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Lexmark CS720 Service Manual

Lexmark CS720 Service Manual

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CS720, CS725, and C4150

5028-135, -630, -639

Service Manual

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Start diagnostics

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Maintenance

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Safety and notices

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Trademarks

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Index

January 25, 2016

P/N 12G3399

www.lexmark.com

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Summary of Contents for Lexmark CS720

Page 1: Service Manual
CS720, CS725, and C4150 5028-135, -630, -639 Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index January 25, 2016 www.lexmark.com P/N 12G3399...
Page 2: Product Information
Trademarks Lexmark and the Lexmark logo 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. PCL is Hewlett-Packard Company’s designation of a set of printer commands (language) and functions included in its printer products.
Page 3: Table Of Contents
5028 Table of contents Product information..................2 Edition notice....................2 Notices and safety information..............13 Laser notice................................13 Avis relatif à l'utilisation du laser........................13 Notiﬁcació del làser............................13 Aviso de láser..............................13 Aviso sobre laser..............................14 Avvertenze sui prodotti laser.......................... 14 Laserinformatie..............................14 Lasererklæring..............................
Page 4 5028 安全信息........................... 21 安全情報........................... 22 安全資訊........................... 22 Preface......................23 Conventions................................23 General caution statements........................... 23 General information................... 25 Finding the serial number..........................25 Paper and specialty media guide......................... 26 Paper guidelines................................26 Using specialty media ..............................27 Supported paper sizes, types, and weights ......................29 Data security notice............................
Page 5 5028 Light print check ................................57 Skewed print service check ............................. 60 Paper jams................................61 Avoiding jams ................................61 Identifying jam locations............................63 Paper jam in trays ................................ 64 Paper jam in the multipurpose feeder ........................65 Paper jam in the standard bin ..........................65 Paper jam in door A ..............................
Page 6 5028 Unsupported internal option service check ......................163 Disabled port service check............................163 Excess options service check ..........................164 Incompatible hardware option service check.....................165 Hard disk failure service check ..........................165 Printer hardware errors..........................166 1yy errors..................................166 6yy errors..................................201 9yy errors..................................207 Symptoms................................. 223 Base printer symptoms ............................223 Control panel service check...........................223 Interlock switch service check..........................224 Sensor (narrow media) and sensor (fuser buckle) service check..............226...
Page 7 5028 Repair information..................253 Removal precautions............................. 253 Data security notice ..............................253 Handling ESD‑sensitive parts..........................254 Controller board/control panel replacement .....................254 Restoring the printer conﬁguration after replacing the controller board ...........255 Restoring solutions, licenses, and conﬁguration settings ................258 Updating the printer ﬁrmware ..........................259 Backing up eSF solutions and settings ......................
Page 8 5028 Motor (deskew) removal ............................299 Fuser fan removal..............................299 Main fan removal ................................301 EP gear box removal ..............................302 LVPS removal................................305 LVPS cage removal ..............................308 Motor (black only retract) removal ........................309 Right removals..............................311 Sensor (weather station) removal ..........................311 Sensor (paper size) removal ............................312 Sensor (waste toner contact) removal .........................314 TMC card removal..............................315 Motor (duplex/MPF) removal ...........................315...
Page 9 5028 Output bin ﬂag removal ............................367 Bottom removals............................. 368 Front cover hinges removal............................368 Tray rail removal.................................369 Aligner idler gears removal ............................370 Isolation unit removal ..............................371 Media feeder removal .............................. 373 550-sheet tray removals..........................375 550-sheet tray right cover removal........................375 Motor (550-sheet tray pass‑through) removal....................
Page 10 5028 Assembly 3: Control panel..........................417 Assembly 4: Fuser............................419 Assembly 5: Transfer module........................421 Assembly 6: Paper feed..........................423 Assembly 7: Paper path 1..........................425 Assembly 8: Paper path 2..........................427 Assembly 9: Duplex............................429 Assembly 10: Electrical........................... 431 Assembly 11: 550‑sheet tray option 1......................435 Assembly 12: 550‑sheet tray option 2.......................437 Assembly 13: Adjustable stand........................439 Assembly 14: Miscellaneous parts.......................
Page 11 5028 Electrophotographic process ..........................461 EP process basics ..............................461 Color theory..............................469 Color theory ................................469 Appendix D: Acronyms................473 Acronyms................................473 Index......................475 Part number index..................481 Part name index..................487 Table of contents...
Page 12 5028 Table of contents...
Page 13: Notices And Safety Information
5028 Notices and safety information Laser notice The printer is certiﬁed in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, 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 14: Aviso Sobre Laser
5028 han diseñado para que el ser humano no acceda nunca a las radiaciones láser por encima del nivel de Clase I durante su uso normal, ni en tareas de mantenimiento o intervenciones de servicio técnico prescritas. Aviso sobre laser Esta impressora foi certiﬁcada nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR capítulo I, subcapítulo J, para produtos a laser de Classe I (1) e, nos demais países, foi certiﬁcada como um produto a laser de Classe I em conformidade com os requisitos da IEC 60825-1.
Page 15: Laser-Hinweis
5028 der ikke er en direkte laserstråling, der overskrider Klasse I-niveauet under normal brug, brugers vedligeholdelse eller de foreskrevne servicebetingelser. Laser-Hinweis Der Drucker wurde in den USA zertiﬁziert und entspricht den Anforderungen der Vorschriften DHHS 21 CFR Kapitel I für Laserprodukte der Klasse I (1), andernorts ist er als Laserprodukt der Klasse I zertiﬁziert, das den Anforderungen von IEC 60825-1 entspricht.
Page 16: レーザーについて
5028 レーザーについて本機は、米国においてクラス I（1）レーザー製品に対する DHHS 21 CFR、Chapter I、Subchapter J の要件に準拠し、その他の国では IEC 60825-1 の要件に準拠するクラス I レーザー製品として認可されています。クラス I レーザー製品は、危険性がないとみなされています。本機には、クラス IIIb（3b）AlGaInP レーザーが内蔵されています。これは、650 ～ 670 ナノメートルの波長で、定格 15 ミリワットで動作するレーザーであり、整備不可のプリントヘッドアセンブリに収容されています。レーザーシステムとプリンタは、通常の操作、ユーザーによるメンテナンス、または所定のサービス条件の下で、ユーザーがクラス I レベルを超えるレーザー放射に絶対にさらされないように設計されています。 레이저 고지사항 프린터는 미국에서 레이저 제품용 DHHS 21 CFR Chapter I, Subchapter J의 요구 사항을 준수하며 이외 지역 에서...
Page 17: Consignes De Sécurité
5028 CAUTION—SHOCK HAZARD: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. CAUTION—POTENTIAL INJURY: The lithium battery in this product is not intended to be replaced.
Page 18: Información De Seguridad
5028 Información de seguridad • La seguridad de este producto se basa en las pruebas y comprobaciones del diseño original y los componentes especíﬁcos. El fabricante no se hace responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
Page 19: Informazioni Sulla Sicurezza
5028 LET OP—KANS OP ELEKTRISCHE SCHOK: Wanneer u dit symbool ziet, bestaat er een gevaar voor gevaarlijke spanning in het gebied van het product waaraan u werkt. Haal de stekker van het product uit het stopcontact voordat u begint, of let extra goed op als het product stroom nodig heeft om een taak te kunnen uitvoeren.
Page 20: Sicherheitshinweise
5028 Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des Originaldesigns und der speziﬁschen Komponenten. Sofern nicht autorisierte Ersatzteile eingesetzt werden, übernimmt der Hersteller keinerlei Verantwortung in Bezug auf die Sicherheit dieses Produkts. • Die Wartungsinformationen für dieses Produkt wurden für ausgebildete Servicemitarbeiter zusammengestellt und dürfen nicht von anderen verwendet werden.
Page 21: Turvallisuusohjeet
5028 FORSIKTIG – FARE FOR ELEKTRISK STØT: Dette symbolet betyr at det er fare for farlig spenning i det området av produktet der du arbeider. Koble fra produktet før du begynner, eller vær forsiktig hvis produktet må ha strøm for å kunne utføre oppgaven. FORSIKTIG –...
