5057-XXX Previous Step Check Check the printhead assembly installation. Go to step 8. Problem solved. Install the printhead assembly properly, and perform a Next print test. Does the problem remain? Check the printhead assembly for connection. Go to step 9. Replace the Go Back connection.
  • Page 243 5057-XXX Solid black Previous Next Go Back Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the four PC cartridges for proper installation. Go to step 2. Correct and clean Check the PC cartridge connections. contaminated pins, or replace Are the PC cartridge connections free of excess wear...

  • Page 244: Vertical Lines And Bands (Process Direction)

    5057-XXX Vertical lines and bands (process direction) Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Is the media transfer route and the media path clear of Go to step 3.
  • Page 245 5057-XXX Previous Step Check Check the upper printer engine card assembly. Go to step 9. Problem solved. Replace the upper printer engine card assembly. Next Go to “Upper printer engine card assembly removal” on page 4-90. Perform a print test. Go Back Does the problem remain? Check the printhead assembly for connection.

  • Page 246: Horizontal White Stripes Or Bands (Side To Side Direction)

    5057-XXX Horizontal white stripes or bands (side to side direction) Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, and recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
  • Page 247 5057-XXX Previous Step Check Check the printhead assembly. Go to step 9. Problem solved. Replace the printhead assembly. Next Go to “Printhead assembly removal” on page 4-104. Does the error continue? Go Back Check the upper printer engine card assembly. Replace the RIP problem solved.

  • Page 248: Vertical Stripes (Process Direction)

    5057-XXX Vertical stripes (process direction) Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
  • Page 249 5057-XXX Previous Step Check Check the upper printer engine card assembly. Problem solved. Replace the RIP card assembly. Replace the upper printer engine card assembly. Next Go to “RIP card Go to “Upper printer engine card assembly removal” assembly on page 4-90.

  • Page 250: Horizontal Stripes (Side To Side Direction)

    5057-XXX Horizontal stripes (side to side direction) Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route.
  • Page 251 5057-XXX Previous Step Check Check the developer/transfer roll HVPS card assembly. Go to step 8. Problem solved. Replace the developer/transfer roll HVPS card Next assembly. Go to “Developer / transfer roll HVPS card assembly removal” on page 4-112. Go Back Perform a print test.

  • Page 252: Partial Lack

    5057-XXX Partial lack Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? Check the four toner cartridges. Problem solved.
  • Page 253 5057-XXX Previous Step Check Check the printhead assembly. Go to step 9. Problem solved. Replace the printhead assembly. Next Go to “Printhead assembly removal” on page 4-104. Does the error continue? Go Back Check the upper printer engine card assembly. Problem solved.
  • Page 254 5057-XXX Spots Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3.

  • Page 255: After Image

    5057-XXX Previous Step Check Check the printhead assembly. Go to step 8. Problem solved. Replace the printhead assembly. Next Go to “Printhead assembly removal” on page 4-104. Does the error continue? Go Back Check the upper printer engine card assembly. Replace the RIP Problem solved.
  • Page 256 5057-XXX Previous Step Check Check the upper printer engine card assembly. Replace the RIP Problem solved. card assembly. Replace the upper printer engine card assembly. Next Go to “RIP card Go to “Upper printer engine card assembly removal” assembly on page 4-90.

  • Page 257: Background (Fog)

    5057-XXX Background (fog) Previous Leading edge Next Go Back Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3.
  • Page 258 5057-XXX Previous Step Check Check the printhead assembly. Go to step 8. Problem solved. Replace the printhead assembly. Next Go to “Printhead assembly removal” on page 4-104. Does the error continue? Go Back Check the upper printer engine card assembly. Replace the RIP Problem solved.
  • Page 259 5057-XXX Skew Previous Leading edge Next Go Back Trailing edge The printed image is not paralleled with both sides of the media. Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement.
  • Page 260 5057-XXX Previous Step Check Check the registration/transport roll assembly. Go to step 7. Replace registration/ Are all drive rolls on the registration/transport roll transport roll Next assembly free of contamination, wear and damage? assembly. Go to “Registration / Go Back transport roll assembly removal”...
  • Page 261 5057-XXX Media damage Previous Leading edge Next Go Back Trailing edge Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for missing printer foot. Is the setup surface normal? Check the media feed.
  • Page 262 5057-XXX Previous Step Check Check the heat roll and pressure roll. Replace the Inspect the fuser unit machine for Remove the fuser unit assembly. assembly. obstructions in Next the media path. CAUTION: Allow the fuser unit assembly to Go to “Fuser unit assembly cool down.
  • Page 263 5057-XXX No fuse Previous Leading edge Next Go Back Trailing edge Step Check Check the fuser unit assembly installation. Go to step 2. Problem solved. Check that the levers, on both sides of the fuser unit assembly, are pushed down. Re-print the defective image.

  • Page 264: Color Misregistration

    5057-XXX Color misregistration Previous Next Go Back Step Check Replace the transfer belt unit assembly. Go to Go to step 2. Problem solved. “Transfer belt unit assembly removal” on page 4-16. Does the error remain? Replace the transfer belt steering motor. Go to Go to step 3.

  • Page 265: Deletions

    5057-XXX Deletions Previous Next Go Back Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? Replace the transfer belt unit assembly. Go to Go to step 3. Problem solved.

  • Page 266: High Frequency Bands

    5057-XXX High frequency bands Previous Next Go Back Step Check Check the four PC cartridges for proper installation. Go to step 2. Correct and clean Check the PC cartridge connections. contaminated pins, or replace Are the PC cartridge connections free of excess wear the appropriate and contamination? PC cartridge or...
  • Page 267 5057-XXX Select a menu or menu item for more details. Previous Supplies Menu Job Menu Serial Menu PCL Emul Menu Color Menu <color> Toner Cancel Job PCL SmartSwitch Font Source Color Adjust Reset Printer Oiler PS SmartSwitch Font Name Color Balance Waste Bottle Print Buffer NPA Mode...
  • Page 268 5057-XXX Previous Next Go Back 2-176 Printer Service Manual...

  • Page 269: Diagnostic Aids

    5057-XXX 3. Diagnostic aids Previous This chapter explains the tests and procedures to identify printer failures and to verify that repairs have corrected the problem. Next Accessing service menus Go Back Access the following menus to identify problems with the printer and run diagnostic tests. Diagnostics Menu 1.

  • Page 270: Diagnostics Menus

    5057-XXX Previous Diagnostics Menus Entering Diagnostics Menus 1. Turn off the printer. Next 2. Press and hold the buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Go Back Available tests Tests appear on the LCD in the order shown: MOTOR TESTS “MOTOR TESTS”...
  • Page 271 5057-XXX Booklet stapler motor Previous Bridge unit bin media exit solenoid Printer Motor Tests Transfer belt steering motor Next CMY PC cartridge drive motor K PC cartridge drive motor Printhead polygon mirror motor Go Back Tray 1 media feed/lift motor Registration clutch 2nd transfer roll retract motor K developer/transport motor...
  • Page 272 5057-XXX Panel Test “Panel Test” on page 3-7. Previous Button Test “Button Test” on page 3-7. DRAM Test “DRAM Test” on page 3-8. “CACHE Test” on page 3-8. CACHE Test DUPLEX TESTS Next Quick Test “Quick Test” on page 3-8. Sensor Test “Sensor Test (duplex)”...

  • Page 273: Motor Tests

    5057-XXX C Channel (925.02) Previous K Channel (925.03) Dev Unit Reset “Dev Unit Reset” on page 3-19. Y Channel M Channel Next C Channel K Channel Go Back ENGINE ADJUST “ENGINE ADJUST” on page 3-20. PH Adjust (registration) PRO-CON RegCon Adjust Booklet Fold Adj Finisher Config Booklet Fold Adjust...

  • Page 274: Print Tests

    5057-XXX The following Printer Motor Tests are available: Previous • Transfer belt steering motor • Y toner add motor • CMY PC cartridge drive motor • K toner add motor • K PC cartridge drive motor • CMY developer drive motor •...

  • Page 275: Panel Test

    5057-XXX Input Source Print Test Previous Regardless of the input source selected, the printer always generates a simplex version of the Print Test page using its default resolution. Print Quality Test Pages Next This setting enables you to view the values of a broad range of the device’s settings and to test the device’s ability to generate acceptable printed output.

  • Page 276: Dram Test

    5057-XXX DRAM Test Previous The DRAM Test is used to check the validity of both the printer’s standard and optional DRAM. The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: Next 1.

  • Page 277: Sensor Test

    5057-XXX Make sure either letter or A4 size paper is loaded in the default paper source. If the default source only supports Previous envelopes, then the Quick Test will be printed from Tray 1. To run the Quick Test: 1. Select DUPLEX TESTS from the Diagnostics Menu. 2.

  • Page 278: Sensor Test

    5057-XXX • Continuous—Media continues feeding from the selected input source until Stop is pressed. Previous Sensor Test (input tray) This test is used to verify that a specific input tray’s sensors are working correctly. To run the Input Tray Sensor Test: Next 1.

  • Page 279: Feed To All Bins

    5057-XXX Press Stop to return to the [Selected Output Bin]. Previous While this test runs, [Selected Output Bin] Feeding...appears on the LCD. During Single tests, no buttons are active. However, during Continuous tests, you can press Stop to cancel the test. Feed To All Bins Next This test can be used to verify that the printer can feed media to the standard bin or any installed output options.

  • Page 280: Hole Punch Test

    5057-XXX To run the Staple Test Previous 1. Select FINISHER TESTS from the Diagnostics Menu. 2. Select Staple Test. The printer feeds eight pieces of media from the default input source to the output bin that supports stapling. After all eight pieces of media are deposited, the device staples the packet. While this test runs, Staple Test Next Running...
  • Page 281 5057-XXX Door G finisher front Previous Surface H eject cover Cover F bridge unit top Available Bin Level Sensors Next Sensor Name Go Back Finisher upper media bin full Stacker bin level1 Stacker bin level2 Stacker bin upper limit Stacker bin no media Stacker bin level encod Available Media Path 1 Sensors Sensor Name...

  • Page 282: Base Sensor Test

    5057-XXX Booklet unit media exit Previous Booklet bin media present Booklet compiler media present Booklet unit interlock Booklet front low staple Next Booklet rear low staple Go Back Available Punch and Staple Sensors Sensor Name Punch side reg1 Punch side reg2 Punch box set Low staple Punch carriage shift hp...
  • Page 283 5057-XXX Door E printer front Previous Door J transfer belt access Devices Sensors Next Sensor Name C PC cartridge present Go Back M PC cartridge present Y PC cartridge present K PC cartridge present Waste toner full Exit Level Sensor Sensor Name Standard bin full Media Path Sensors...

  • Page 284: Printer Setup

    5057-XXX PRINTER SETUP Previous To enter the PRINTER SETUP screen, select PRINTER SETUP from the Diagnostics Menu. PRINTER SETUP values appear on the LCD. If required, reset the values and submit. Next Defaults The value of this setting determines whether the printer uses the US or Non-US factory default value for the Go Back printer settings listed below: Printer Setting...

  • Page 285: Event Log

    5057-XXX If the printer’s firmware detects that either of the printer’s Configuration IDs has not been defined or is invalid, Previous then the following occurs: 1. The firmware automatically uses the Configuration IDs defined for the printer’s standard model. 2. The Configuration ID setting is the only item that appears when you open the Diagnostics menu. 3.

  • Page 286: Trans Belt Hp Fail Clear

    5057-XXX Each logged event is identified by the text that appeared when the event occurred. For instance, if the log Previous recorded a 900 Service Error, the Display Log would show 900 Service RIP Software. Log entries appear in chronological order. If additional log entries exist, select to view the next log entries.

  • Page 287: Fuser Temp Fail Clear

    5057-XXX Dev Unit Reset Previous To perform the Dev Unit Reset Test: 1. Select Dev Unit Reset from the Diagnostics Menu. Next The following tests appear on the LCD: Select the following: Appears on the LCD: Go Back Y Channel Y Channel Testing...

  • Page 288: Engine Adjust

    5057-XXX ENGINE ADJUST Previous To begin PH Adjust (media tray registration), the test page must be printed. To print the test page the printer must be in standard mode. Next 1. Select Menus. 2. Select Reports. 3. Select Network Setup Page Go Back The following report prints.
  • Page 289 5057-XXX Adj Lead Reg ALL (appears on LCD) Registration values appear on the LCD. If Previous required, reset the values and Select (Adj lead reg all trays) to submit the changes. Adj Lead Reg Tr165 (appears on LCD) Registration values appear on the LCD. If required, reset the values and Select (Adj lead reg tray 1 - plain/color) to submit the changes.
  • Page 290 5057-XXX Previous PRO-CON (ATC sensor setup and adjust) This procedure is used to adjust the following: Sensor (C ATC) Sensor (M ATC) Sensor (Y ATC) Sensor (K ATC) Next Select PRO-CON and select: Then Select: Appears on the LCD Go Back ATC Sensor Adjust values Sen Grad SNR-Y Registration values appear on the LCD.

  • Page 291: Color Registration (Regcon)

    5057-XXX Color registration (RegCon) Previous The purpose of the color registration is to establish correct horizontal and vertical positioning of the four primary color images. The procedure consists of the following steps, which must be performed in the listed sequence: Next 1.

  • Page 292: Entering Configuration Menu

    5057-XXX Entering Configuration Menu Previous 1. Turn off the printer. 2. Press and hold the Select and Right Arrow buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Next Available menus Go Back Maintenance Counter Value “Maintenance Counter Value”...