Page 22: 安全情報
5028 当心—可能的伤害：本产品中的锂电池不可更换。如果不正确更换锂电池，可能会有爆炸危险。不要再充电、拆解或焚烧锂电池。丢弃旧的锂电池时应按照制造商的指导及当地法规进行处理。安全情報本製品の安全性は、本来の設計、特定コンポーネントの試験、承認に基づいています。承認されていない交換 • 部品をお客様が使用した場合、メーカーは安全性に対して責任を負いません。本製品のメンテナンス情報は、専門のサービス担当者による利用を目的としており、その他の人を対象としてい • ません。本製品の分解や保守サービスを行う場合は、感電や傷害の危険性があります。専門のサービス担当者はこの • 危険性を理解し、十分な対策を講じる必要があります。危険！感電の恐れあり：この表記がある場合、対象製品の作業領域には、高電圧による危険性が生じています。作業を始める前に、製品から電源コードを取り外してください。また作業時に、製品に給電する必要がある場合は、十分に注意するようにしてください。危険！ケガの恐れあり：この製品に使用されているリチウム電池は、交換を前提としていません。リチウム電池の交換を誤ると破裂する危険性があります。リチウム電池の充電、解体、焼却はしないでください。使用済みのリチウム電池を廃棄する際は、製造元の指示およびお使いの地域の法律に従ってください。安全資訊本產品安全性係以原始設計及特定元件之測試與核准為依據。如有使用未獲授權替換組件之情形者，製造 • 商對安全性概不負責。 • 本產品之維護資訊僅供專業維修人員使用，而非預定由他人使用。 • 拆裝及維修本產品時，有可能造成電擊與人員損傷之危險。專業維修人員應瞭解前項危險並採取必要措施。請當心－有觸電的危險：當您看到此符號時，表示您所在產品工作區有危險電壓。開始工作之前，請先拔掉產品電源線，若產品必須接上電源方能執行作業，用電時請務必小心。請當心－有潛在傷害的危險：本產品中的鋰電池原本並不需要予以更換。若未正確更換鋰電池，可能會有爆炸的危險。請勿將鋰電池充電、拆裝或焚燒。請遵照製造商的指示及當地法規，丟棄用過的電池。 Notices and safety information...
Page 23: Preface
5028 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: • General information provides a general description of the printer, tools, and equipment needed to service the printer. • Diagnostic information contains diagnostic aids such as error code tables, symptoms, and service checks that you can use to isolate failing ﬁeld replaceable units (FRUs).
Page 24 CAUTION—POTENTIAL INJURY: Only a Lexmark Inline Surge Protector that is properly connected between the printer and the power cord provided with the printer may be used with this product. The use of non-Lexmark surge protection devices may result in a risk of ﬁre, property damage, or poor printer performance.
Page 25: General Information
General information The Lexmark CS720 and CS725 are network‑capable, A4 laser printers that print both color and monochrome print jobs. All information in this service manual pertains to all models unless explicitly noted. The printers are available in the following models: Model Conﬁgurations...
Page 26: Paper And Specialty Media Guide
5028 Paper and specialty media guide Paper guidelines Paper characteristics The following paper characteristics affect print quality and reliability. Consider these factors before printing on them: Weight “Supported paper types and weights” on page Curl Curl is the tendency for paper to curl at its edges. Excessive curl can cause paper feeding problems. Curl can occur after the paper passes through the printer, where it is exposed to high temperatures.
Page 27: Using Specialty Media
5028 To help avoid paper jams and poor print quality: • Always use new, undamaged paper. • Before loading paper, know the recommended printable side of the paper. This information is usually indicated on the paper package. • Do not use paper that has been cut or trimmed by hand. •...
Page 28 Print samples on labels being considered for use before buying large quantities. • For more information on label printing, characteristics, and design, see the Card Stock & Label Guide on the Lexmark Web site at http://support.lexmark.com. • Use labels designed speciﬁcally for laser printers.
Page 29: Supported Paper Sizes, Types, And Weights
5028 Supported paper sizes, types, and weights The following tables provide information on standard and optional paper sources and the sizes, types, and weights of paper they support. Note: For an unlisted paper size, select the closest larger listed size. Supported paper sizes Paper sizes supported by the trays and multipurpose feeder Paper size...
Page 30: Supported Paper Types And Weights
5028 Paper size Dimensions 550‑sheet tray Multipurpose feeder Two‑sided printing 10 Envelope 105 x 241 mm (4.1 x 9.5 in.) Monarch Envelope 98.4 x 190.5 mm (3.9 x 7.5 in.) 98 x 162 mm (3.9 x 6.4 in.) to Other Envelope 176 x 250 mm (6.9 x 9.8 in.) Universal 104.8 x 148 mm (4.13 x 5.83 in.)
Page 31: Data Security Notice
5028 Data security notice Identifying printer memory • Volatile memory—The printer uses standard random access memory (RAM) to buffer user data temporarily during simple print and copy jobs. • Non-volatile memory—The printer may use two forms of non-volatile memory: EEPROM and NAND (ﬂash memory).
Page 32 5028 • #1 Phillips screwdriver, magnetic • #2 Phillips screwdriver, magnetic • #2 Phillips screwdriver, magnetic short-blade • 7/32 inch (5.5 mm) open-end wrench • 7.0 mm nut driver • Needle‑nose pliers • Diagonal side cutters • Spring hook • Feeler gauges •...
Page 33: Diagnostic Information
5028 Diagnostic information CAUTION—SHOCK HAZARD: To avoid the risk of electrical shock and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and computers or peripherals.
Page 34: Fixing Print Quality Issues
5028 The progress bar appears on the splash screen. The printer begins to POST, and the motors and sensors are polled and tested. The home screen displays. Printer calibration may begin. Note: If any of the tests fail, the printer displays an error code. Fixing print quality issues Initial print quality check Before troubleshooting print problems, perform the following:...
Page 35 5028 Actions Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper type and size settings match the paper type and size set on the tray. Do the settings match? Step 2 Go to step 3.
Page 36: Background Or Gray Background Check
5028 Background or gray background check Leading edge ABCDE ABCDE ABCDE Trailing edge Action Step 1 Go to step 2. Go to step 3. From the home screen, touch Settings > Reports > Device > Device Statistics. Check the status of the imaging unit if it was recently replaced. Does the status show that the imaging unit was recently replaced? Step 2 Go to step 3.
Page 37: Blank Or White Pages Check
5028 Action Step 8 Go to step 9. The problem is solved. Remove the printhead, and then clean the printhead lenses. See “Printhead removal” on page 361. Does the problem remain? Step 9 Contact the next The problem is level of support. solved.
Page 38 5028 Action Step 5 Go to step 6. The problem is solved. • If the affected color is cyan, magenta, or yellow, then replace the developer unit of the affected color. • If the affected color is black, then replace the imaging unit. Does the problem remain? Step 6 Go to step 8.
Page 39: Gapping Or Half Color Page Check
5028 Action Step 13 Go to step 14. The problem is solved. Replace the cable. Does the problem remain? Step 14 Go to step 15. The problem is solved. Replace the printhead. See “Printhead removal” on page 361. Does the problem remain? Step 15 Contact the next The problem is...
Page 40: Blurred Print Or Color Misalignment Check
5028 Action Step 4 Go to step 5. The problem is solved. • If the affected color is cyan, magenta, or yellow, then replace the developer unit of the affected color. • If the affected color is black, then replace the imaging unit. Does the problem remain? Step 5 Contact the next...
Page 41: Horizontal Colored Lines Or Banding Check
5028 Action Step 6 Go to step 7. The problem is solved. Perform the color alignment service check for all the colors. Does the problem remain? Step 7 Go to step 8. The problem is solved. Perform the auto alignment sensors service check. Does the problem remain? Step 8 Go to step 9.
Page 42 5028 Actions Step 1 Go to step 2. Go to step 3. Enter the Diagnostics menu, and then navigate to: Advanced Print Quality Samples > Advanced Print Quality Samples Check the test page for lines. Are the lines white? Step 2 Go to step 3.
Page 43: Text Or Images Cut Off Check
5028 Text or images cut off check Leading edge ABCDE ABCDE ABCDE Trailing edge Actions Step 1 Contact the next Go to step 2. level of support. From the home screen, touch Settings > Device > Preferences. Check if the paper type and size settings match the paper type and size set on the tray.