  • Page 293: Reset Maintenance Counter

    5057-XXX After installing the required maintenance kit, reset this count to zero. Previous Reset Maintenance Counter After scheduled maintenance, reset the Maintenance Counter. Next To reset the maintenance page counter to zero: 1. Select Reset Maintenance Counter from the Configuration Menu. Go Back 2.

  • Page 294: A5/Statement

    5057-XXX To change the value of this setting: Previous 1. Select SIZE SENSING from the Configuration Menu. The screen displays each size sensing equipped input source and its current Size Sensing value. 2. Select Back to cancel and return to the Configuration Menu. 3.

  • Page 295: Factory Defaults

    2. Select Restore Base to restore all non-critical base printer NVRAM settings. 3. Select Restore Network to restore all network NVRAM settings. 4. Select Restore LES to remove all Lexmark Embedded Solution applications When you select either value, the LCD displays Restoring Factory Defaults and then Resetting the Device.

  • Page 296: Envelope Prompts

    5057-XXX To change this setting: Previous 1. Select Paper Prompts from the Configuration Menu. 2. Make your selection and press 3. To exit this screen without changing the setting's value, select Back. Next Envelope Prompts This setting controls the tray the user is directed to refill when a specific envelope size is out. The selections are Go Back Auto (default), MP Feeder, and Manual Env.

  • Page 297: Tray Low Message

    5057-XXX To change this setting: Previous 1. Select Short Edge Printing from the Configuration Menu. 2. Select Back to cancel and return to the Configuration Menu. 3. Press to save the change. Next Tray Low Message This setting allows you to disable any Tray Low warnings that the printer may register. Go Back Selecting Disabled turns off the tray low prompts.

  • Page 298: Repeating Defects

    5057-XXX Repeating defects Previous Roll Pitch 2nd transfer roll 83.05 mm Registration roll 62.61 mm Next Developer magnetic roll 33.76 mm Developer auger roll 43.89 mm Fuser hot roll 85.15 mm Go Back Charge roll 43.98 mm PC drum 94.25 mm Transfer belt 949.00 mm Fuser...

  • Page 299: Repair Information

    5057-XXX 4. Repair information Previous Warning: Read the following before handling electronic parts. Next Handling ESD-sensitive parts Go Back Many electronic products use parts that are known to be sensitive to electrostatic (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...

  • Page 300: Removal Procedures

    5057-XXX Previous Removal procedures Before starting service work Next CAUTION: Go Back Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly. CAUTION: While performing service around the fuser assembly, ensure the fuser area has cooled down. Note: Some removal procedures require removing cable ties.

  • Page 301: Printer Front Door Assembly Removal

    5057-XXX Printer front door assembly removal Previous 1. Open the printer front door assembly. 2. Press the tab, and rotate the two flexible supports (A) 90°, and pull from the machine. 3. Remove the two flexible supports (A). 4. Remove the two screws securing the two brackets (B) to the printer front door assembly (C). Next 5.

  • Page 302: Right Cover Assembly Removal

    5057-XXX Right cover assembly removal Previous Note: Detach the finisher if equipped. Refer to the MFP or Printer Finisher Service Manual. 1. Open the transfer belt unit access door (A). 2. Remove the three screws securing the right cover assembly (B) to the machine. Next 3.

  • Page 303: Rear Cover Assembly Removal

    5057-XXX Rear cover assembly removal Previous Note: Remove the blind cover (A) if the printer is equipped with a 1TM, 3TM, or a TTM. 1. Remove all connectors and power cords from the rear of the machine. 2. Remove the four screws securing the rear cover assembly (B) to the machine. Next 3.

  • Page 304: Rear Left Middle Cover Removal

    5057-XXX Rear left middle cover removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Open the printer left door assembly. 3. Remove the screw securing the rear left middle cover (A) to the machine. 4.

  • Page 305: Rear Left Upper Cover Removal

    5057-XXX Rear left upper cover removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. Warning: Ensure that the rear left middle cover is removed before removing the rear left upper cover, or damage will occur. 2.

  • Page 306: Printer Left Lower Door Assembly Removal

    5057-XXX Printer left lower door assembly removal Previous 1. Remove the media tray 1. 2. Open the printer left lower door assembly. 3. Disconnect the connector from the printer left lower door assembly (A). 4. Release the harness from the clamp. Next 5.

  • Page 307: Front Left Cover Removal

    5057-XXX Front left cover removal Previous 1. Open the printer front door assembly. 2. Remove the two screws securing the front left cover (A) to the machine. 3. Move the front left cover (A) up and pull out. 4. Remove the front left cover (A). Next Go Back Duplex media inverter assembly removal...

  • Page 308: Duplex Unit Assembly Removal

    5057-XXX Previous Next Go Back Duplex unit assembly removal 1. Remove the two screws securing the duplex unit assembly (A) to the printer left door assembly (B). 2. Gently pull the duplex unit assembly (A) from the printer left door assembly (B). Note: When removing the duplex unit assembly (A), the plastic panel (C) may become detached.

  • Page 309: Sensor (Duplex Wait) Removal

    5057-XXX Sensor (duplex wait) removal Previous 1. Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-10. 2. Remove the screw securing the bracket (A) to the duplex unit assembly (B). 3. Release the hooks securing the sensor (duplex wait) (C) to the bracket (A). 4.

  • Page 310: Duplex Media Exit Turn Guide Removal

    5057-XXX Duplex media exit turn guide removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...

  • Page 311: Duplex Drive Motor Removal

    5057-XXX Replacement note: When replacing the printer left door assembly (B), ensure that the duplex media exit guide Previous (A) is held up, or the printer left door assembly (B) will not close properly. Black line Next Go Back Duplex drive motor removal 1.

  • Page 312: Duplex Controller Card Assembly Removal

    5057-XXX Duplex controller card assembly removal Previous 1. Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-10. 2. Remove the screw securing the connector access cover (A) to the duplex unit assembly (C). 3. Disconnect the connectors from the duplex controller card assembly (B). 4.

  • Page 313: Fuser Unit Assembly Removal

    5057-XXX Fuser unit assembly removal Previous CAUTION: The fuser unit assembly can be extremely hot, handle with care to avoid getting burned. Next 1. Open the printer left door assembly. Go Back 2. Loosen the two thumb screws to release the fuser unit assembly (A) from the machine. 3.

  • Page 314: Transfer Belt Unit Assembly Removal

    5057-XXX Transfer belt unit assembly removal Previous Warning: When removing the transfer belt unit assembly, do not touch the belt surface, or damage will occur. Note: Detach the finisher if equipped. Refer to the MFP or the Printer Finisher Service Manual. 1.

  • Page 315: Transfer Belt Cleaning Assembly Removal

    5057-XXX Transfer belt cleaning assembly removal Previous Warning: When removing the transfer belt unit assembly, do not touch the belt surface, or damage will occur. Note: It is not required to completely remove the transfer belt unit assembly (B) from the machine. It can be partially pulled out to provide access to the transfer belt cleaning assembly (A).

  • Page 316: Standard Media Exit Bin Full Actuator Removal

    5057-XXX Previous Connectors Next Go Back Standard media exit bin full actuator removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. Warning: Ensure that the rear left middle cover is removed before removing the rear left upper cover, or damage will occur.

  • Page 317: Switch (Printer Left Door Interlock) Removal

    5057-XXX Previous Next Go Back Switch (printer left door interlock) removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. Warning: Ensure that the rear left middle cover is removed before removing the rear left upper cover, or damage will occur.
  • Page 318 5057-XXX 5. Remove the screw securing the bracket (A) to the standard media exit bin shift assembly. Previous 6. Remove the bracket (A). 7. Release the hooks securing the switch (printer left door interlock) (B) to the bracket (A). 8. Remove the switch (printer left door interlock). Next Go Back Hooks...

  • Page 319: Sensor (Standard Media Bin Full) Removal

    5057-XXX Sensor (standard media bin full) removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. Warning: Ensure that the rear left middle cover is removed before removing the rear left upper cover, or damage will occur.

  • Page 320: Sensor (Media Out) Removal

    5057-XXX Sensor (media out) removal Previous 1. Remove the printer left lower door assembly. See “Printer left lower door assembly removal” on page 4-8. 2. Remove the media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-21.
  • Page 321 5057-XXX 4. Remove the media out actuator (A). Previous Next Go Back Front Bosses Lower view 4-23 Repair information...

  • Page 322: Sensor (Media Level) Removal

    5057-XXX Sensor (media level) removal Previous 1. Remove the printer left lower door assembly. See “Printer left lower door assembly removal” on page 4-8. 2. Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-21.

  • Page 323: Sensor (Fuser Exit) Removal

    5057-XXX Sensor (fuser exit) removal Previous 1. Open the printer left door assembly. 2. Remove the E-clip securing the fuser exit roll assembly (A) to the machine. 3. Remove the bushing (B). 4. Remove the fuser exit roll assembly (A). Next 5.

  • Page 324: Printer Left Door Assembly Removal

    5057-XXX Printer left door assembly removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...
  • Page 325 5057-XXX Previous C-clip Next Go Back Safety screw Approximately 75° Replacement warning: When replacing the printer left door assembly (B), ensure that the black lines are aligned on the damper assembly (E), or the door will not properly operate. Black line 4-27 Repair information...
  • Page 326 5057-XXX ‘ Previous Next Go Back Replacement warning: When replacing the printer left door assembly (B), ensure that the duplex media exit turn guide (F) is held in its upper-most position, or the printer left door assembly (B) will not close properly. 4-28 Printer Service Manual...

  • Page 327: Printer Left Door Damper Removal

    5057-XXX Printer left door damper removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...

  • Page 328: Sensor (Media On Belt) Removal

    5057-XXX Replacement warning: When replacing the printer left door assembly (D), ensure that the duplex media exit turn Previous guide (E) is held in its upper-most position, or the printer left door assembly (D) will not close properly. Next Go Back Sensor (media on belt) removal 1.
  • Page 329 5057-XXX 2nd transfer roll retract cam assembly removal Previous 1. Remove the 2nd transfer roll assembly. See “2nd transfer roll assembly removal” on page 4-35. 2. Remove the two screws securing the registration pinch guide assembly (A) to the machine. 3.
  • Page 330 5057-XXX Previous Connector Next Go Back Replacement note: When reinstalling the transfer roll retract cam assembly (D), ensure that the bushing (E), pin (F), and washer are replaced. E-clip Actuator Connector 4-32 Printer Service Manual...
  • Page 331 5057-XXX Previous Next Go Back 4-33 Repair information...

  • Page 332: Sensor (2Nd Transfer Roll Retract Hp) Removal

    5057-XXX Sensor (2nd transfer roll retract HP) removal Previous 1. Remove the 2nd transfer roll assembly. See “2nd transfer roll assembly removal” on page 4-35. 2. Remove the two screws securing the registration pinch guide assembly (A) to the machine. 3.

  • Page 333: Nd Transfer Roll Retract Motor Assembly Removal

    5057-XXX 2nd transfer roll retract motor assembly removal Previous 1. Remove the 2nd transfer roll assembly. See “2nd transfer roll assembly removal” on page 4-35. 2. Remove the 2nd transfer roll retract cam assembly. See “2nd transfer roll retract cam assembly removal” on page 4-31.

  • Page 334: Registration / Transport Roll Assembly Removal

    5057-XXX Warning: When removing the main transfer roll assembly (B), do not touch the roll surface. Previous Next Go Back Replacement warning: When reinstalling the transfer roll assembly (B), do not touch the roll surface. Registration / transport roll assembly removal 1.

  • Page 335: Registration Clutch Removal

    5057-XXX Registration clutch removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...

  • Page 336: Sensor (Transparency Detect) Removal

    5057-XXX 9. Disconnect the connector from the sensor (registration) (C). Previous Next Go Back Sensor (transparency detect) removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal”...

  • Page 337: Waste Toner Cartridge Cover Removal

    5057-XXX Waste toner cartridge cover removal Previous 1. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3. 2. Lower the waste toner cartridge cover (A) to its lower-most position. 3. Remove the waste toner cartridge. 4.

  • Page 338: Sensor (Waste Toner Cartridge Full) Removal

    5057-XXX Previous Connectors Next Go Back Sensor (waste toner cartridge full) removal 1. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3. 2. Remove the front left cover. See “Front left cover removal” on page 4-9.

  • Page 339: Switch (Waste Toner Cartridge Interlock) Removal

    5057-XXX Switch (waste toner cartridge interlock) removal Previous 1. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3. 2. Remove the front left cover. See “Front left cover removal” on page 4-9. 3. Remove the waste toner cartridge cover. See “Waste toner cartridge cover removal”...

  • Page 340: Inner Cover Removal

    5057-XXX Inner cover removal Previous 1. Open the printer front door assembly. 2. Remove the front left cover. See “Front left cover removal” on page 4-9. 3. Remove the waste toner cartridge cover. See “Waste toner cartridge cover removal” on page 4-39.

  • Page 341: Waste Toner Agitator Motor Assembly Removal

    5057-XXX Waste toner agitator motor assembly removal Previous 1. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3. 2. Remove the front left cover. See “Front left cover removal” on page 4-9. 3. Remove the waste toner cartridge cover. See “Waste toner cartridge cover removal”...

  • Page 342: Image Density Sensor Assembly Removal

    5057-XXX Replacement warning: Ensure that all PC cartridge units are properly seated and aligned before raising the Previous transfer belt lift handle to its upper-most position, or damage will occur. Never force the transfer belt lift handle into its home position, or damage will occur. Next Go Back Button...
  • Page 343 5057-XXX Warning: Note the orientation of the harnesses to ensure they are not pinched when replacing the harness Previous access cover (A), or damage will occur. 8. Remove the harness access cover (A) from the machine. Next Go Back Connectors 9.

  • Page 344: Cmy Toner Add Assembly Removal

    5057-XXX 12. Remove the image density sensor assembly (A). Previous Next Go Back Replacement note: Requires color calibration adjustments. Replacement warning: When replacing the harness access cover, ensure that the harnesses are not pinched, or damage will occur. CMY toner add assembly removal 1.
  • Page 345 5057-XXX 8. Remove the appropriate CMY toner add assemblies (A). Previous Next Shutter Go Back 4-47 Repair information...

  • Page 346: K Toner Add Assembly Removal

    5057-XXX K toner add assembly removal Previous Warning: Ensure the three CMY toner add assemblies are removed before removing the K toner add assembly, or damage will occur. 1. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3.
  • Page 347 5057-XXX Warning: When removing the CMY toner add assemblies, the toner cartridges should be left installed in order Previous to reduce toner spillage. 7. Remove the three CMY toner add assemblies. See “CMY toner add assembly removal” on page 4-46. Warning: When removing the K toner add assembly, the toner cartridge should be left installed in order to reduce toner spillage.
  • Page 348 5057-XXX Warning: Note the orientation of the four developer unit harnesses and the three erase lamp harnesses to ensure Previous proper reinstallation or damage may occur. 14. While holding the four developer unit assemblies firmly inside the machine, gently remove the developer interlock plate assembly (A).
  • Page 349 5057-XXX Replacement note: When replacing the developer interlock plate assembly (A), install the bottom edge first Previous and ensure that all four developer unit assemblies are properly aligned when replacing the developer interlock plate assembly (A). Next Go Back 4-51 Repair information...
  • Page 350 5057-XXX Replacement warning: Ensure that the erase lamp harnesses and developer unit assembly harnesses are Previous correctly installed in the clamps, or they may become detached. Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle up and down several times before reinstalling the inner cover. Erase lamp &...

  • Page 351: Developer Unit Assembly Removal

    5057-XXX Developer unit assembly removal Previous Note: The following procedure can be applied to the C, M, Y, and K developer unit assemblies. Warning: When removing developer unit assemblies, ensure that the area on the floor in front of the machine is protected from toner spillage.
  • Page 352 5057-XXX Warning: Ensure that the harness coupler (B) is removed from the old developer unit assembly (A) and installed Previous on the new one. Next Go Back Note: Installation of a new developer requires installation of the appropriate carrier. See page 4-60 for the instructions on how to install the new carrier.
  • Page 353 5057-XXX detached. Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle up Previous and down several times before reinstalling the inner cover. Erase lamp & developer unit assembly harnesses Next Go Back Clamps Clamp 11.
  • Page 354 5057-XXX 12. Clean the four printhead glass windows using the printhead cleaning tool. Previous Next Go Back 4-56 Printer Service Manual...

  • Page 355: Developer Carrier Removal And Replacement

    5057-XXX Developer carrier removal and replacement Previous Note: The following procedure can be applied to the C, M, Y, and K developer carriers. Warning: Always perform the sensor (ATC sensor) setup and adjustment if required or print quality problems may occur. Go to “Sensor (ATC) setup”...
  • Page 356 5057-XXX 11. Remove the top cover (A). Previous Next Go Back 12. Completely remove the carrier (B) from the assembly by dumping it and using a toner vacuum or if installing a new developer unit assembly, go to next step. 4-58 Printer Service Manual...
  • Page 357 5057-XXX Replacement warning: If reusing an existing developer unit assembly, ensure that all traces of old carrier (B) Previous are removed from the developer unit assembly, or print quality issues may occur. Next Go Back 4-59 Repair information...
  • Page 358 5057-XXX To install the new carrier (B): Previous Warning: Ensure that the carrier is installed evenly and uniformly in the assembly, or spillage may occur. 1. Open the appropriate bag, and dump the appropriate carrier into the appropriate assembly. Hook Next Tabs Go Back...

  • Page 359: Photoconductor (Pc) Unit Assembly Removal

    5057-XXX Photoconductor (PC) unit assembly removal Previous Warning: Ensure that all four PC cartridges are concealed from all sources of light, or damage will occur. Note: This procedure can be applied to either the C, M, Y, or K PC unit assemblies. 1.
  • Page 360 5057-XXX 5. Pull the appropriate PC unit assembly (C) from the machine. Previous Next Go Back Note: When the PC unit assembly (C) is removed, ensure that it is stored in the position as shown in the graphic below. 4-62 Printer Service Manual...

  • Page 361: Transfer Belt Lift Latch Assembly Removal

    5057-XXX Replacement warning: When replacing the PC unit assembly (C), ensure that the rail on the PC unit assembly Previous (C) is properly inserted into the metal track or physical binding and damage will occur. In the event that the PC unit assembly (C) becomes bound, it can be removed by twisting it in a clockwise direction while pulling it from the machine.

  • Page 362: Left Transfer Belt Lift Assembly Removal

    5057-XXX 9. Remove the transfer belt lift latch assembly (A). Previous Next Go Back Left transfer belt lift assembly removal 1. Remove the four PC cartridge unit. See “PC cartridge unit removal” on page 4-43 2. Remove the rear cover assembly. See “Rear cover assembly removal”...
  • Page 363 5057-XXX 13. Remove the plastic cover (A). Previous Next Go Back 14. Remove the transfer belt lift handle assembly. See “Transfer belt lift handle assembly removal” on page 4-70. 15. Remove the waste toner agitator motor assembly. See “Waste toner agitator motor assembly removal” on page 4-43.
  • Page 364 5057-XXX 19. Remove the bracket (A). Previous Next Go Back 20. Remove the two screws securing the left elevator assembly (B) to the front of the machine. 4-66 Printer Service Manual...
  • Page 365 5057-XXX 21. Remove the two screws from the left transfer belt lift assembly (B). Previous Next Go Back Note: In order to remove the left transfer belt lift assembly (B), two E-clips and two washers must be removed. The two E-clips and two washers are located inside the machine in the area where the K PC unit is located.
  • Page 366 5057-XXX 23. Remove the left transfer belt lift assembly (B) from the machine. Previous Next Go Back Replacement note: Ensure that the two E-clips, four washers, and two bearings are properly reinstalled when installing the new left transfer belt lift assembly (B). Replacement warning: When replacing the transfer belt lift handle assembly (B), the two transfer belt lift mechanisms must be correctly timed or print quality problems and damage will occur.
  • Page 367 5057-XXX Replacement warning: After replacing the transfer belt lift handle assembly (B), the two transfer belt lift Previous mechanisms must be correctly aligned or print quality problems and damage will occur. Once the alignment is correctly set, replace the two plastic rack gear caps. Replacement warning: When replacing the transfer belt lift handle assembly (B), ensure the two timing marks on the two sector gears are aligned with the two timing knotches in the two rack gears.

  • Page 368: Transfer Belt Lift Handle Assembly Removal

    5057-XXX Transfer belt lift handle assembly removal Previous Next Go Back Warning: When replacing the transfer belt lift handle assembly, the two transfer belt lift mechanisms must be correctly timed or print quality problems and damage will occur. Replacement warning: After replacing the transfer belt lift handle assembly (B), the two transfer belt lift mechanisms must be correctly aligned or print quality problems and damage will occur.
  • Page 369 5057-XXX 4. Remove the transfer belt unit assembly. See “Transfer belt unit assembly removal” on page 4-16 Previous 5. Remove the front left cover. See “Front left cover removal” on page 4-9. 6. Remove the screw securing the plastic cover (A) to the machine. 7.
  • Page 370 5057-XXX 8. Gently release the hooks on the two plastic rack gear caps with a small flat-tip screwdriver. Previous 9. Remove the two plastic rack gear caps. 10. Remove the screw and washer securing the left hinge pin. 11. Remove the left hinge pin. Next Go Back 4-72...
  • Page 371 5057-XXX 12. Remove the E-clip securing the right hinge pin. Previous 13. Remove the right hinge pin. Next Go Back 4-73 Repair information...
  • Page 372 5057-XXX 14. Remove the transfer belt lift handle assembly (B) from the machine. Previous Warning: When extending the two rack gears, ensure they do not become bent or damaged. 15. Ensure the two rack gears are fully extended toward the front of the machine before reinstalling the transfer belt lift handle assembly (B).
  • Page 373 5057-XXX Replacement warning: After replacing the transfer belt lift handle assembly (B), the two transfer belt lift Previous mechanisms must be correctly aligned or print quality problems and damage will occur. Once the alignment is correctly set, replace the two plastic rack gear caps. Replacement warning: When replacing the transfer belt lift handle assembly (B), ensure the two timing marks on the two sector gears are aligned with the two timing knotches in the two rack gears.

  • Page 374: Transfer Belt Steering Motor Removal

    5057-XXX Transfer belt steering motor removal Previous 1. Remove the front left cover. See “Front left cover removal” on page 4-9. 2. Remove the waste toner cartridge cover. See “Waste toner cartridge cover removal” on page 4-39. 3. Remove the waste toner cartridge sensor assembly. See “Waste toner cartridge sensor assembly removal”...

  • Page 375: K Erase Lamp Assembly Removal

    5057-XXX 12. Gently raise the rear of the appropriate CMY erase lamp assembly (B) to detach the mounting hook from the Previous machine. 13. Remove the appropriate CMY erase lamp assembly (B). Next Go Back Connector Mounting hook K erase lamp assembly removal Warning: Ensure the transfer belt assembly unit is removed, or damage will occur.
  • Page 376 5057-XXX 13. Gently raise the rear of the K erase lamp assembly (B) to detach the mounting hook from the machine. Previous 14. Remove the K erase lamp assembly (B). Connector Next Go Back 4-78 Printer Service Manual...

  • Page 377: Printhead Shutter Motor Assembly Removal

    5057-XXX Previous Mounting hook Next Go Back Printhead shutter motor assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6.
  • Page 378 5057-XXX Replacement warning: When reinstalling the printhead shutter motor assembly (A), ensure that the plastic arm is Previous inserted into the printhead shutter (B). Connectors Next Go Back 4-80 Printer Service Manual...

  • Page 379: Switch (Printer Front Door Interlock) Removal

    5057-XXX Switch (printer front door interlock) removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the right cover assembly. See “Right cover assembly removal” on page 4-4. 3. Remove the top cover assembly. See “Top cover assembly removal”...

  • Page 380: Sensor (Printer Left Lower Door Interlock) Removal

    5057-XXX Sensor (printer left lower door interlock) removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...

  • Page 381: Controller Box Assembly Removal

    5057-XXX 8. Remove the RIP card cooling fan cover assembly (A). Previous Connector Next Go Back Connector Controller box assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the right cover assembly. See “Right cover assembly removal”...

  • Page 382: Switch (Main Power) Removal

    5057-XXX Switch (main power) removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the right cover assembly. See “Right cover assembly removal” on page 4-4. 3. Remove the top cover assembly. See “Top cover assembly removal”...

  • Page 383: Bridge Card Assembly Removal

    5057-XXX Bridge card assembly removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the right cover assembly. See “Right cover assembly removal” on page 4-4. 3. Remove the top cover assembly. See “Top cover assembly removal”...

  • Page 384: Rip Card Access Cover Removal

    5057-XXX RIP card access cover removal Previous 1. Using your finger, lift the RIP card access cover (A) by the notch. 2. Remove the RIP card access cover (A). Next Go Back RIP card assembly removal Warning: In the event of replacement of any one of the following components: •...

  • Page 385: Hard Drive Removal

    5057-XXX 3. Remove the RIP card assembly (A) from the machine. Previous Next Go Back 4. Remove the riser card assembly. See “Interconnect card assembly removal” on page 4-88. Replacement warning: When replacing the RIP card assembly, ensure the interconnect card assembly is removed from the defective RIP card assembly and installed on the replacement rip card assembly or the machine will not function.

  • Page 386: Interconnect Card Assembly Removal

    5057-XXX Interconnect card assembly removal Previous Warning: In the event of replacement of any one of the following components: • RIP card assembly • Interconnect card assembly Next Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
  • Page 387 5057-XXX 12. Remove the upper printer engine card bracket assembly (A). Previous Next Go Back Connector Replacement warning: Ensure that the upper printer engine card (B) assembly and the lower printer engine card assembly (C) are connected. 4-89 Repair information...

  • Page 388: Upper Printer Engine Card Assembly Removal

    5057-XXX Upper printer engine card assembly removal Previous WARNING When reinstalling the upper printer engine card assembly, ensure that the NVM board from the defective upper printer engine card assembly is installed on the replacement upper printer engine card assembly, or the machine will not function. Go to page 4-91.

  • Page 389: Upper Printer Engine Card Assembly Re-Installation

    5057-XXX Previous Next Go Back Bottom view Replacement warning: When reinstalling the upper printer engine card assembly (B), ensure that the NVM board (D) is installed on the new upper printer engine card assembly (B), or the machine may not function properly.

  • Page 390: Lower Printer Engine Card Bracket Assembly Removal

    5057-XXX Turn on the machine. Previous Note: If an 84.xx error occurs, it means that the NVM board was incorrectly installed. Make sure that the NVM board installed is the old NVM board from the defective upper printer engine card. Perform color registration adjustment.