Page 44: Vertical White Lines Check
5028 Action Step 5 Go to step 6. Go to step 7. Check the printer for toner leaks. Are there toner leaks? Step 6 Go to step 7. The problem is solved. Clean the printer thoroughly using a toner vacuum. Perform a print job to clear the remaining toner from the imaging components.
Page 45 5028 Action Step 1 Go to step 5. Go to step 2. Enter the Diagnostics menu, and then navigate to: Advanced Print Quality Samples > Advanced Print Quality Samples Check the test page. Did the print defect appear on all the pages? Step 2 Go to step 3.
Page 46: Ghost Images Check
5028 Ghost images check Leading edge A B C D A B C D A B C D A B C D Trailing edge Action Step 1 Go to step 2. Go to step 4. From the home screen, touch Status/supplies > Hardware. Check the status of the black and color imaging components.
Page 47: Solid Color Or Black Image Check
5028 Action Step 7 Contact the next The problem is level of support. solved. Replace the fuser. See “Fuser removal” on page 333. Does the problem remain? Solid color or black image check Action Step 1 Go to step 2. Go to step 3.
Page 48: Vertical Colored Lines Or Banding Check
5028 Action Step 5 Go to step 6. The problem is solved. Replace the printhead. See “Printhead removal” on page 361. Does the problem remain? Step 6 Go to step 7. The problem is solved. Check the toner cartridge contacts for damage, and replace if necessary.
Page 49: Image Void Scan Direction Check
5028 Action Step 1 Go to step 2. Go to step 4. Enter the Diagnostics menu, and then navigate to: Advanced Print Quality Samples > Advanced Print Quality Samples Check the test page. Is only one color producing the defect? Step 2 Go to step 3.
Page 50 5028 Action Step 3 Go to step 4. Go to step 5. Check if the problem affects only one color. Does the problem affect only one color? Step 4 Go to step 6. The problem is solved. • If the affected color is cyan, magenta, or yellow, then reseat the developer unit of the affected color.
Page 51: Image Void Process Direction Check
5028 Image void process direction check Action Step 1 Go to step 2. The problem is solved. Load paper from a fresh package. Note: Paper may absorb moisture due to high humidity. Store paper in its original wrapper until it is ready to be used. Does the problem remain? Step 2 Go to step 3.
Page 52: Dark Print Check
5028 Action Step 9 Go to step 10. The problem is solved. Replace the printhead. See “Printhead removal” on page 361. Does the problem remain? Step 10 Contact the next The problem is level of support. solved. Replace the controller board. See “Controller board removal”...
Page 53: Missing Color Check
5028 Action Step 5 Go to step 6. The problem is solved. Remove the imaging kit, and then reseat the developer unit of the affected color. Does the problem remain? Step 6 Go to step 7. The problem is solved. Check the HVPS cable for proper connection and damage, and replace if necessary.
Page 54: Uneven Print Density Check
5028 Action Step 2 Go to step 3. The problem is solved. Reseat all the developer units in the imaging kit. Enter the Diagnostics menu, and then navigate to: Advanced Print Quality Samples > Advanced Print Quality Samples Check the test page. Does the problem remain? Step 3 Go to step 4.
Page 55: Repeating Defects Check
5028 Action Step 2 Go to step 3. The problem is solved. Change the paper size and type, or adjust the size settings in the tray. Does the problem remain? Step 3 Go to step 4. Go to step 5. Check the paper for texture or rough ﬁnish.
Page 56 5028 Action Step 4 Contact the next The problem is level of support. solved. • If the affected color is cyan, magenta, or yellow, then replace the developer unit of the affected color. • If the affected color is black, then replace the imaging unit. Does the problem remain? Step 5 Go to step 6.
Page 57: Random Marks Check
5028 Random marks check Action Step 1 Go to step 2. Go to step 3. Check the printer for toner leaks. Are there toner leaks? Step 2 Go to step 3. The problem is solved. Clean the printer thoroughly using a toner vacuum. Perform a print job to clear the remaining toner from the imaging components.
Page 58 5028 Action Step 3 Go to step 4. Go to step 12. Enter the Diagnostics menu, and then navigate to: Advanced Print Quality Samples > Advanced Print Quality Samples Check the test page. Is only one color affected? Step 4 Go to step 6.
Page 59 5028 Action Step 11 Go to step 12. The problem is solved. Replace the motor. See “Motor (EP drive) removal” on page 296. Does the problem remain? Step 12 Go to step 14. Go to step 13. Remove the printhead, and then check the printhead lenses for dust or debris.
Page 60: Skewed Print Service Check
5028 Action Step 20 Go to step 21. The problem is solved. Reseat the HVPS and make sure that the contacts freely move. Does the problem remain? Step 21 Go to step 22. The problem is solved. Replace the transfer module. See “Transfer module removal”...
Page 61: Paper Jams
5028 Action Step 6 Go to step 8. Go to step 7. Check the isolation unit for dust or debris. Is the isolation unit free of dust or debris? Step 7 Go to step 8. The problem is solved. Remove the dust or debris. Does the problem remain? Step 8 Go to step 11.
Page 62 5028 Correct loading of paper Incorrect loading of paper • Do not load or remove a tray while the printer is printing. • Do not load too much paper. Make sure that the stack height is below the maximum paper ﬁll indicator. •...
Page 63: Identifying Jam Locations
5028 • Make sure that the paper size and type are set correctly on the computer or printer control panel. • Store paper according to manufacturer recommendations. Identifying jam locations Notes: • When Jam Assist is set to On, the printer ﬂushes blank pages or pages with partial prints after a jammed page has been cleared.
Page 64: Paper Jam In Trays
5028 Paper jam in trays Pull out the tray. Warning—Potential Damage: A sensor inside the optional tray is easily damaged by static electricity. Touch a metal surface before removing the jammed paper in the tray. Remove the jammed paper. Note: Make sure that all paper fragments are removed. Insert the tray.
Page 65: Paper Jam In The Multipurpose Feeder
5028 Paper jam in the multipurpose feeder Remove paper from the multipurpose feeder. Pull out the tray. Remove the jammed paper. Note: Make sure that all paper fragments are removed. Insert the tray. Paper jam in the standard bin Remove the jammed paper. Note: Make sure that all paper fragments are removed.
Page 66: Paper Jam In Door A
5028 Open doors A and D, and then remove any paper fragments. CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching it. Close doors D and A.
Page 67 5028 Open the fuser access door. Remove the jammed paper. Note: Make sure that all paper fragments are removed. Close door A. Diagnostic information...
Page 68 5028 Paper jam in the duplex unit Open door A. CAUTION—HOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching it. Open the duplex cover. Remove the jammed paper.
Page 69: Paper Jams
5028 200 paper jams 200 paper jam messages Error code Description Action 200.05 Paper fed from the MPF never cleared the sensor “Sensor (input): Paper failed to clear (input). service check” on page 200.12 Paper fed from tray 1 was detected earlier than “Sensor (input): Paper arrived too early expected at the sensor (input).
Page 70 5028 Sensor (input): Paper arrived too early service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 71 5028 Action Step 2 Go to step 3. The problem is solved. Change the paper size or adjust the size setting in the tray. Does the problem remain? Step 3 Go to step 5. Go to step 4. Check the paper path for paper jams and fragments. Is the paper path free of jams and fragments? Step 4 Go to step 5.
Page 72 5028 Sensor (input): Paper failed to clear service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 73 5028 Action Step 9 Go to step 10. The problem is solved. Check the motor cable for proper connection and damage, and replace if necessary. Does the problem remain? Step 10 Contact the next The problem is level of support. solved.
Page 74 5028 Action Step 7 Go to step 9. The problem is solved. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Input). Does the sensor status change while toggling the sensor? Step 8 Go to step 9.
Page 75: Paper Jams
5028 Action Step 5 Go to step 8. Go to step 6. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Input). Does the sensor status change while toggling the sensor? Step 6 Go to step 7.
Page 76: Paper Jams
5028 Action Step 3 Go to step 5. Go to step 4. Check the paper path for partially fed or jammed paper. Is the paper path free of partially fed or jammed paper? Step 4 Go to step 5. The problem is solved.
Page 77 5028 Error code Description Action 202.24 Paper fed from tray 2 cleared the sensor (fuser “Sensor (fuser exit): Paper cleared too exit) earlier than expected. early service check” on page 202.25 Paper fed from tray 2 never cleared the sensor “Sensor (fuser exit): Paper failed to clear (fuser exit).