  • Page 391: Lower Printer Engine Card Assembly Removal

    5057-XXX Lower printer engine card assembly removal Previous 1. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-111. 2. Remove the developer / transfer roll HVPS card assembly. See “Developer / transfer roll HVPS card assembly removal”...

  • Page 392: Transfer Belt Drive Motor Assembly Removal

    5057-XXX 7. Remove the transfer belt drive motor cooling fan (A). Previous Next Go Back Transfer belt drive motor assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 393: Switch (Transfer Belt Access Door Interlock) Removal

    5057-XXX Switch (transfer belt access door interlock) removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-111.

  • Page 394: V Lvps Card Bracket Assembly Removal

    5057-XXX 6. Remove the laser diode power card assembly (A). Previous Next Go Back 24V LVPS card bracket assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 395: V Lvps Card Assembly Removal

    5057-XXX Previous Next Go Back 24V LVPS card assembly removal 1. Disconnect the three connectors from the 24V LVPS card assembly (A). 2. Remove the three screws securing the 24V LVPS card assembly (A). 3. Remove the 24V LVPS card assembly (A). 5V LVPS card bracket assembly removal 1.

  • Page 396: V Lvps Card Assembly Removal

    5057-XXX 6. Remove the four screws securing the 5V LVPS card bracket assembly (A) to the machine. Previous 7. Remove the 5V LVPS card bracket assembly (A). Next Go Back 5V LVPS card assembly removal 1. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 397: V Lvps Cooling Fan Removal

    5057-XXX 24V LVPS cooling fan removal Previous 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-111.

  • Page 398: Cmy Developer Drive Motor Assembly

    5057-XXX 8. Remove the rear lower cooling fan assembly (A). Previous Connector Next Go Back CMY developer drive motor assembly 1. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-111. 2.

  • Page 399: Cmyk Pc Cartridge Drive Motor Assembly Removal

    5057-XXX Previous Next Go Back CMYK PC cartridge drive motor assembly removal Warning: Ensure that all four PC cartridges are concealed from all sources of light, or damage will occur. 1. Remove the four PC cartridges from the machine. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 400: Fuser Cooling Fan Removal

    5057-XXX 16. Remove the CMYK PC cartridge drive motor assembly (A). Previous Next Connector Go Back Connector Screwdriver access hole Fuser cooling fan removal 1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-4. 2. Disconnect the connector from the fuser cooling fan (A). 3.

  • Page 401: Cmyk Toner Add Motor Assembly Removal

    5057-XXX 4. Remove the main power switch actuator (A). Previous Next Go Back CMYK toner add motor assembly removal 1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-4. 2. Remove the printer front door assembly. See “Printer front door assembly removal”...

  • Page 402: Printhead Assembly Removal

    5057-XXX 16. Remove the CMYK toner add motor assembly (A). Previous Next Go Back CMYK transfer HVPS card assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 403: Transfer Belt Waste Toner Auger Assembly Removal

    5057-XXX 2. Remove the base machine from the scanner/ADF stand assembly. Previous 3. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 4. Remove the right cover assembly. See “Right cover assembly removal” on page 4-4. 5.
  • Page 404 5057-XXX 4. Move the transfer belt waste toner auger assembly (A) toward the rear of the machine. Previous 5. Remove the transfer belt waste toner auger assembly (A) from the machine. Next Go Back K developer / transport drive motor assembly removal 1.
  • Page 405 5057-XXX 16. Gently remove the K developer transport drive motor assembly (A). Previous Next Go Back Connector Frame clamp Connector Clamp Clamps Connectors Clamps 4-107 Repair information...

  • Page 406: K Developer Clutch Removal

    5057-XXX Previous Next Go Back Connector K developer clutch removal 1. Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-10. 2. Remove the fuser unit assembly. See “Duplex controller card assembly removal” on page 4-14. 3. Remove the rear cover assembly. See “Rear cover assembly removal”...

  • Page 407: Ac Drive Card Bracket Assembly Removal

    5057-XXX 15. Remove the K developer clutch (D). Previous Next Go Back AC drive card bracket assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 408: Noise Filter Assembly Removal

    5057-XXX 12. Remove the AC drive card bracket assembly (A). Previous Next Go Back Noise filter assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 409: Rear Upper Cooling Fan Bracket Assembly Removal

    5057-XXX 11. Remove the noise filter assembly (A). Previous Next Go Back Rear upper cooling fan bracket assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Disconnect the connector from the rear upper cooling fan bracket assembly (A). 3.

  • Page 410: Developer / Transfer Roll Hvps Card Assembly Removal

    5057-XXX 4. Remove the rear upper cooling fan (A) from the rear upper cooling fan bracket. Previous Next Go Back Connector Developer / transfer roll HVPS card assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5.

  • Page 411: Charge Roll Hvps Card Assembly Removal

    5057-XXX 11. Remove the developer / transfer roll HVPS card assembly (B). Previous Connectors Next Go Back Charge roll HVPS card assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 412: Mpf / Transport Drive Motor Assembly Removal

    5057-XXX 6. Remove the charge roll HVPS card assembly (A). Previous Next Go Back Hooks MPF / transport drive motor assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 413: Feed Roll Removal

    5057-XXX 9. Remove the MPF/transport drive motor assembly (A). Previous Connector Next Go Back Feed roll removal 1. Remove the media tray. 2. Move the feed unit front guide (A) in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.

  • Page 414: Pick Roll Removal

    5057-XXX Pick roll removal Previous 1. Remove the media tray. 2. Move the media feed unit front guide (A) in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4. Remove the pick roll (B). Next Note: Do not touch the rubber surface of the feed roll (B).

  • Page 415: Separation Roll Removal

    5057-XXX Separation roll removal Previous 1. Remove the media tray. 2. Move the feed unit front guide (A) in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). 4. Remove the separation roll (B). Next Note: Do not touch the rubber surface of the feed roll (B).

  • Page 416: Fuser Exit Roll Assembly Removal

    5057-XXX 13. Remove the connection from the sensor (RFID toner cartridge) (A). Previous Next Go Back Fuser exit roll assembly removal 1. Open the printer left door assembly. 2. Remove the E-clip securing the fuser exit roll assembly (A) to the machine. 3.

  • Page 417: Sensor (Mpf Media Out) Removal

    5057-XXX 7. Remove the MPF media out actuator (B). Previous Next Go Back Sensor (MPF media out) removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. 2. Remove the rear left middle cover. See “Rear left middle cover removal”...

  • Page 418: Media Feed Lift Motor Removal

    5057-XXX 6. Release the two hooks of the two feed shaft cores (B), and move them both outwards in the directions in the Previous arrows. Note: When removing the MPF feed roll assembly (C), do not touch the rubber surface. 7.

  • Page 419: Switch (Media Size) Removal

    5057-XXX 4. Remove the media feed lift motor (B). Previous Next Go Back Connector Rear Switch (media size) removal Note: This procedure can be applied to tray 1 or tray 2 switch (media size). 1. Remove media Tray 1 and media Tray 2. 2.

  • Page 420: Sheet Dual Input (Ttm)—Top Cover Removal

    5057-XXX Previous 2000-sheet dual input (TTM) removals Next Go Back 2000-sheet dual input (TTM)—top cover removal 1. Pull out tray 2 assembly. 2. Remove the two screws securing the top cover (A). 3. Remove the top cover (A). 2000-sheet dual input (TTM)—foot cover removal 1.

  • Page 421: Sheet Dual Input (Ttm)—Right Cover Removal

    5057-XXX 4. Remove the foot cover (A). Previous Next Go Back Front 2000-sheet dual input (TTM)—right cover removal 1. Remove the four screws securing the right cover (A). 2. Remove the right cover (A) by lifting up and out. 2000-sheet dual input (TTM)— tray module left cover removal 1.

  • Page 422: Sheet Dual Input (Ttm)—Rear Cover Removal

    5057-XXX 2. Remove the tray module left cover (A). Previous Next Go Back 2000-sheet dual input (TTM)—rear cover removal 1. Remove the four screws securing the rear cover (A). 2. Remove the rear cover (A). 2000-sheet dual input (TTM)—caster removal 1.

  • Page 423: Sheet Dual Input (Ttm)—Tray Support Roll Removal

    5057-XXX 7. Remove the caster (A). Previous Next Go Back 2000-sheet dual input (TTM)—tray support roll removal 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove media tray 3 assembly. See “2000-sheet dual input (TTM)—TTM media tray 3 assembly removal”...
  • Page 424 5057-XXX 8. Remove the shafts (D). Previous 9. Remove the tray support rolls (B). Next Go Back 4-126 Printer Service Manual...

  • Page 425: Sheet Dual Input (Ttm)—Ttm Media Tray 4 Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—TTM media tray 4 assembly removal Previous 1. Pull out the TTM media tray 4 assembly. 2. Remove the two screws securing the TTM tray 4 media transport assembly (A) to the TTM media tray 4 assembly (B).

  • Page 426: Sheet Dual Input (Ttm)—Ttm Media Tray 3 Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—TTM media tray 3 assembly removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Open the TTM left door assembly. 3. Loosen the screw securing the TTM tray 3 stopper (A). Next 4.

  • Page 427: Sheet Dual Input (Ttm)—Tray 3 Rear Cable Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—tray 3 rear cable assembly removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123.
  • Page 428 5057-XXX 8. Move the rear lift cable pulley (D) toward the rear of the tray to release the two tray 3 rear cables (E) from the tray Previous lift shaft assembly (B). Next Go Back Rear 9. Remove the two tray 3 rear cables (E) from the tray lift shaft assembly (B). 10.

  • Page 429: Sheet Dual Input (Ttm)—Tray 3 Front Cable Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—tray 3 front cable assembly removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123.

  • Page 430: Sheet Dual Input (Ttm)—Media Tray 4 Front Cover Removal

    5057-XXX 2000-sheet dual input (TTM)—media tray 4 front cover removal Previous 1. Pull out the media tray 4 assembly. 2. Remove the four screws securing the tray 4 front cover (A). 3. Remove the tray 4 front cover (A). 4. Remove the six screws securing the bracket (B) to the tray. Next 5.
  • Page 431 5057-XXX 5. Gently move the tray lift shaft assembly (B) toward the rear of the tray and detach the rear bushing (C) from the Previous frame. Note: Do not remove the front lift cable pulley (A), or the front lift cables will become detached. 6.
  • Page 432 5057-XXX 12. Remove the tray 4 rear cables (D) from the bottom plate (H). Previous Next Go Back Replacement note: Before re-installing: – It is recommended that all four cables be replaced. – Ensure tray 4 rear cables (D) are not twisted or kinked. –...

  • Page 433: Sheet Dual Input (Ttm)—Tray 4 Front Cables Removal

    5057-XXX 2000-sheet dual input (TTM)—tray 4 front cables removal Previous 1. Remove the media tray 4 assembly. See “2000-sheet dual input (TTM)—TTM media tray 4 assembly removal” on page 4-127. 2. Remove the tray 4 front cover. See “2000-sheet dual input (TTM)—media tray 4 front cover removal” on page 4-132.

  • Page 434: Sheet Dual Input (Ttm)—Media Feed Unit Assembly Removal (Tray 4)

    5057-XXX 10. Remove the tray 4 front cables (C) from the bottom plates (F). Previous Next Go Back Replacement note: Before re-installing: – It is recommended that all four cables be replaced. – Ensure tray 4 front cables (C) are not twisted or kinked. –...
  • Page 435 5057-XXX 7. Remove the two screws securing the media feed unit assembly (A). Previous Connectors Next Go Back Front 8. Remove one screw securing the front bracket (B) to the machine. 9. Remove the front bracket (B). 10. Move the media feed unit assembly (A) to the left and up in the direction of the arrow. 11.

  • Page 436: Sheet Dual Input (Ttm)—Sensor (Tray 4 Feed-Out) Removal

    5057-XXX 2000-sheet dual input (TTM)—sensor (tray 4 feed-out) removal Previous 1. Remove the media tray 2 assembly. 2. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 3. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)—TTM media tray 3 assembly removal”...

  • Page 437: Sheet Dual Input (Ttm) Switch (Media Size) Removal

    5057-XXX 2000-sheet dual input (TTM) switch (media size) removal Previous Note: This procedure can be applied to tray 1 or tray 2 switch (media size). 1. Remove media Tray 1 and media Tray 2. 2. Remove one screw securing the switch (media size) (A) to the bracket inside the machine. Next 3.

  • Page 438: Sheet Dual Input (Ttm)—Switch (Ttm Media Size) Removal

    5057-XXX 2000-sheet dual input (TTM)—switch (TTM media size) removal Previous Note: This removal procedure may be applied to media tray 3 and media tray 4. 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123.

  • Page 439: Sheet Dual Input (Ttm)—Media Feed Unit Assembly 2 Removal

    5057-XXX 2000-sheet dual input (TTM)—media feed unit assembly 2 removal Previous 1. Remove the media tray 2. 2. Open the TTM left door assembly. 3. Disconnect the connector from the media feed unit assembly (A). 4. Release the harness from the clamp. Next 5.
  • Page 440 5057-XXX Previous Next Go Back 4-142 Printer Service Manual...

  • Page 441: Sheet Dual Input (Ttm)—Sensor (Tray 3 Feed-Out) Removal

    5057-XXX 2000-sheet dual input (TTM)—sensor (tray 3 feed-out) removal Previous 1. Open the TTM left door assembly. 2. Remove the two screws securing the two support straps (A) to the machine. 3. Disconnect the connector to the bracket (B). 4. Remove the two screws securing the bracket (B) to the machine. Next 5.

  • Page 442: Sheet Dual Input (Ttm)—Sensor (Tray 2 Feed-Out) Removal

    5057-XXX 2000-sheet dual input (TTM)—sensor (tray 2 feed-out) removal Previous 1. Open the TTM left door assembly. 2. Remove the two screws securing bracket (A) to the machine. 3. Remove the bracket (A). 4. Disconnect the connector from the sensor (tray 2 feed-out) (B). Next 5.
  • Page 443 5057-XXX 8. Remove the media feed lift motor (B). Previous Next Go Back Connector Rear 4-145 Repair information...

  • Page 444: Sheet Dual Input (Ttm)—One-Way Clutch / Gear Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—one-way clutch / gear assembly removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)—TTM media tray 3 assembly removal” on page 4-128.
  • Page 445 5057-XXX 10. Remove the tray lift one-way gear 24 tooth (C). Previous Harness Next Go Back Washer Rear Replacement note: Before re-installing, ensure all gears and washers are securely attached to the bracket (A). 4-147 Repair information...

  • Page 446: Sheet Dual Input (Ttm)—Media Out Actuator Removal

    5057-XXX 2000-sheet dual input (TTM)—media out actuator removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)—TTM media tray 3 assembly removal” on page 4-128.

  • Page 447: Sheet Dual Input (Ttm)—Sensor (Media Level) Removal

    5057-XXX 2000-sheet dual input (TTM)—sensor (media level) removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)—TTM media tray 3 assembly removal”...

  • Page 448: Sheet Dual Input (Ttm)—Sensor (Media Out) Removal

    5057-XXX 2000-sheet dual input (TTM)—sensor (media out) removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)—TTM media tray 3 assembly removal” on page 4-128.

  • Page 449: Sheet Dual Input (Ttm)—Feed Roll Removal

    5057-XXX 2000-sheet dual input (TTM)—feed roll removal Previous 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.
  • Page 450 5057-XXX 2000-sheet dual input (TTM)—feed roll one-way clutch removal Previous 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)—feed roll removal” on page 4-151. 3. Remove the feed roll one-way clutch (A) from the shaft (B). Next Go Back 4-152...

  • Page 451: Sheet Dual Input (Ttm)—One-Way 22 Tooth Removal

    5057-XXX 2000-sheet dual input (TTM)—one-way 22 tooth removal Previous 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)—feed roll removal” on page 4-151. 3. Remove the feed roll one-way clutch. See “2000-sheet dual input (TTM)—feed roll one-way clutch removal” on page 4-152.

  • Page 452: Sheet Dual Input (Ttm)—Separation Roll One-Way Friction Clutch Removal

    5057-XXX 2000-sheet dual input (TTM)—separation roll one-way friction clutch removal Previous 1. Remove the media tray assembly. 2. Remove the separation roll. See “2000-sheet dual input (TTM)—separation roll removal” on page 4-155. 3. Remove the separation roll spacer (A). 4. Remove the separation roll one-way friction clutch (B). Next Go Back 4-154...

  • Page 453: Sheet Dual Input (Ttm)—Separation Roll Removal

    5057-XXX 2000-sheet dual input (TTM)—separation roll removal Previous 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). Next Go Back 4-155...
  • Page 454 5057-XXX 4. Remove the separation roll (B). Previous Note: Do not touch the rubber surface of the feed roll (B). Next Go Back Replacement note: Before re-installing, do not touch the rubber surface of the separation roll (B). 4-156 Printer Service Manual...

  • Page 455: Sheet Dual Input (Ttm)—Pick Roll Removal

    5057-XXX 2000-sheet dual input (TTM)—pick roll removal Previous 1. Remove the media tray assembly. 2. Move the front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4.

  • Page 456: Sheet Dual Input (Ttm)—Left Door Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—left door assembly removal Previous 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)— tray module left cover removal” on page 4-123. 2. Open the TTM left door assembly. 3. Remove the two screws securing the two support straps (A) to the machine. Next 4.
  • Page 457 5057-XXX 2000-sheet dual input (TTM)—switch (TTM left door interlock) removal Previous 1. Open the TTM left door assembly. 2. Remove the screw securing the support strap (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.

  • Page 458: Sheet Dual Input (Ttm)—Tray 4 Lift Gear Assembly Removal

    5057-XXX 2000-sheet dual input (TTM)—tray 3 lift gear assembly removal Previous 1. Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-124. 2. Pull the tray 3 media assembly out of the machine. 3. Remove the two screws securing the tray 3 lift gear assembly (A) to the machine. Note: When removing the tray 3 lift gear assembly (A), the tray lift coupling assembly (B) my become detached.
  • Page 459 5057-XXX 2000-sheet dual input (TTM)—tray lift coupling assembly removal Previous Note: This procedure can be applied to both the tray 3 and the tray 4 media assemblies. 1. Remove the tray 3 lift gear or the tray 3 lift gear assembly. See “2000-sheet dual input (TTM)—tray 3 lift gear assembly removal”...
  • Page 460 5057-XXX 4. Remove the tray module drive motor (A). Previous Next Go Back Connector 4-162 Printer Service Manual...

  • Page 461: Sheet Dual Input (Ttm)—Ttm Tray 4 Transport Motor Removal

    5057-XXX 2000-sheet dual input (TTM)—TTM tray 4 transport motor removal Previous 1. Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-124. 2. Disconnect the connector from the TTM tray 4 transport motor (A). 3. Release the harness from the clamp. 4.

  • Page 462: X 500-Sheet Drawer (3Tm) Removals

    5057-XXX Previous 3X 500-sheet drawer (3TM) removals Next Go Back 3X 500-sheet drawer (3TM) —top cover removal 1. Pull out tray 2 assembly (A). 2. Remove the two screws securing the top cover (B). 3. Remove the top cover (B). 4-164 Printer Service Manual...
  • Page 463 5057-XXX 3X 500-sheet drawer (3TM) —foot cover removal Previous 1. Remove the media tray 4 assembly. 2. Remove the two screws securing the foot cover (A) to the machine. 3. Remove the foot cover (A). Next Go Back Front 3X 500-sheet drawer (3TM) —right cover removal 1.
  • Page 464 5057-XXX 3X 500-sheet drawer (3TM) —tray module left cover removal Previous 1. Remove the four screws securing the tray module left cover (A). 2. Remove the tray module left cover (A). Next Go Back 3X 500-sheet drawer (3TM) —rear cover removal 1.

  • Page 465: X 500-Sheet 3Tm)—Media Feed Unit Assembly Removal (Tray 4)

    5057-XXX 3X 500-sheet drawer (3TM) —caster removal Previous 1. Remove the media tray 2 assembly. 2. Remove the media tray 3 assembly. 3. Remove the media tray 4 assembly. 4. Place the right side of the drawer down. Next 5. Remove the three screws securing the caster (A). 6.

  • Page 466: X 500-Sheet Drawer (3Tm)—Sensor (Tray 4 Feed-Out) Removal

    5057-XXX 3X 500-sheet drawer (3TM)—sensor (tray 4 feed-out) removal Previous 1. Open the 3TM left door assembly. 2. Remove the two screws securing the two support straps (A) to the machine. 3. Disconnect the connector from the sensor (tray 4 feed-out) (B). 4.

  • Page 467: X 500-Sheet Drawer (3Tm)—Sensor (Tray 2 Feed-Out) Removal

    5057-XXX 3X 500-sheet drawer (3TM)—sensor (tray 2 feed-out) removal Previous 1. Open the 3TM left door assembly. 2. Remove the two screws securing bracket (A) to the machine. 3. Remove the bracket (A). 4. Disconnect the connector from the sensor (tray 2 feed-out) (B). Next 5.

  • Page 468: X 500-Sheet Drawer (3Tm)—Switch (Media Size) Removal

    5057-XXX 3X 500-sheet drawer (3TM)—switch (media size) removal Previous Note: This removal procedure may be applied to media tray 2, 3 and media tray 4 assemblies. 1. Remove the media tray 2 assembly. 2. Remove the media tray 3 assembly. Next 3.

  • Page 469: X 500-Sheet Drawer (3Tm)—Media Feed Unit Assembly Removal (Tray 3)

    5057-XXX 3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3) Previous 1. Remove the media tray 4 assembly. 2. Open the 3TM left door assembly. 3. Remove the two screws securing the two support straps (A) to the machine. 4.
  • Page 470 5057-XXX Previous Next Go Back 4-172 Printer Service Manual...

  • Page 471: X 500-Sheet Drawer (3Tm)—Media Feed Unit Assembly Removal (Tray 2)

    5057-XXX 3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2) Previous 1. Remove the media tray 2 assembly. 2. Open the 3TM left door assembly. 3. Remove the two screws securing the two support straps (A) to the machine. 4.

  • Page 472: X 500-Sheet Drawer (3Tm)—Sensor (Tray 3 Feed-Out) Removal

    5057-XXX Previous Next Go Back 3X 500-sheet drawer (3TM)—sensor (tray 3 feed-out) removal 1. Open the 3TM left door assembly. 2. Remove the two screws securing the two support straps (A) to the machine. 3. Disconnect the connector from the sensor (tray 3 feed-out) (B). 4.

  • Page 473: X 500-Sheet Drawer (3Tm)—Media Feed Lift Motor Removal

    5057-XXX 7. Remove the sensor (tray 3 feed-out) (B). Previous Next Go Back 3X 500-sheet drawer (3TM)—media feed lift motor removal 1. Remove the media feed unit assembly. See“3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2)” on page 4-173, “3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3)”...

  • Page 474: X 500-Sheet Drawer (3Tm)—One-Way Clutch / Gear Assembly Removal

    5057-XXX 3X 500-sheet drawer (3TM)—one-way clutch / gear assembly removal Previous 1. Remove the media feed unit assembly. See“3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2)” on page 4-173 “3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3)” on page 4-171.

  • Page 475: X 500-Sheet Drawer (3Tm)—Media Out Actuator Removal

    5057-XXX 3X 500-sheet drawer (3TM)—media out actuator removal Previous 1. Remove the media feed unit assembly. See“3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2)” on page 4-173 “3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3)” on page 4-171.

  • Page 476: X 500-Sheet Drawer (3Tm)—Sensor (Media Level) Removal

    5057-XXX 3X 500-sheet drawer (3TM)—sensor (media level) removal Previous 1. Remove the media feed unit assembly. See“3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2)” on page 4-173 “3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3)” on page 4-171.

  • Page 477: X 500-Sheet Drawer (3Tm)—Sensor (Media Out) Removal

    5057-XXX 3X 500-sheet drawer (3TM)—sensor (media out) removal Previous 1. Remove the media feed unit assembly. See“3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2)” on page 4-173 “3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3)” on page 4-171.

  • Page 478: X 500-Sheet Drawer (3Tm)—Feed Roll Removal

    5057-XXX 3X 500-sheet drawer (3TM)—feed roll removal Previous 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.

  • Page 479: X 500-Sheet Drawer (3Tm)—Feed Roll One-Way Clutch Removal

    5057-XXX 3X 500-sheet drawer (3TM)—feed roll one-way clutch removal Previous 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)—feed roll removal” on page 4-151. 3. Remove the feed roll one-way clutch (A) from the shaft (B). Next Go Back Front...

  • Page 480: X 500-Sheet Drawer (3Tm)—One-Way 22 Tooth Removal

    5057-XXX 3X 500-sheet drawer (3TM)—one-way 22 tooth removal Previous 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)—feed roll removal” on page 4-151. 3. Remove the feed roll one-way clutch. See “2000-sheet dual input (TTM)—feed roll one-way clutch removal” on page 4-152.

  • Page 481: X 500-Sheet Drawer (3Tm)—Separation Roll One-Way Friction Clutch Removal

    5057-XXX 3X 500-sheet drawer (3TM)—separation roll one-way friction clutch removal Previous 1. Remove the media tray assembly. 2. Remove the separation roll. See “2000-sheet dual input (TTM)—separation roll removal” on page 4-155. 3. Remove the separation roll spacer (A). 4. Remove the separation roll one-way friction clutch (B). Next Go Back Front...

  • Page 482: X 500-Sheet Drawer (3Tm)—Separation Roll Removal

    5057-XXX 3X 500-sheet drawer (3TM)—separation roll removal Previous 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). Next Go Back Front...
  • Page 483 5057-XXX 4. Remove the separation roll (B). Previous Note: Do not touch the rubber surface of the feed roll (B). Next Go Back Front Replacement note: Before re-installing, do not touch the rubber surface of the separation roll (B). 4-185 Repair information...

  • Page 484: X 500-Sheet Drawer (3Tm)—Pick Roll Removal

    5057-XXX 3X 500-sheet drawer (3TM)—pick roll removal Previous 1. Remove the media tray assembly. 2. Move the front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4.

  • Page 485: X 500-Sheet Drawer (3Tm)—3Tm Left Door Assembly Removal

    5057-XXX 3X 500-sheet drawer (3TM)—3TM left door assembly removal Previous 1. Open the 3TM left door assembly. 2. Remove the two screws securing the two supports straps (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.

  • Page 486: X 500-Sheet Drawer (3Tm)—Tray Module Drive Motor Assembly Removal

    5057-XXX 7. Remove the switch (tray module left door interlock) (C). Previous Next Go Back 3X 500-sheet drawer (3TM)—tray module drive motor assembly removal 1. Remove the rear cover. See “3X 500-sheet drawer (3TM)—rear cover removal” on page 4-166. 2. Disconnect the connector from the tray module drive motor (A). 3.