Page 78 5028 Action Step 4 Go to step 5. The problem is solved. Remove the paper jams and fragments. Does the problem remain? Step 5 Go to step 7. Go to step 6. Check the fuser rollers for damage. Are the rollers free of damage? Step 6 Go to step 7.
Page 79 5028 Action Step 6 Go to step 7. The problem is solved. Remove the obstructions in the fuser area. Does the problem remain? Step 7 Go to step 8. The problem is solved. Check the fuser for damage or life expiration, and replace if necessary.
Page 80 5028 Action Step 14 Go to step 15. The problem is solved. Replace the motor. See “Motor (fuser) removal” on page 318. Perform a print job. Does the problem remain? Step 15 Contact the next Go to step 16. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics &...
Page 81 5028 Action Step 4 Go to step 5. The problem is solved. Remove the jams and fragments. Does the problem remain? Step 5 Go to step 7. Go to step 6. Check the fuser for obstructions. Is the fuser free from obstructions? Step 6 Go to step 7.
Page 82 5028 Action Step 12 Go to step 13. The problem is solved. Check the motor cable for proper connection and damage, and replace if necessary. Does the problem remain? Step 13 Contact the next The problem is level of support. solved.
Page 83 5028 Action Step 7 Go to step 8. The problem is solved. Replace the fuser. See “Fuser removal” on page 333. Does the problem remain? Step 8 Contact the next The problem is level of support. solved. Perform a print job. Does the problem remain? Sensor (fuser exit) static jam service check Action...
Page 84: Paper Jams
5028 Action Step 7 Contact the next The problem is level of support. solved. Check the sensor for damage, and replace if necessary. Perform a print job. Does the problem remain? 203 paper jams 203 paper jam messages Error code Description Action 203.91...
Page 85: Paper Jams
5028 Action Step 6 Go to step 7. The problem is solved. Check the cable on the JDSNS connector on the controller board for proper connection and damage, and replace if necessary. Does the problem remain? Step 7 Contact the next The problem is level of support.
Page 86: Paper Jams
5028 Action Step 5 Contact the next Go to step 6. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Narrow media). Does the sensor status change while toggling the sensor? Step 6 Go to step 7.
Page 87: Paper Jams
5028 Action Step 4 Go to step 5. The problem is solved. Remove the partially fed or jammed paper. Does the problem remain? Step 5 Contact the next Go to step 6. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics &...
Page 88 5028 Error code Description Action 230.25 Paper fed from tray 2 never cleared the sensor “Sensor (duplex path 1): Paper failed to (duplex path 1). clear service check” on page 230.32 Paper fed from tray 3 was detected earlier than “Sensor (duplex path 1): Paper arrived expected at the sensor (duplex path 1).
Page 89 5028 Action Step 5 Contact the next The problem is level of support. solved. Perform a print job. Does the problem remain? Sensor (duplex path 1): Paper failed to arrive service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings >...
Page 90 5028 Action Step 9 Go to step 11. Go to step 10. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Duplex path 1). Does the sensor status change while toggling the sensor? Step 10 Go to step 11.
Page 91 5028 Action Step 4 Go to step 5. The problem is solved. Change the paper size or adjust the size setting in the tray. Does the problem remain? Step 5 Go to step 7. Go to step 6. Check the paper path for paper jams and obstructions. Is the paper path free of jams and obstructions? Step 6 Go to step 7.
Page 92 5028 Action Step 12 Contact the next The problem is level of support. solved. Replace the motor. See “Motor (duplex/MPF) removal” on page 315. Perform a print job. Does the problem remain? Sensor (duplex path 1): Paper cleared too early service check Action Step 1 Go to step 3.
Page 93: Paper Jams
5028 Action Step 8 Contact the next The problem is level of support. solved. Perform a print job. Does the problem remain? 231 paper jams 231 paper jam messages Error code Description Action 231.12 Paper fed from tray 1 was detected earlier than “Sensor (duplex path 2): Paper arrived expected at the sensor (duplex path 2).
Page 94 5028 Sensor (duplex path 2): Paper arrived too early service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 95 5028 Action Step 3 Go to step 5. Go to step 4. Check the duplex paper path for paper jams and obstructions. Is the paper path free of jams and obstructions? Step 4 Go to step 5. The problem is solved.
Page 96 5028 Action Step 11 Go to step 12. The problem is solved. Check the duplex drive gears in the printer for damage, and replace if necessary. Does the problem remain? Step 12 Contact the next The problem is level of support. solved.
Page 97 5028 Action Step 7 Go to step 10. Go to step 8. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Duplex path 2). Does the sensor status change while toggling the sensor? Step 8 Go to step 9.
Page 98 5028 Action Step 2 Go to step 3. The problem is solved. Change the paper size or adjust the size setting in the tray. Does the problem remain? Step 3 Go to step 5. Go to step 4. Check the duplex rollers for damage. Are the rollers free of damage? Step 4 Go to step 5.
Page 99: Paper Jams
5028 Action Step 2 Go to step 3. The problem is solved. Change the paper size or adjust the size setting in the tray. Does the problem remain? Step 3 Go to step 5. Go to step 4. Check the paper path for partially fed or jammed paper. Is the paper path free of partially fed or jammed paper? Step 4 Go to step 5.
Page 100 5028 Error code Description Action 232.91 Paper remains detected at the sensor (duplex “Sensor (duplex path 2) static jam path 2) after the printer is turned on. service check” on page Sensor (MPF/pass‑through): Paper (duplex job) failed to arrive service check Action Step 1 Go to step 3.
Page 101 5028 Action Step 9 Go to step 10. The problem is solved. Check the sensor cable for proper connection and damage, and replace if necessary. Does the problem remain? Step 10 Go to step 11. The problem is solved. Replace the isolation unit. See “Isolation unit removal”...
Page 102 5028 Sensor (MPF/pass‑through): Paper (duplex job) failed to clear service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 103 5028 Action Step 10 Contact the next Go to step 11. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Motor tests > Deskew Touch Start. Does the motor run? Step 11 Go to step 12. The problem is solved.
Page 104: Paper Jams
5028 Action Step 5 Go to step 8. Go to step 6. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Input). Does the sensor status change while toggling the sensor? Step 6 Go to step 7.
Page 105 5028 Error code Description Action 240.82 The motor (duplex/MPF) has stalled. “Motor (duplex/MPF) jam service check” on page 115. 240.84 The motor (duplex/MPF) failed to achieve expected speed or has stalled. 240.91 Paper remains detected at the sensor (MPF/pass- “Sensor (MPF/pass-through) static jam through) after the printer is turned on.
Page 106 5028 Action Step 8 Go to step 9. Contact the next level of support. Check the sensor and sensor ﬂag for damage. Is the sensor or sensor ﬂag damaged? Step 9 Contact the next The problem is level of support. solved.
Page 107 5028 Action Step 8 Go to step 9. The problem is solved. Replace the pick rollers. Does the problem remain? Step 9 Go to step 11. Go to step 10. Check the pick rollers for proper installation. Firmly press the pick roller assembly upward to make sure that it is properly engaged to the shaft.
Page 108 5028 Action Step 17 Contact the next Go to step 18. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Motor tests > Duplex/MPF Select a setting, and then touch Start. Does the motor run? Step 18 Go to step 19.
Page 109 5028 Action Step 6 Go to step 7. The problem is solved. Replace the crumpled or damaged paper. Does the problem remain? Step 7 Go to step 9. Go to step 8. Check the condition of the tray 2 pick rollers. Are the pick rollers free from excess wear, contamination, and damage? Step 8...
Page 110 5028 Action Step 15 Go to step 16. The problem is solved. Check the sensor for damage, and replace if necessary. Does the problem remain? Step 16 Go to step 19. Go to step 17. Enter the Diagnostics menu, and then navigate to: Printer diagnostics &...
Page 111 5028 Action Step 3 Go to step 6. Go to step 4. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (MPF/pass‑through). Does the sensor status change while toggling the sensor? Step 4 Go to step 5.
Page 112 5028 Action Step 11 Contact the next The problem is level of support. solved. Replace the motor (550-sheet tray pass‑through). See “Motor (550-sheet tray pass‑through) removal” on page 376. Perform a print job. Does the problem remain? Sensor (MPF/pass-through): Paper (tray 4) failed to arrive service check Action Step 1 Go to step 3.