  • Page 487: X 500-Sheet Drawer (3Tm)—3Tm Controller Card Assembly Removal

    5057-XXX 3X 500-sheet drawer (3TM)—3TM controller card assembly removal Previous 1. Remove the rear cover. See “3X 500-sheet drawer (3TM)—rear cover removal” on page 4-166. 2. Disconnect the nine connectors from the 3TM controller card assembly (A). 3. Remove the four screws securing the 3TM controller card assembly (A) to the machine. 4.

  • Page 488: X 500-Sheet Drawer (1Tm) Removals

    5057-XXX Previous 1X 500-sheet drawer (1TM) removals Next Go Back 1X 500-sheet drawer (1TM) —top cover removal 1. Pull out tray 2 assembly (A). 2. Remove the two screws securing the top cover (B). 3. Remove the top cover (B). 4-190 Printer Service Manual...
  • Page 489 5057-XXX 1X 500-sheet drawer (1TM) —foot cover removal Previous 1. Open the 1TM front door. 2. Remove the two screws securing the foot cover (A) to the machine. 3. Remove the foot cover (A). Next Go Back 1X 500-sheet drawer (1TM) —right cover removal 1.
  • Page 490 5057-XXX 1X 500-sheet drawer (1TM) —tray module left cover removal Previous 1. Remove the four screws securing the tray module left cover (A). 2. Remove the tray module left cover (A). Next Go Back 1X 500-sheet drawer (1TM) —rear cover removal 1.

  • Page 491: X 500-Sheet Drawer (1Tm)—Media Feed Unit Assembly Removal (Tray 2)

    5057-XXX 1X 500-sheet drawer (1TM) —caster removal Previous 1. Remove the media tray 2 assembly. 2. Place the right side of the drawer down. 3. Remove the three screws securing the caster (A). 4. Remove the caster (A). Next Go Back 1X 500-sheet drawer (1TM)—media feed unit assembly removal (tray 2) 1.

  • Page 492: X 500-Sheet Drawer (1Tm)—Sensor (Tray 2 Feed-Out) Removal

    5057-XXX 1X 500-sheet drawer (1TM)—sensor (tray 2 feed-out) removal Previous 1. Open the 1TM left door assembly. 2. Remove the two screws securing bracket (A) to the machine. 3. Remove the bracket (A). 4. Disconnect the connector from the sensor (tray 2 feed-out) (B). Next 5.

  • Page 493: X 500-Sheet Drawer (1Tm)—Switch (Media Size) Removal

    5057-XXX 1X 500-sheet drawer (1TM)—switch (media size) removal Previous 1. Remove the media tray 2 assembly. 2. Open the 1TM front door. 3. Disconnect the connector from the switch (media size) (A). 4. Remove the screw securing the switch (media size) (A). Next 5.

  • Page 494: X 500-Sheet Drawer (1Tm)—Media Feed Lift Motor Removal

    5057-XXX 1X 500-sheet drawer (1TM)—media feed lift motor removal Previous 1. Remove the media feed unit assembly. See “1X 500-sheet drawer (1TM)—media feed unit assembly removal (tray 2)” on page 4-193. 2. Disconnect the harness from the media feed lift motor (A). 3.
  • Page 495 5057-XXX 6. Remove the tray lift one-way gear 24 tooth (C). Previous Harness Next Go Back Washer Rear Replacement note: Before re-installing, ensure all gears and washers are securely attached to the bracket (A). 4-197 Repair information...

  • Page 496: X 500-Sheet Drawer (1Tm)—Media Out Actuator Removal

    5057-XXX 1X 500-sheet drawer (1TM)—media out actuator removal Previous 1. Remove the media feed unit assembly. See “1X 500-sheet drawer (1TM)—media feed unit assembly removal (tray 2)” on page 4-193. 2. Release the two bosses on the media out actuator (A) from the media feed unit assembly. 3.

  • Page 497: X 500-Sheet Drawer (1Tm)—Sensor (Media Level) Removal

    5057-XXX 1X 500-sheet drawer (1TM)—sensor (media level) removal Previous 1. Remove the media feed unit assembly. See “1X 500-sheet drawer (1TM)—media feed unit assembly removal (tray 2)” on page 4-193. 2. Disconnect the connector from the sensor (media level) (A). 3.

  • Page 498: X 500-Sheet Drawer (1Tm)—Sensor (Media Out) Removal

    5057-XXX 1X 500-sheet drawer (1TM)—sensor (media out) removal Previous 1. Remove the media feed unit assembly. See “1X 500-sheet drawer (1TM)—media feed unit assembly removal (tray 2)” on page 4-193. 2. Remove the media out actuator. See “1X 500-sheet drawer (1TM)—media out actuator removal” on page 4-198.

  • Page 499: X 500-Sheet Drawer (1Tm)—Feed Roll Removal

    5057-XXX 1X 500-sheet drawer (1TM)—feed roll removal Previous 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.

  • Page 500: X 500-Sheet Drawer (1Tm)—Feed Roll One-Way Clutch Removal

    5057-XXX 1X 500-sheet drawer (1TM)—feed roll one-way clutch removal Previous 1. Remove the media tray assembly. 2. Remove the feed roll. See “1X 500-sheet drawer (1TM)—feed roll removal” on page 4-201. 3. Remove the feed roll one-way clutch (A) from the shaft (B). Next Go Back 4-202...
  • Page 501 5057-XXX 1X 500-sheet drawer (1TM)—one-way 22 tooth removal Previous 1. Remove the media tray assembly. 2. Remove the feed roll. See “1X 500-sheet drawer (1TM)—feed roll removal” on page 4-201. 3. Remove the feed roll one-way clutch. See “1X 500-sheet drawer (1TM)—feed roll one-way clutch removal” on page 4-202.

  • Page 502: X 500-Sheet Drawer (1Tm)—Separation Roll One-Way Friction Clutch Removal

    5057-XXX 1X 500-sheet drawer (1TM)—separation roll one-way friction clutch removal Previous 1. Remove the media tray assembly. 2. Remove the separation roll. See “1X 500-sheet drawer (1TM)—separation roll removal” on page 4-205. 3. Remove the separation roll spacer (A). 4. Remove the separation roll one-way friction clutch (B). Next Go Back Seal...

  • Page 503: X 500-Sheet Drawer (1Tm)—Separation Roll Removal

    5057-XXX 1X 500-sheet drawer (1TM)—separation roll removal Previous 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). 4.

  • Page 504: X 500-Sheet Drawer (1Tm)—Pick Roll Removal

    5057-XXX 1X 500-sheet drawer (1TM)—pick roll removal Previous 1. Remove the media tray assembly. 2. Move the front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4.

  • Page 505: X 500-Sheet Drawer (1Tm)—Tray Module Left Door Assembly Removal

    5057-XXX 1X 500-sheet drawer (1TM)—tray module left door assembly removal Previous 1. Open the 3TM/TMM left door assembly. 2. Remove the two screws securing the two supports straps (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.

  • Page 506: X 500-Sheet Drawer (1Tm)—Switch (Tray Module Left Door Interlock) Removal

    5057-XXX 1X 500-sheet drawer (1TM)—switch (tray module left door interlock) removal Previous 1. Open the 1TM left door assembly. 2. Remove the screw securing the support strap (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.
  • Page 507 5057-XXX 1X 500-sheet drawer (1TM)—tray module drive motor assembly removal Previous 1. Remove the rear cover. See “1X 500-sheet drawer (1TM)—rear cover removal” on page 4-192. 2. Disconnect the connector from the tray module drive motor (A). 3. Remove the two screws securing the tray module drive motor (A) to the machine. 4.

  • Page 508: Setup And Adjustments

    5057-XXX Previous Setup and adjustments Sensor (ATC) setup Next Step Check Go Back Warning: Before installing any new developer unit assembles in the machine, record the bar code number located on the sensor (ATC) for all new developer units being installed. Example: Sensor (C ATC) XXX Sensor (M) ATC XXX...
  • Page 509 5057-XXX Previous Step Check Update the following settings using the newly converted values from step 2 for all newly installed developer units: Sensitivity gradient Next Sensor output reference Go Back 1. Enter the Diagnostics Menu. 2. Touch ENGINE ADJUST. 3. Touch ATC Sensor Adjust Values 4.
  • Page 510 5057-XXX Previous ATC VALUE CONVERSION CHART Bar code number Sensitivity gradient default value Standard TC output default value (last 2 digits) Next Go Back 4-212 Printer Service Manual...
  • Page 511 5057-XXX Previous ATC VALUE CONVERSION CHART Bar code number Sensitivity gradient default value Standard TC output default value (last 2 digits) Next Go Back 4-213 Repair information...

  • Page 512: Color Registration (Regcon)

    5057-XXX Previous ATC VALUE CONVERSION CHART Bar code number Sensitivity gradient default value Standard TC output default value (last 2 digits) Next Go Back Color registration (RegCon) 4-214 Printer Service Manual...

  • Page 513: Measurement Cycle Test

    5057-XXX Measurement cycle test Previous Step Check Perform the Measurement cycle test. Perform the Go to step 2. Next “Control sensor 1. Enter the Diagnostics Menu. check”. 2. Select ENGINE ADJUST. “Control 3. Select RegCon adjust Go Back sensor check” on 4.

  • Page 514: Control Sensor Check

    5057-XXX Control sensor check Previous Step Check Perform the Control sensor check test. Perform the Go to step 2. Next “Control sensor 1. Enter the Diagnostics Menu. cycle”. 2. Select ENGINE ADJUST. “Control 3. Select RegCon adjust Go Back sensor cycle” on 4.

  • Page 515: Belt Edge Learn Test

    5057-XXX Belt edge learn test Previous Step Check Perform the Belt edge learn test. Perform “Skew Go to step 2. Next setup”. 1. Enter the Diagnostics Menu. “Skew fine 2. Select ENGINE ADJUST. setup” on 3. Select RegCon adjust Go Back page 4-217.
  • Page 516 5057-XXX Previous Step Check Perform the Skew fine setup printhead adjustment. Perform the In/Out Adjust the setup. printhead Select Cycle result values. adjustment screws “In/out Next then perform the setup” on In/Out setup. page 4-222. Locate the following new values for the following settings: “In/out Y- Skew adjustment setup”...
  • Page 517 5057-XXX Previous Step Check Analyze the fine skew setup. Go to step 4. Go to step 6. 1. Enter the Diagnostics Menu. Next 2. Select ENGINE ADJUST. 3. Select RegCon adjust 4. Select Control setup cycles 5. Select Cycle result values Go Back Locate the following new values for the following settings: Patch-B in...
  • Page 518 5057-XXX Previous Step Check Perform the skew rough setup printhead adjustment. Re-perform step 1. Go to step 6. If the test fails then 1. Enter the Diagnostics Menu. replace the Next 2. Select ENGINE ADJUST. printhead. 3. Select RegCon adjust “Printhead 4.
  • Page 519 5057-XXX Previous Step Check Check the image density sensor assembly for toner Remove and clean Go to step 8. contamination. the image density sensor assembly. Is the above component dirty or contaminated? Next “Image density sensor assembly removal” on Go Back page 4-44.

  • Page 520: In/Out Setup

    5057-XXX In/out setup Previous Step Check Perform the In/out setup: Perform the Go to step 2. Next Center setup. 1. Enter the Diagnostics Menu. “Center 2. Select ENGINE ADJUST. setup” on 3. Select RegCon adjust Go Back page 4-226. 4. Select Control setup cycles 5.
  • Page 521 5057-XXX Previous Step Check Perform the skew rough setup printhead adjustment. Re-perform step 1. Go to step 7. If the test fails then 1. Enter the Diagnostics Menu. replace the Next 2. Select ENGINE ADJUST. printhead. 3. Select RegCon adjust “Printhead 4.
  • Page 522 5057-XXX Previous Step Check Perform the In/out skew setup printhead adjustment. Go to the Center Adjust the setup. printhead 1. Enter the Diagnostics Menu. adjustment screw “Center Next 2. Select ENGINE ADJUST. then go to Center setup” on 3. Select RegCon adjust. setup.
  • Page 523 5057-XXX Previous Step Check Check the image density sensor assembly for toner Remove and clean Go to step 8. contamination. the image density sensor assembly. Is the above component dirty or contaminated? Next “Image density sensor assembly removal” on Go Back page 4-44.

  • Page 524: Center Setup

    5057-XXX Center setup Previous Step Check Warning: Ensure that the image density sensor Go to step 2. Repeat step 1. Next assembly is moved to the center position or the test will not function. Move the image density sensor assembly to the center Go Back position.
  • Page 525 5057-XXX Previous Step Check Perform the center setup: Move the image Go to step 3. density sensor 1. Enter the Diagnostics Menu. back to its original Next 2. Select ENGINE ADJUST. position. 3. Select RegCon adjust The color 4. Select Control setup cycles registration 5.