Page 113 5028 Action Step 8 Go to step 11. Go to step 9. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (Pass‑through (tray 2)). Does the sensor status change while toggling the sensor? Step 9 Go to step 10.
Page 114 5028 Action Step 15 Go to step 16. The problem is solved. Check the motor cable for proper connection and damage, and replace if necessary. Does the problem remain? Step 16 Go to step 17. The problem is solved. Replace the motor (550-sheet tray pass‑through). See “Motor (550-sheet tray pass‑through) removal”...
Page 115 5028 Action Step 3 Contact the next Go to step 4. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Sensor tests Find the sensor (MPF/pass‑through). Does the sensor status change while toggling the sensor? Step 4 Go to step 5.
Page 116: Paper Jams
5028 Action Step 6 Go to step 7. Go to step 8. Check the duplex and MPF paper path exiting tray 1. Is the paper path free of fragments and contamination? Step 7 Go to step 8. The problem is solved.
Page 117 5028 Error code Description Action 241.82 The motor (tray 1 pick) failed to achieve expected “Motor (tray 1 pick) jam service check” speed or has stalled. on page 123. 241.83 241.84 241.91 Paper remains detected at the sensor (tray 1 pick) “Sensor (tray 1 pick) static jam service after the printer is turned on.
Page 118 5028 Action Step 8 Go to step 9. The problem is solved. Check the sensor for damage and replace if necessary. See “Sensor (input) removal” on page 341. Does the problem remain? Step 9 Contact the next Go to step 10. level of support.
Page 119 5028 Action Step 5 Go to step 6. Go to step 7. Check the paper condition in tray 1. Is the paper crumpled or damaged? Step 6 Go to step 7. The problem is solved. Replace the crumpled or damaged paper. Does the problem remain? Step 7 Go to step 9.
Page 120 5028 Action Step 14 Go to step 15. The problem is solved. Check the sensor cable for proper connection and damage, and replace if necessary. Does the problem remain? Step 15 Go to step 16. The problem is solved. Check the sensor for damage, and replace if necessary. See “Sensor (input) removal”...
Page 121 5028 Action Step 2 Go to step 3. The problem is solved. Change the paper size or adjust the size setting in the tray. Does the problem remain? Step 3 Go to step 4. Go to step 5. Check the tray for overﬁlling. Is the tray overﬁlled? Step 4 Go to step 5.
Page 122 5028 Action Step 4 Go to step 5. The problem is solved. Remove the excess paper from the tray. Does the problem remain? Step 5 Go to step 6. Go to step 7. Check the paper condition in the tray. Is the paper crumpled or damaged? Step 6 Go to step 7.
Page 123 5028 Action Step 2 Go to step 3. The problem is solved. Change the paper size or adjust the size setting in the tray. Does the problem remain? Step 3 Contact the next Go to step 4. level of support. Enter the Diagnostics menu, and then navigate to: Printer diagnostics &...
Page 124: Paper Jams
5028 Action Step 5 Go to step 7. Go to step 6. Check the paper path exiting the tray. Is the paper path free of fragments and contamination? Step 6 Go to step 7. The problem is solved. Clean the paper path. Does the problem remain? Step 7 Contact the next...
Page 125 5028 Error code Description Action 242.26 Paper fed from tray 2 was picked but it never “Sensor (tray [x] pass-through): Tray [x] arrived at the sensor (tray 2 trailing edge). failed to pick service check” on page 141. 242.27 Paper fed from tray 2 never cleared the sensor “Sensors (tray [x] trailing edge and (tray 2 trailing edge).
Page 126 5028 Error code Description Action 242.47 Paper fed from tray 4 never cleared the sensor “Sensors (tray [x] trailing edge and (tray 2 trailing edge). pass‑through): Paper failed to clear service check” on page 143. 242.48 Paper fed from tray 4 was detected later than “Sensors (tray [x] trailing edge and expected at the sensor (tray 2 pass-through) or at pass-through): Paper arrived too late...
Page 127 5028 Error code Description Action 243.35 Paper fed from tray 3 cleared the sensor (tray 3 “Sensors (tray [x] trailing edge and pass-through) or the sensor (tray 3 trailing edge) pass-through): Paper cleared too late later than expected. service check” on page 138.
Page 128 5028 Error code Description Action 243.95 Paper cleared the sensor (tray 3 pass-through) or “Sensors (tray [x] trailing edge and the sensor (tray 3 trailing edge) later than pass-through): Paper cleared too late expected. Paper source is undetermined. service check” on page 138.
Page 129 5028 Error code Description Action 244.94 Paper cleared the sensor (tray 4 pass-through) or “Sensors (tray [x] trailing edge and pass- the sensor (tray 4 trailing edge) earlier than through): Paper cleared too early service expected. Paper source is undetermined. check”...
Page 130 5028 Action Step 6 Go to step 8. Go to step 7. Reseat the sensor cable, and then check the sensor for misalignment and damage. Is the sensor properly installed and free of damage? Step 7 Go to step 8. The problem is solved.
Page 131 5028 Action Step 3 Go to step 5. Go to step 4. Check the paper path for partially fed or jammed paper. Is the paper path free of partially fed or jammed paper? Step 4 Go to step 5. The problem is solved.
Page 132 5028 Action Step 11 Contact the next The problem is level of support. solved. Perform a print test. Does the problem remain? Sensor (tray 2 pass-through): Paper failed to arrive service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings >...
Page 133 5028 Action Step 9 Go to step 11. Go to step 10. Check the paper path for partially fed or jammed paper. Is the paper path free of partially fed or jammed paper? Step 10 Go to step 11. The problem is solved.
Page 134 5028 Action Step 17 Go to step 20. Go to step 18. Enter the Diagnostics menu, and then navigate to: Additional input tray diagnostics > Motor tests Find the motor (Pass-through (tray 3)), and then touch Start. Does the motor run? Step 18 Go to step 20.
Page 135 5028 Action Step 5 Go to step 6. Go to step 7. Check the paper tray for overﬁlling. Is the paper tray overﬁlled? Step 6 Go to step 7. The problem is solved. Remove the excess paper from the tray. Does the problem remain? Step 7 Go to step 8.
Page 136 5028 Action Step 14 Go to step 17. Go to step 15. Enter the Diagnostics menu, and then navigate to: Additional input tray diagnostics > Motor tests Find the motor (Pass-through (tray 3)), and then touch Start. Does the motor run? Step 15 Go to step 17.
Page 137 5028 Sensors (tray [x] trailing edge and pass-through): Paper cleared too early service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 138 5028 Action Step 10 Go to step 12. Go to step 11. Reseat the sensor cable, and then check the sensor for misalignment and damage. Is the sensor properly installed and free of damage? Step 11 Go to step 12. The problem is solved.
Page 139 5028 Action Step 3 Go to step 5. Go to step 4. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 4 Go to step 5. The problem is solved.
Page 140 5028 Action Step 12 Go to step 13. The problem is solved. Reinstall or replace the motor. See “Motor (duplex/MPF) removal” on page 315. Does the problem remain? Step 13 Go to step 16. Go to step 14. Enter the Diagnostics menu, and then navigate to: Additional input tray diagnostics >...
Page 141 5028 Sensor (tray [x] pass-through): Tray [x] failed to pick service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 142 5028 Action Step 10 Go to step 11. The problem is solved. Reinstall the pick roller assembly. Does the problem remain? Step 11 Go to step 13. Go to step 12. Check the condition of the pick rollers. Are the pick rollers free from excess wear, contamination, and damage? Step 12 Go to step 13.
Page 143 5028 Action Step 18 Go to step 21. Go to step 19. Enter the Diagnostics menu, and then navigate to: Additional input tray diagnostics > Motor tests > Motor tests > Pick (tray [x]) Select a setting, and then touch Start. Does the motor run? Step 19 Go to step 21.
Page 144 5028 Action Step 4 Go to step 5. The problem is solved. Remove the partially fed or jammed paper. Does the problem remain? Step 5 Go to step 8. Go to step 6. Enter the Diagnostics menu, and then navigate to: Additional input tray diagnostics >...
Page 145 5028 Action Step 12 Go to step 14. Go to step 13. Reseat the sensor cable, and then check the sensor for misalignment and damage. Is the sensor properly installed and free of damage? Step 13 Go to step 14. The problem is solved.