  • Page 526: Transfer Belt Lift Mechanism Adjustment

    5057-XXX Transfer belt lift mechanism adjustment Previous Step Check Next Access the transfer belt lift latch assembly. Go to step 7. Go to next step. 1. Open the printer front door. 2. Release the transfer belt lift latch assembly. Go Back 3.
  • Page 527 5057-XXX Previous Step Check Check the gear teeth on the following parts for damage: Replace the Go to next step. appropriate • Left transfer belt lift assembly plunger (B) assemblies. See Next • Right transfer belt lift assembly plunger (C) “Left transfer belt lift assembly...
  • Page 528 5057-XXX Previous Step Check The transfer belt alignment must be correct on both sides Go to next step. Replace the for proper operation. The top of the transfer belt (E) and appropriate the top of the right side cover (F) must be parallel, as assembly.
  • Page 529 5057-XXX Previous Step Check The timing marks must be aligned for proper operation. The transfer belt Perform the lift mechanism is transfer belt lift Check the timing marks (E) located on the following adjusted adjustment. Next components: correctly. • Left transfer belt lift assembly plunger •...
  • Page 530 5057-XXX Previous Next Go Back 4-232 Printer Service Manual...
  • Page 531 5057-XXX 5. Connector locations Previous Locations Next Go Back Waste toner agitator motor assembly Sensor (waste toner cartridge full) Switch (waste toner cartridge interlock) Connector locations...
  • Page 532 5057-XXX Previous Next Go Back Image density sensor assembly Duplex unit assembly Printer left door assembly Printer Service Manual...
  • Page 533 5057-XXX Previous Fuser unit assembly Next Go Back Thumb screws C toner add motor K toner add motor M toner add motor Y toner add motor Main power switch activator Switch (main power) Connector locations...
  • Page 534 5057-XXX Previous Printhead Next Go Back Polygon mirror motor Printer Service Manual...
  • Page 535 5057-XXX Previous Next Go Back Charge roll HVPS card assembly 24 V LVPS card assembly Developer/transfer roll HVPS card assembly Connector locations...
  • Page 536 5057-XXX Previous Next Go Back AC drive card assembly Printer power Finisher power hookup connector hookup connector Upper printer engine card assembly NVM card assembly Printer Service Manual...
  • Page 537 5057-XXX Previous Lower printer card assembly Next Go Back CMYK transfer roll HVPS card assembly 5V LVPS card assembly Connector locations...
  • Page 538 5057-XXX Previous Next Feed/lift motor Sensor (media out) Go Back Sensor (media level) Media feed unit assembly Sensor (printer left lower door interlock) Sensor (tray 1 feed-out) Printer left lower door assembly Printer Service Manual...
  • Page 539 5057-XXX Previous Next Go Back Connector locations...
  • Page 540 5057-XXX Previous Next Go Back 5-10 Printer Service Manual...
  • Page 541 5057-XXX Previous 3TM controller card assembly Next Tray module drive motor Go Back Feed/lift motor Sensor (media out) Sensor (media level) Switch (tray module Media feed left door interlock) unit assembly Sensor (tray 2 feed-out) Sensor (tray 3 feed-out) 3TM left door assembly Sensor (tray 4 feed-out) 5-11 Connector locations...
  • Page 542 5057-XXX Previous Next Go Back TTM controller card assembly Tray module drive motor TTM tray 4 transport drive motor 5-12 Printer Service Manual...
  • Page 543 5057-XXX Previous Next Go Back Switch (media size) Switch (TTM media size) 5-13 Connector locations...
  • Page 544 5057-XXX Previous Next Go Back Media feed unit assembly Sensor (tray 4 feed-out) 5-14 Printer Service Manual...

  • Page 545: Preventive Maintenance

    Damaged, missing, or altered parts, especially in the area of the on/off switch and the power supply • Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments EVERY EVERY EVERY...

  • Page 546: Scheduled Maintenance

    5057-XXX Previous EVERY EVERY EVERY LEXMARK C935 SERVICE NOTE: 100K 600K CALL DEVELOPER UNITS Transfer Next Developer unit (4) Replace C developer carrier Replace Go Back M developer carrier Replace Y developer carrier Replace K developer carrier Replace TRANSFER ROLL...
  • Page 547 5057-XXX After replacing the kit, the maintenance count must be reset to zero to clear the “80 scheduled maintenance” Previous message. To reset the maintenance count Turn off the printer. Press and hold the 2 and 6 buttons simultaneously. Next Turn on the printer.
  • Page 548 5057-XXX Previous Next Go Back Printer Service Manual...

  • Page 549: Parts Catalog

    PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. Model name Configuration Machine type Maximum speed Lexmark X940e Network 7510-030 35 PPM Lexmark X945e Network 7510-230 45 PPM Lexmark C935 Network 5057-230 45 PPM Parts catalog...

  • Page 550: Assembly 1: Covers 1

    5057-XXX Assembly 1: Covers 1 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X0840 Switch (printer front door interlock) 40X0553 Switch (transfer access door interlock) 40X3780 Right cover assembly 40X3778 Printer front door assembly (this comes assembled) 40X3779 Printhead slit glass cleaner assembly MFP Service Manual...

  • Page 551: Assembly 2: Covers 2

    5057-XXX Assembly 2: Covers 2 Previous Next Go Back Parts catalog...
  • Page 552 5057-XXX Assembly 2: Covers 2 Previous Asm- Part FRUs/ Units/ Description index number mach 40X3782 RIP card access cover 40X3781 Top cover assembly Next 40X3787 Switch (main power) 40X3786 Main power switch actuator Go Back 40X3783 Main switch cable assembly 40X3785 Inner cover 40X4111...

  • Page 553: Assembly 3: Covers 3

    5057-XXX Assembly 3: Covers 3 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3796 Rear left upper cover 40X3793 Rear left middle cover 40X3795 Left front cover 40X3794 Rear left lower cover 40X3788 Rear blind cover 40X3791 Rear cover assembly 110 V 40X3792...

  • Page 554: Assembly 4: Pc Cartridge And Developer Drive

    5057-XXX Assembly 4: PC cartridge and developer drive Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3671 Developer idler gear assembly 40X3669 CMY developer drive motor assembly 40X3670 Developer/transport drive motor assembly 40X3672 MPF/transport drive motor assembly 40X3667 CMYK PC cartridge drive motor assembly 40X3668...

  • Page 555: Assembly 5: Id Sensor And Transfer Belt Steering

    5057-XXX Assembly 5: ID sensor and transfer belt steering Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3674 Image density sensor assembly 40X3673 Transfer belt steering motor Parts catalog...

  • Page 556: Assembly 6: Media Tray

    5057-XXX Assembly 6: Media tray Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3677 Switch (media size) 40X3676 Media tray slide 40X3678 Media tray assembly kit • Media tray assembly • #1 label • #2 label •...

  • Page 557: Assembly 7: Printer Left Lower Door And Media Feed Unit

    5057-XXX Assembly 7: Printer left lower door and media feed unit Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3688 Sensor (printer left lower door interlock) 40X0613 Hinge pin 40X3680 Printer left lower door assembly (this comes assembled) 40X3681 Sensor (tray 1 feed-out) 40X3682...

  • Page 558: Assembly 8: Media Feed Unit

    5057-XXX Assembly 8: Media feed unit Previous Next Go Back 7-10 MFP Service Manual...
  • Page 559 5057-XXX Assembly 8: Media feed unit Previous Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3687 Media out actuator Next 40X3688 Sensor (tray media out) 40X3688 Sensor (tray media level) Go Back 40X3684 Media feed lift motor 40X0888 Bushing 6 mm 40X0590...

  • Page 560: Assembly 9: Mpf Feed Unit Assembly 1

    5057-XXX Assembly 9: MPF feed unit assembly 1 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4079 MPF feed unit assembly (this comes assembled) 7-12 MFP Service Manual...

  • Page 561: Assembly 10: Mpf Feed Unit Assembly 2

    5057-XXX Assembly 10: MPF feed unit assembly 2 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4079 MPF feed unit assembly (this comes assembled) 40X3688 Sensor (MPF media out) 40X3709 MPF media out actuator 40X0755 MPF pickup spring 7-13 Parts catalog...

  • Page 562: Assembly 11: Mpf Feed Unit Assembly 3

    5057-XXX Assembly 11: MPF feed unit assembly 3 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4079 MPF feed unit assembly (this comes assembled) 40X3711 MPF pick roll kit • MPF pick roll (2) 40X1381 Bushing 8 mm 7-14 MFP Service Manual...

  • Page 563: Assembly 12: Registration / Transport Roll Assembly

    5057-XXX Assembly 12: Registration / transport roll assembly Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3692 Registration/transport roll assembly (this comes assembled) 40X3695 Sensor (transparency detect) 40X3694 Sensor (registration) 40X3693 Registration clutch 7-15 Parts catalog...

  • Page 564: Assembly 13: Printer Left Door And Duplex

    5057-XXX Assembly 13: Printer left door and duplex Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4078 Printer left door assembly (this comes assembled) 40X3697 Printer left door damper assembly 40X3696 Printer left door damper idler gear 40X3799 Duplex unit assembly (this comes assembled) 40X3798...

  • Page 565: Assembly 14: Printer Left Door Assembly 1

    5057-XXX Assembly 14: Printer left door assembly 1 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4078 Printer left door assembly (this comes assembled) 40X3699 Sensor (fuser exit) 40X4098 Printer left door closed actuator 40X3698 2nd transfer roll assembly 40X3700 Printer left door duplex exit guide 7-17...

  • Page 566: Assembly 15: Printer Left Door Assembly 2

    5057-XXX Assembly 15: Printer left door assembly 2 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4078 Printer left door assembly (this comes assembled) 40X3704 Printer left door damper sector gear 40X3688 Sensor (2nd transfer roll retract HP) 40X3701 2nd transfer roll retract cam assembly 40X3702...

  • Page 567: Assembly 16: Duplex Media Inverter Assembly

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

  • Page 568: Assembly 17: Duplex 2

    5057-XXX Assembly 17: Duplex 2 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3799 Duplex unit assembly (this comes assembled) 40X3802 Duplex drive motor 40X3801 Sensor (duplex wait) 40X3800 Duplex controller card assembly 40X3803 Switch (duplex left door interlock) 7-20 MFP Service Manual...

  • Page 569: Assembly 18: Standard Media Exit Shift

    5057-XXX Assembly 18: Standard media exit shift Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3705 Standard media exit shift assembly (this comes assembled) 40X3707 Standard bin full actuator 40X3688 Sensor (standard bin full) 40X0840 Switch (printer left door interlock) 40X3706 Standard exit top cover 40X4080...

  • Page 570: Assembly 19: Printhead Assembly

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

  • Page 571: Assembly 20: Xerographic And Waste Toner

    5057-XXX Assembly 20: Xerographic and waste toner Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3713 Waste toner cartridge cover 40X3715 Switch (waste toner cartridge interlock) 40X3717 Sensor (waste toner cartridge full) 40X3714 Waste toner cartridge sensor assembly (this comes assembled) 40X3716 Waste toner agitator motor assembly 7-23...

  • Page 572: Assembly 21: Erase Lamps And Developer Interlock Plate

    5057-XXX Assembly 21: Erase lamps and developer interlock plate Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3720 K erase lamp assembly 40X3719 CMY erase lamp assembly 40X3718 Developer interlock plate assembly 7-24 MFP Service Manual...

  • Page 573: Assembly 22: Transfer Belt Lift 1

    5057-XXX Assembly 22: Transfer belt lift 1 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3722 Right transfer belt lift assembly 40X3727 Transfer belt lift handle assembly 40X3723 Transfer belt lift latch assembly with label 40X3721 Left transfer belt lift assembly 7-25 Parts catalog...

  • Page 574: Assembly 23: Transfer Belt

    5057-XXX Assembly 23: Transfer belt Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3732 Transfer belt unit assembly 40X3733 Transfer belt cleaner assembly 40X3729 Transfer belt auger front gear 14T 40X3731 Transfer belt auger assembly 40X0880 Bushing 6 mm 40X3730 Transfer belt auger rear gear 18T...

  • Page 575: Assembly 24: Transfer Belt Lift 2

    5057-XXX Assembly 24: Transfer belt lift 2 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3735 Transfer belt lift rear plunger assembly 40X3734 Transfer belt lift recoil spring 40X3736 Transfer belt lift front plunger assembly 7-27 Parts catalog...

  • Page 576: Assembly 25: Toner Dispense

    5057-XXX Assembly 25: Toner Dispense Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3740 K toner dispense assembly 40X3739 C toner dispense assembly 40X3738 M toner dispense assembly 40X3737 Y toner dispense assembly 40X3741 CMYK toner add motor assembly 40X0636 Sensor (RFID toner cartridge) 7-28...

  • Page 577: Assembly 26: Developer Unit Assemblies

    5057-XXX Assembly 26: Developer unit assemblies Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X6788 Developer unit assembly 40X3744 Y developer carrier 40X3745 M developer carrier 40X3746 C developer carrier 40X3743 K developer carrier 7-29 Parts catalog...

  • Page 578: Assembly 27: Fuser Assembly

    5057-XXX Assembly 27: Fuser assembly Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X4153 Fuser assembly 100 V 40X3747 Fuser assembly 110 V 40X3748 Fuser assembly 220 V 7-30 MFP Service Manual...
  • Page 579 5057-XXX Assembly 28: Cooling fans Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3750 Fuser cooling fan 40X3749 Printhead shutter motor assembly 40X3752 Rear lower cooling fan assembly (this comes assembled) 40X3751 Transfer belt drive motor cooling fan 7-31 Parts catalog...

  • Page 580: Assembly 29: Electrical 1

    5057-XXX Assembly 29: Electrical 1 Previous Next Go Back 7-32 MFP Service Manual...
  • Page 581 5057-XXX Assembly 29: Electrical 1 Previous Asm- Part FRUs/ Units/ Description index number mach 40X3762 Laser diode power card assembly 40X3757 Lower printer engine card assembly Next 40X3758 24 V LVPS card assembly 40X3763 Rear upper cooling fan Go Back 40X3759 24 V LVPS cooling fan 40X3760...