Page 146 5028 Action Step 3 Go to step 5. Go to step 4. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 4 Go to step 5. The problem is solved.
Page 147 5028 Action Step 13 Go to step 15. Go to step 14. Check the paper path exiting the paper tray. Is the paper path free of fragments and contamination? Step 14 Go to step 15. The problem is solved. Clean the paper path. Does the problem remain? Step 15 Go to step 18.
Page 148 5028 Action Step 21 Go to step 22. The problem is solved. Replace the media feeder. See “Media feeder removal” on page 373. Does the problem remain? Step 22 Go to step 25. Go to step 23. Enter the Diagnostics menu, and then navigate to: Additional input tray diagnostics >...
Page 149: User Attendance Messages
31.80' All fuser sensors are out of range. Reinstall the “Fuser service check” on page 184. fuser. Z code: • 31.xxN— Non-genuine Lexmark supply 32 user attendance error messages Error code Description Action 32.40z Cartridge compatibility problem. Replace the “Missing toner, developer, or unsupported black cartridge.
Page 150: User Attendance Error Messages
33.50z Non-Lexmark black developer. The smart chip contents have been manipulated by a third party manufacturer. 33.64z Non-Lexmark color imaging unit. The smart chip contents have been manipulated by a third party manufacturer. Z codes: • 33.xxA— Non-genuine Lexmark supply •...
Page 151: User Attendance Error Messages
5028 42 user attendance error messages Error code Description Action 42.xyK Printer and cartridge region mismatch. Replace “Region mismatch service check” on the black cartridge. page 158. 42.xyC Printer and cartridge region mismatch. Replace the cyan cartridge. 42. xyM Printer and cartridge region mismatch. Replace the magenta cartridge.
Page 152: User Attendance Error Messages
5028 80 user attendance error messages Error code Description Action 80.01 The maintenance kit is nearly low. The backup “Maintenance kit service check” on roll or fuser page count threshold has been page 159. reached. 80.09 The maintenance kit is nearly low. The user‑selected EWS set point has been reached.
Page 153: User Attendance Error Messages
5028 Error code Description Action 83.19 The transfer module is low. The user-selected EWS set point has been reached. 83.21 The transfer module is very low. The transfer module page count threshold has been reached. 83.29 The transfer module is very low. The user- selected EWS set point has been reached.
Page 154: User Attendance Error Messages
5028 85 user attendance error messages Error code Description Action 85.01 The black imaging unit is nearly low. The “Cartridge or photoconductor error service photoconductor threshold has been reached. check” on page 159. 85.09 The black imaging unit is nearly low. The user‑selected EWS set point has been reached.
Page 155: User Attendance Error Messages
5028 88 user attendance error messages Error code Description Action 88.01z The cartridge is nearly low. The TMC threshold “Cartridge or photoconductor error service has been reached. check” on page 159. 88.09z The cartridge is nearly low. The user‑selected EWS set point has been reached. 88.11z The cartridge is low, and [x] estimated pages remain.
Page 156: Missing Toner, Developer, Or Photoconductor Service Check
5028 Error code Description Action Defective ﬂash memory. “Flash memory failure service check” on page 162. Flash memory is full. “Insufficient ﬂash memory service check” on page 162. Unformatted ﬂash memory. “Flash memory failure service check” on page 162. Serial port or network error. “Flash memory failure service check”...
Page 157 5028 Action Step 3 Go to step 4. The problem is solved. Check the pogo pin contacts for damage, and replace if necessary. Does the problem remain? Step 4 Go to step 6. Go to step 5. Check the pogo pin contacts for dust or debris. Are the contacts free of dust or debris? Step 5 Go to step 6.
Page 158: Waste Toner Bottle Service Check
5028 Waste toner bottle service check Action Step 1 Go to step 2. The problem is solved. Reseat the waste toner bottle. Does the problem remain? Step 2 Go to step 4. Go to step 3. Check if the printer is placed on a ﬂat surface. Is the printer placed on a ﬂat surface? Step 3 Go to step 4.
Page 159: Maintenance Kit Service Check
5028 Maintenance kit service check Action Warning—Potential Damage: Do not perform this step if the Contact the next The problem is printer is on. level of support. solved. Replace the required maintenance kit. Reset the maintenance counter: • For 300K, enter the Conﬁguration menu, and then navigate to Reset Maintenance counter >...
Page 160: Mismatched Paper Size Service Check
5028 Mismatched paper size service check Action Step 1 Go to step 3. Go to step 2. From the home screen, touch Settings > Device > Preferences. Check if the paper size matches the size set on the tray guides. Does the paper size match the size set on the tray? Step 2 Go to step 3.
Page 161: Insufficient Memory Service Check
5028 Insufficient memory service check Action Step 1 Go to step 2. The problem is solved. Reset the printer, and then navigate to: Paper Menu > Print Settings > Download Target > Disk Does the problem remain? Step 2 Go to step 3. The problem is solved.
Page 162: Flash Memory Failure Service Check
5028 Flash memory failure service check Action Step 1 Go to step 2. The problem is solved. Navigate to Settings > Print settings > Job Accounting Menu Settings > Log Near Full Level. Make sure that the value is set to maximum.
Page 163: Unsupported Internal Option Service Check
5028 Action Step 4 Go to step 5. The problem is solved. Check the controller board pins for damage, and replace if necessary. See “Controller board removal” on page 357. Does the problem remain? Step 5 Contact the next The problem is level of support.
Page 164: Excess Options Service Check
5028 Action Step 3 Go to step 4. The problem is solved. If applicable, make sure that the option card is supported. Does the problem remain? Step 4 Go to step 5. The problem is solved. Check the controller board pins for damage, and replace if necessary.
Page 165: Incompatible Hardware Option Service Check
5028 Action Step 6 Contact the next The problem is level of support. solved. Check the controller board pins for damage, and replace if necessary. See “Controller board removal” on page 357. Does the problem remain? Incompatible hardware option service check Action Step 1 Go to step 2.
Page 166: Printer Hardware Errors
The problem is solved. Make sure that the ﬁrmware version installed is the latest. Note: The latest ﬁrmware versions are available on the Technical service bulletins at support.lexmark.com. Does the problem remain? Step 3 Go to step 4. The problem is solved.
Page 167 5028 Error code Description Action 100.35 The following sensors appear to be disconnected: “Sensor (duplex/MPF input) service check” on page 180. Sensor (MPF paper present) Sensor (duplex path 2) Sensor (fuser buckle) Sensor (narrow media) 100.36 The MPF paper present sensor is unplugged. 100.37 The duplex path 2 sensor is unplugged.
Page 168 5028 110 error messages Error code Description Action 110.20 Printhead error was detected before the motor “Printhead service check” on page 182. was turned on. 110.21 No printhead power when the laser servo started. 110.31 Printhead error (no ﬁrst Hysnc) was detected. 110.32 Printhead error (lost ﬁrst Hysnc) was detected.
Page 169 5028 121 error messages Error code Description Action 121.02 Fuser went over the required temperature during “Fuser service check” on page 184. EWC/line voltage detection. 121.03 Fuser hardware and driver mismatch. 121.06 Fuser power is at 100% but did not reach the required temperature.
Page 170 5028 Error code Description Action 121.33 Fuser did not reach the required temperature while “Fuser service check” on page 184. the page is in the fuser. 121.34 Fuser did not reach the required temperature during steady state control. 121.35 Fuser too warm to power up and execute EWC/line voltage detection after a wrong fuser was installed.
Page 171: Error Message
5028 126 and 127 error messages Error code Description Action 126.01 LVPS line voltage error was detected. “LVPS service check” on page 185. 126.02 LVPS line voltage error was detected. 126.06 LVPS 25V line error was detected. 126.07 LVPS 5V rail was down during POR. 126.10 No line frequency was detected.
Page 172 5028 144 error messages Error code Description Action 144.80 The motor (Y developer) did not turn on. “Motor (Y developer) service check” on page 188. 144.81 The motor (Y developer) did not turn off. 144.82 The motor (Y developer) speed did not ramp up to the required level.
Page 173 5028 149 error messages Error code Description Action 149.80 The motor (output) did not turn on. “Motor (output) service check” on page 191. 149.81 The motor (output) did not turn off. 149.82 The motor (output) speed did not ramp up to the required level.
Page 174 5028 161 and 162 error messages Error code Description Action 161.80 The motor (tray 1 pick) did not turn on. “Tray pick roller assembly and lift motor service check” on page 196. 161.81 The motor (tray 1 pick) did not turn off. 161.82 The motor (tray 1 pick) speed did not ramp up to the required level.
Page 175 5028 153 error messages Error code Description Action 153.80 The isolation unit did not turn on. “Isolation unit service check” on page 194. 153.81 The isolation unit did not turn off. 153.82 The isolation unit speed did not ramp up to the required level.
Page 176 5028 166–168 error messages 166.80 The motor (tray 2 pass-through) did not turn on. “Motor (tray [x] transport) failure service check” on page 198. 166.81 The motor (tray 2 pass-through) did not turn off. 166.82 The motor (tray 2 pass-through) speed did not ramp up to the required level.
Page 177 5028 Error code Description Action 172.82 The LVPS fuser fan peed did not ramp up to the “LVPS fuser fan service check” on required level. page 199. 172.83 The LVPS fuser fan stalled. 172.84 The LVPS fuser fan ran too slow. 172.85 The LVPS fuser fan ran too fast.
Page 178 5028 Action Step 8 Go to step 9. The problem is solved. Check the green, yellow, and blue cables connecting the JPKSNS1 connector to the blue and green cables on the isolation unit for proper connection and damage. Replace the cables if necessary. Does the problem remain? Step 9 Contact the next...
Page 179 5028 Action Step 4 Contact the next The problem is level of support. solved. Check the sensors for damage, and replace if necessary. Does the problem remain? Fuser sensors service check Action Step 1 Go to step 2. Go to step 3. Check the error that appeared.
Page 180 5028 Sensor (duplex/MPF input) service check Action Step 1 Go to step 2. Go to step 5. Check the error that appeared. Is the error 100.35? Step 2 Go to step 4. Go to step 3. Remove the cable cover from the front door. Check if the cable is properly connected to the door and to the JMSNS1 connector on the controller board.
Page 181 5028 Sensor (weather station) service check Action Step 1 Go to step 2. The problem is solved. Check the sensor cable for proper connection and damage, and replace if necessary. Does the problem remain? Step 2 Contact the next The problem is level of support.
Page 182: Printhead Service Check
5028 Action Step 6 Go to step 7. The problem is solved. Replace the input option controller board. See “550-sheet tray controller board assembly removal” on page 382. Does the problem remain? Step 7 Contact the next The problem is level of support.
Page 183 5028 Motor (fuser) service check Action Step 1 Go to step 2. The problem is solved. Reset the printer. Does the problem remain? Step 2 Go to step 3. Go to step 4. Check the fuser for damage or life expiration, and replace if necessary.
Page 184: Fuser Service Check
5028 Fuser service check Action Step 1 Go to step 3. Go to step 2. Check the fuser for proper installation. Is the fuser properly installed? Step 2 Go to step 3. The problem is solved. Reinstall the fuser. Does the problem remain? Step 3 Go to step 5.
Page 185: Lvps Service Check
5028 LVPS service check Action Step 1 Go to step 2. The problem is solved. Reset the printer. Does the problem remain? Step 2 Go to step 4. Go to step 3. Check the LVPS cable on the JLVPS connector on the controller board for proper connection.
Page 186 5028 Action Step 3 Go to step 4. The problem is solved. Reconnect the cable. Does the problem remain? Step 4 Go to step 5. The problem is solved. Check the cable for damage, and replace if necessary. Does the problem remain? Step 5 Go to step 6.
Page 187 5028 Action Step 4 Go to step 5. The problem is solved. Replace the motor (EP drive). See “Motor (EP drive) removal” on page 296. Does the problem remain? Step 5 Contact the next The problem is level of support. solved.
Page 188 5028 Motor (Y developer) service check Action Step 1 Go to step 2. The problem is solved. Reset the printer. Does the problem remain? Step 2 Go to step 3. Go to step 6. Remove the imaging kit, and then remove the transfer module. “Transfer module removal”...
Page 189 5028 Action Step 9 Go to step 10. The problem is solved. Replace the motor (Y developer). See “Motor (EP drive) removal” on page 296. Does the problem remain? Step 10 Contact the next The problem is level of support. solved.
Page 190 5028 Action Step 6 Go to step 7. The problem is solved. Reconnect the cable. Does the problem remain? Step 7 Go to step 8. The problem is solved. Check the cable for damage, and replace if necessary. Does the problem remain? Step 8 Go to step 9.
Page 191 5028 Action Step 5 Go to step 7. Go to step 6. Check the cable on the motor and on the JMTR1 connector on the controller board for proper connection. Is the cable properly connected at both ends? Step 6 Go to step 7.
Page 192 5028 Action Step 4 Go to step 5. The problem is solved. Replace the motor. See “Motor (output) removal” on page 297. Does the problem remain? Step 5 Go to step 6. The problem is solved. Reset the printer. Does the problem remain? Step 6 Contact the next The problem is...
Page 193 5028 Action Step 6 Contact the next The problem is level of support. solved. Replace the controller board. See “Controller board removal” on page 357. Does the problem remain? Motor (K developer) service check Action Step 1 Go to step 2. The problem is solved.
Page 194 5028 Action Step 7 Go to step 8. The problem is solved. Reconnect the cable. Does the problem remain? Step 8 Go to step 9. The problem is solved. Check the cable for damage, and replace if necessary. Does the problem remain? Step 9 Go to step 10.
Page 195 5028 Action Step 5 Go to step 7. Go to step 6. Check the cable on the motor and on the JMTR1 connector on the controller board for proper connection. Is the cable properly connected at both ends? Step 6 Go to step 7.
Page 196 5028 Tray 1 sensor (media out) cable is unplugged service check Action Step 1 Go to step 2. The problem is solved. Check the cable on the JMTR1 connector on the controller board for proper connection, and reseat if necessary. Does the problem remain? Step 2 Go to step 3.
Page 197 5028 Action Step 6 Go to step 7. The problem is solved. Replace the media feeder. See “Media feeder removal” on page 373. Does the problem remain? Step 7 Contact the next The problem is level of support. solved. Replace the controller board. See “Controller board removal”...
Page 198 5028 Motor (tray [x] transport) failure service check Action Step 1 Go to step 2. The problem is solved. Reset the printer Does the problem remain? Step 2 Go to step 4. Go to step 3. Check the connections between the motor (tray [x] transport) and controller board.
Page 199 5028 Motor (pick and lift) service check Action Step 1 Go to step 2. The problem is solved. Check the pick roller for damage and proper installation, and replace if necessary. Does the problem remain? Step 2 Go to step 3. The problem is solved.
Page 200: Main Fan Service Check
5028 Action Step 4 Go to step 5. The problem is solved. Reconnect the cable. Does the problem remain? Step 5 Go to step 6. The problem is solved. Replace the fuser fan. See “Fuser fan removal” on page 299. Does the problem remain? Step 6 Contact the next...
Page 201: Yy Errors
5028 6yy errors 647 error messages Error code Description Action 647.80 The motor (deskew) did not turn on. “Motor (deskew) service check” on page 190. 647.81 The motor (deskew) did not turn off. 647.82 The motor (deskew) speed did not ramp up to the required level.
Page 202 5028 653 error messages Error code Description Action 653.80 The motor (ISO) did not turn on. “Isolation unit service check” on page 194. 653.81 The motor (ISO) did not turn off. 653.82 The motor (ISO) speed did not ramp up to the required level.
Page 203 5028 Motor (tray 1 pick) lifting error service check Action Step 1 Go to step 2. The problem is solved. Reset the printer. Does the problem remain? Step 2 Go to step 3. The problem is solved. Make sure that the tray insert is properly seated or fully inserted. Does the problem remain? Step 3 Go to step 8.
Page 204 5028 Action Step 10 Go to step 13. Go to step 11. Check the motor (tray 1 pick) for proper operation and noise. Remove the tray insert. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Motor tests > Pick (tray Select Pick (tray 1) lifting, and then touch Start.
Page 205 5028 Action Step 4 Go to step 6. Go to step 5. Check the cable that connects the sensor (tray [x] pick roller index) to the controller board. Are both ends of the cable properly seated? Step 5 Go to step 6. The problem is solved.