  • Page 582: Assembly 30: Electrical 2

    5057-XXX Assembly 30: Electrical 2 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3764 AC drive card bracket assembly 110 V (this comes assembled) 40X3765 AC drive card bracket assembly 220 V (this comes assembled) 40X3766 Outlet power panel cable assembly 7-34 MFP Service Manual...

  • Page 583: Assembly 31: Electrical 3

    5057-XXX Assembly 31: Electrical 3 Previous Next Go Back 7-35 Parts catalog...
  • Page 584 5057-XXX Assembly 31: Electrical 3 Previous Asm- Part FRUs/ Units/ Description index number mach 40X3775 DC main cable assembly 40X3776 DC rear right cable assembly Next 40X3774 2nd transfer charge roll cable 40X3771 CK transfer roll cable assembly Go Back 40X3770 YM transfer roll cable assembly 40X3772...

  • Page 585: Assembly 32: Electrical 4

    5057-XXX Assembly 32: Electrical 4 Previous Next Go Back 7-37 Parts catalog...
  • Page 586 40X3807 RIP bridge card assembly Next 40X2359 Interconnect card assembly 40X5864 SFP RIP card assembly (C935 model) Go Back 40X3808 Upper printer engine card chassis assembly 40X4081 Upper printer engine card cable assembly WARNING: In the event of replacement of any one of the following components: •...

  • Page 587: Assembly 33: 1Tm Covers

    5057-XXX Assembly 33: 1TM covers Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3825 Tray module right cover 40X3824 Tray module foot cover 40X4142 1TM front door assembly 40X3826 Tray module left cover 40X3827 Tray module rear cover 40X3823 Tray module top cover 7-39...
  • Page 588 5057-XXX Assembly 34: 1TM feed unit assembly Previous Next Go Back 7-40 MFP Service Manual...
  • Page 589 5057-XXX Assembly 34: 1TM feed unit assembly Previous Asm- Part FRUs/ Units/ Description index number mach 40X3677 Switch (media size) 40X3676 Media tray slide Next 40X3675 Media tray catch 40X3678 Media tray assembly kit Go Back • Media tray assembly •...

  • Page 590: Assembly 35: 1Tm Media Feed Unit

    5057-XXX Assembly 35: 1TM media feed unit Previous Next Go Back 7-42 MFP Service Manual...
  • Page 591 5057-XXX Assembly 35: 1TM media feed unit Previous Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3687 Media out actuator Next 40X3688 Sensor (tray media out) 40X3688 Sensor (tray media level) Go Back 40X3684 Media feed lift motor 40X0888 Bushing 6 mm 40X0590...

  • Page 592: Assembly 36: 1Tm Left Door

    5057-XXX Assembly 36: 1TM left door Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3818 Tray 2 feed-out sensor cable assembly 40X3817 Sensor (tray 2 feed-out) 40X3821 Switch (tray module left door interlock) 40X4141 1TM left door assembly (this comes assembled) 40X4119 Tray module media transport roll assembly 7-44...
  • Page 593 5057-XXX Assembly 37: 1TM drive and electrical Previous Next Go Back 7-45 Parts catalog...
  • Page 594 5057-XXX Assembly 37: 1TM drive and electrical Previous Asm- Part FRUs/ Units/ Description index number mach 40X4152 1TM controller card assembly 40X3812 Tray module drive motor assembly Next 40X4068 Tray module left retaining bracket 40X4034 Tray module retainer screw Go Back 40X3815 Media transport gear 33T 40X3813...

  • Page 595: Assembly 38: 3Tm Covers

    5057-XXX Assembly 38: 3TM covers Previous Next Go Back 7-47 Parts catalog...
  • Page 596 5057-XXX Assembly 38: 3TM covers Previous Asm- Part FRUs/ Units/ Description index number mach 40X3825 Tray module right cover 40X3824 Tray module foot cover Next 40X3826 Tray module left cover 40X3827 Tray module rear cover Go Back 40X3823 Tray module top cover 7-48 MFP Service Manual...

  • Page 597: Assembly 39: 3Tm Feed Unit Assembly

    5057-XXX Assembly 39: 3TM feed unit assembly Previous Next Go Back 7-49 Parts catalog...
  • Page 598 5057-XXX Assembly 39: 3TM feed unit assembly Previous Asm- Part FRUs/ Units/ Description index number mach 40X3677 Switch (media size) 40X3676 Media tray slide Next 40X3675 Media tray catch 40X3678 Media tray assembly kit Go Back • Media tray assembly •...

  • Page 599: Assembly 40: 3Tm Media Feed Unit

    5057-XXX Assembly 40: 3TM media feed unit Previous Next Go Back 7-51 Parts catalog...
  • Page 600 5057-XXX Assembly 40: 3TM Media feed unit Previous Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3687 Media out actuator Next 40X3688 Sensor (tray media out) 40X3688 Sensor (tray media level) Go Back 40X3684 Media feed lift motor 40X0888 Bushing 6 mm 40X0590...

  • Page 601: Assembly 41: 3Tm Left Door

    5057-XXX Assembly 41: 3TM left door Previous Next Go Back 7-53 Parts catalog...
  • Page 602 5057-XXX Assembly 41: 3TM left door Previous Asm- Part FRUs/ Units/ Description index number mach 40X3818 Tray 2 feed-out sensor cable assembly 40X3817 Sensor (tray 2 feed-out) Next 40X3821 Switch (tray module left door interlock) 40X3819 Tray 3/4 feed-out sensor actuator Go Back 40X3820 Sensor (tray 3 feed-out)

  • Page 603: Assembly 42: 3Tm Drive And Electrical

    5057-XXX Assembly 42: 3TM drive and electrical Previous Next Go Back 7-55 Parts catalog...
  • Page 604 5057-XXX Assembly 42: 3TM drive and electrical Previous Asm- Part FRUs/ Units/ Description index number mach 40X3811 3TM controller card assembly 40X3812 Tray module drive motor assembly Next 40X4068 Tray module left retaining bracket 40X4034 Tray module retainer screw Go Back 40X3815 Media transport gear 33T 40X3813...

  • Page 605: Assembly 43: Ttm Covers

    5057-XXX Assembly 43: TTM covers Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3825 Tray module right cover 40X3824 Tray module foot cover 40X3826 Tray module left cover 40X3827 Tray module rear cover 40X3823 Tray module top cover 7-57 Parts catalog...

  • Page 606: Assembly 44: Ttm Media Trays

    5057-XXX Assembly 44: TTM media trays Previous Next Go Back 7-58 MFP Service Manual...
  • Page 607 5057-XXX Assembly 44: TTM media trays Previous Asm- Part FRUs/ Units/ Description index number mach 40X3678 Media tray assembly kit • Media tray assembly Next • #1 label • #2 label • #3 label • #4 label Go Back • Instruction label 40X3830 Switch (TTM media size) 40X3831...

  • Page 608: Assembly 45: Ttm Media Tray 3

    5057-XXX Assembly 45: TTM media tray 3 Previous Next Go Back 7-60 MFP Service Manual...
  • Page 609 5057-XXX Assembly 45: TTM tray 3 Previous Asm- Part FRUs/ Units/ Description index number mach 40X0711 TTM tray separation pad 40X3832 TTM tray 3 front cover Next 40X4126 TTM tray lift idler pulley 40X4127 TTM tray lift idler pulley guide Go Back 40X4084 TTM tray 3 lift cable...

  • Page 610: Assembly 46: Ttm Media Tray 4

    5057-XXX Assembly 46: TTM media tray 4 Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3836 TTM tray 4 front cover 40X4126 TTM tray lift idler pulley 40X4127 TTM tray lift idler pulley guide 40X4085 TTM tray 4 lift cable 40X0723 TTM tray 4 rear support roll (2) 40X0711...

  • Page 611: Assembly 47: Ttm Media Tray 4 Transport

    5057-XXX Assembly 47: TTM media tray 4 transport Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3838 TTM tray 4 media transport assembly 40X3679 Media feed unit assembly 40X3841 TTM tray 4 lower media guide 40X3840 TTM tray 4 upper media guide 40X3694 Sensor (tray 4 feed-out)

  • Page 612: Assembly 48: Ttm Media Transport

    5057-XXX Assembly 48: TTM media transport Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3817 Sensor (tray 2 feed-out) 40X3843 TTM vertical turn guide 40X3679 Media feed unit assembly 40X3842 Tray 3 feed-out sensor assembly (this comes assembled) 40X3818 Tray 2 feed-out sensor cable assembly 40X4119...

  • Page 613: Assembly 49: Ttm Left Door

    5057-XXX Assembly 49: TTM left door Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3844 TTM left door assembly (this comes assembled) 40X3821 Switch (tray module left door interlock) 7-65 Parts catalog...

  • Page 614: Assembly 50: Ttm Tray Lift Drive

    5057-XXX Assembly 50: TTM tray lift drive Previous Next Go Back Asm- Part FRUs/ Units/ Description index number mach 40X3848 TTM tray lift coupling assembly 40X3847 TTM tray lift gear 17T 40X0880 Bushing 6 mm 40X3845 TTM tray 3 lift gear assembly 40X3846 TTM tray 4 lift gear assembly 7-66...

  • Page 615: Assembly 51: Ttm Drive And Electrical

    5057-XXX Assembly 51: TTM drive and electrical Previous Next Go Back 7-67 Parts catalog...
  • Page 616 5057-XXX Assembly 51: TTM drive and electrical Previous Asm- Part FRUs/ Units/ Description index number mach 40X3850 TTM controller card assembly 40X3849 TTM tray 4 transport drive motor assembly Next 40X3812 Tray module drive motor assembly 40X4068 Tray module left retaining bracket Go Back 40X3815 Media transport gear 33T...

  • Page 617: Assembly 52: Miscellaneous

    40X4102 SFP relocation kit 40X4112 SFP relocation kit with options 56P2129 Lexmark MarkNet N7020e (4 USB ports) 1-0/100/1000 w/out power cord 56P2744 N4050e 802.11g Wireless Print Server (Americas, Argentina, & Brazil) w/out power cord 56P2745 N4050e 802.11g Wireless Print Server (European, UK/Ireland, & Australia)
  • Page 618 40X1378 Marknet N8050 802.11g wireless, US 40X1562 Marknet N8050 802.11g wireless, International 40X1593 Lexmark marknet N7000e (1 USB port) 10/100 ethernet 40X1594 Lexmark marknet N7002e (1 parallel port) 10/100 ethernet 40X1592 Lexmark marknet N7020e (4 USB ports) 10/100/1000 ethernet 40X2610 Hard drive assembly includes: •...
  • Page 619 5057-XXX Index 3-18 Numerics Clear the Event Log 3-17 Display the Event Log 1-53 1TM main components 3-18 Print the Event Log 1-49 1TM theory FINISHER TESTS 1-52 1TM media feed units 3-12 Feed Tests 1-50 media transport 3-12 Hole Punch Test 1-51 media tray assembly 3-12...
  • Page 620 5057-XXX 2-136 250.00 sensor (registration) late jam (feeding from the printer left lower door open Previous 2-49 2-136 2-137 MPF) scheduled maintenance required 2-59 2-137 841.00 image pipeline ASIC failure standard bin 1 full 2-60 2-138 849.00 hard drive failure toner cartridge RFID failure 2-63 2-64...
  • Page 621 5057-XXX 1-21 CMY toner add motor assembly Previous 1-20 CMYK PC cartridge drive motor assembly removals 1-21 K developer clutch 4-115 feed roll 1-19 K developer/transport drive motor assembly 4-116 pick roll 1-19 MPF/transport drive motor 4-24 sensor (media level) 1-22 waste toner agitator motor assembly 4-22...
  • Page 622 5057-XXX 4-132 tray 4 transport assembly Previous 4-125 tray support roll removals—3X 500-sheet drawer (3TM) 4-164 4-165 4-166 4-167 4-190 4-191 top cover 4-192 4-193 Next ii-xxiii safety information safety inspection guide scheduled maintenance Go Back 2-23 Service checks service checks 2-60 900.xx System software service error...

  • Page 623: Part Number Index

    Lexmark marknet N7002e (1 parallel port) 10/100 ethernet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 624 5057-XXX 40X2768 IPDS card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-70 Previous 40X2769...
  • Page 625 5057-XXX 40X3719 CMY erase lamp assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24 Previous 40X3720...
  • Page 626 5057-XXX 40X3785 Inner cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous 40X3786 Main power switch actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 627 USB connector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56P2129 Lexmark MarkNet N7020e (4 USB ports) 1-0/100/1000 w/out power cord - - - - - - - - - - - - - - - - - - - - - - 7-69 56P2744 N4050e 802.11g Wireless Print Server (Americas, Argentina, &...
  • Page 628 5057-XXX Previous Next Go Back I-10 Printer Service Manual...
  • Page 630 5057 AND 7510 Tray Modules SENSOR (tray2 feed out) +5VDC 5V RTN SENSOR (tray4 feed out) 1TM ONLY +5VRTN +5VDC +5VDC 5V RTN SWITCH (TTM media 5V RTN size) #4 +5VDC P546 P546 P548 +5VDC5V RTN SWITCH (media size #2) 5V RTN SENSOR (tray3 5V RTN (SHORTING WIRE)

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