Page 206 5028 Action Step 12 Go to step 13. The problem is solved. Replace the paper feeder. See “Media feeder removal” on page 373. Does the problem remain? Step 13 Contact the next The problem is level of support. solved. Reset the printer. Does the problem remain? Motor (tray [x] pass‑through) stalled service check Action...
Page 207: Yy Errors
5028 Action Step 6 Contact the next The problem is level of support. solved. Replace the controller board. See “550-sheet tray controller board assembly removal” on page 382. Does the problem remain? 9yy errors Procedure before starting the 9yy service checks You will need to retrieve certain information.
Page 208 5028 • Fwedebugs can also be referred to as LBtrace. If FWEdebugs does not appear in the list, then look for LBtrace. Multiple LBtrace logs can appear in the list of links referred to in step 2. Open a Web browser, type http://printer_IP_address/se, and then press Enter. Click List Fwedebugs captured during reboots.
Page 209 5028 91y error messages Error code Description Action 910.xx A general engine software error. “91x.xx (910.xx‑919.xx) Engine software service check” on page 218. 911.xx A general engine software error. 912.xx A general engine software error. 913.xx A general engine software error. 914.xx A general engine software error.
Page 210 5028 Error code Description Action 954.xx The NVRAM chip failure with controller part. Go to “950.xx NVRAM failure service check” on page 218. 955.xx The Code ROM or NAND ﬂash failed the Cyclic Redundancy Check (CRC) check or the NAND experienced an uncorrectable multi- bit failure.
Page 211 5028 97y error messages Error code Description Action 975.xx Network error: unrecognizable network port. Replace the standard network card or the card in the speciﬁed slot. 975.xx 976.xx Unrecoverable software or error in network “Standard network/network card or network card x. error service check”...
Page 212 5028 980–984 error messages Error code Description Action 980.xx Engine experiencing unreliable “Options communication error communication with the speciﬁed device. service check” on page 222. Note: <device> can be one of the following: • Tray 2 • Tray 3 • Tray 4 981.xx Engine protocol violation detected by the...
Page 213 207. Determine the operating system used when the error occurred. If possible, determine whether a PostScript or PCL ﬁle was sent to the printer when the error occurred. Ask the customer which Lexmark Solutions applications are installed on the printer.
Page 214 5028 Action Step 5 Go to step 31. The problem is solved. Replace the controller board. See “Controller board removal” on page 357. Reset the printer. Note: If a different error code displays, then go to the service check for that error code. Does the problem remain? Step 6 Go to step 31.
Page 215 Perform a print job. Does the problem remain? Step 15 Go to step 31. The problem is solved. Install a Lexmark‑recommended memory option. Perform a print job. Does the problem remain? Step 16 Go to step 17. Go to step 21.
Page 216 5028 Action Step 18 Go to step 19. The problem is solved. Upgrade the ﬁrmware if it was not upgraded in a previous step. Note: Contact your next level of support for the correct ﬁrmware level to use. Reset the printer. Perform a print job.
Page 217 5028 Action Step 25 Go to step 31. Go to step 26. Replace the faulty ISP option. Reset the printer. Does the problem remain? Step 26 Go to step 27. The problem is solved. Verify if there are more ISP options to install? Are there more ISP options to install? Step 27 Go to step 29.
Page 218 5028 91x.xx (910.xx‑919.xx) Engine software service check Actions Step 1 Go to step 2. Go to step 3. Remove the controller board shield. See “Controller board shield removal” on page 356. Check the cables on the controller board for proper connection.
Page 219 5028 Actions Step 4 Go to step 5. The problem is solved. Replace the controller board with a new, and not previously installed, controller board. See “Controller board removal” on page 357. Does the problem remain? Step 5 Go to step 6. The problem is solved.
Page 220 5028 Invalid ﬁrmware/controller board service check Action Step 1 Go to step 2. The problem is solved. Update the printer ﬁrmware. Note: Contact the next level of support for the correct ﬁrmware level. Does the problem remain? Step 2 Contact the next The problem is level of support.
Page 221 5028 Standard network/network card error service check Action Step 1 Go to step 2. Go to step 3. Check if the network card is installed. Is the network card installed? Step 2 Contact the next The problem is level of support. solved.
Page 222 5028 Options communication error service check Action Step 1 Go to step 2. The problem is solved. Check if the ﬁrmware is updated, and then update the ﬁrmware if necessary. Make sure that the printer supports the option. See the Printer, Option, and Stand Compatibility Guide.
Page 223: Symptoms
5028 Symptoms Base printer symptoms Symptom Action Printer has no power. “Dead machine service check” on page 226. Control panel not functioning. “Control panel service check” on page 223. False values for the front door appear on the “Interlock switch service check” on page 224.
Page 224: Interlock Switch Service Check
5028 Action Step 6 Go to step 7. The problem is solved. Check the cable for damage, and replace if necessary. Does the problem remain? Step 7 Go to step 8. The problem is solved. Replace the control panel cable. Does the problem remain? Step 8 Go to step 12.
Page 225 5028 Action Step 2 Go to step 4. Go to step 3. Check the sensor cable for proper connection. Is the cable properly connected? Step 3 Go to step 4. The problem is solved. Reconnect the cable. Does the problem remain? Step 4 Go to step 6.
Page 226: Sensor (Narrow Media) And Sensor (Fuser Buckle) Service Check
5028 Action Step 11 Contact the next The problem is level of support. solved. Replace the controller board. See “Controller board removal” on page 357. Does the problem remain? Sensor (narrow media) and sensor (fuser buckle) service check Actions Step 1 Go to step 2.
Page 227 5028 Action Step 3 Go to step 4. The problem is solved. Check the power cord for damage, and replace if necessary. Does the problem remain? Step 4 Go to step 6. Go to step 5. Check the cable on the LVPS and on the JLVPS connector on the controller board for proper connection.
Page 228: Mobile Solutions Module Nfc Service Check
Does the problem remain? Step 5 Go to step 7. Go to step 6. Make sure that the latest version of the Lexmark Mobile Printing application is installed on the Android device. Is the latest version of the application installed? Step 6 Go to step 7.
Page 229: Network Service Check
• Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. • For more network troubleshooting information, consult the Lexmark Network Setup Guide. Diagnostic information...
Page 230 5028 Actions Step 1 Go to step 2. The problem is solved. If the printer is physically connected to the network, make sure that the Ethernet cable is properly connected on both ends. Does the problem remain? Step 2 Go to step 4. Go to step 3.
Page 231 5028 Actions Step 10 Go to step 11. The problem is solved. Using the subnet address supplied by the network administrator, assign a unique IP address to the printer. Note: The printer IP address should match the IP address on the print driver.
Page 232: Toner Meter Cycle (Tmc) Card Service Check
5028 Actions Step 19 Go to step 20. The problem is solved. If there is an attached antenna, check it for damage, and replace if necessary. Does the problem remain? Step 20 Go to step 21. The problem is solved. Make sure that the antenna is properly connected to the wireless card.
Page 233: Usb Service Check
5028 USB service check Actions Step 1 Go to step 2. Properly connect the cable at both ends. Is the USB cable properly connected to the printer and host PC? Step 2 Issue ﬁxed. Go to step 3. Try a different USB cable. Does this ﬁx the issue? Step 3 Replace the...
Page 234: Toner Patch Sensing Service Check
5028 Toner patch sensing service check Pre‑check procedure Enter the Diagnostics menu, and then navigate to: Printer setup > EP setup > Toner patch sensor adjust > Clean sensing and laser optics Allow the cleaning operation to run for three minutes. Enter the Diagnostics menu, and then navigate to: Printer diagnostics &...
Page 235 5028 Action Step 1 Go to step 2. The problem is solved. From the home screen, touch Settings > Reports > Print Quality Pages. On the Device information section of the print quality test page, check the CalSet values of the following: •...
Page 236: Auto Alignment Service Check
5028 Action Step 6 Go to step 7. The problem is solved. Reinstall, repair, or replace the TPS sled and wiper mechanism. Perform the auto alignment service check. See “Auto alignment service check” on page 236. Does the problem remain? Step 7 Go to step 8.
Page 237 5028 • AA Result 7—Coarse data within limits • AA Result 8—Coarse data deﬁcient • AA Result 9—Coarse failed to converse • AA Result 10—Coarse exceeds sense limits • AA Result 11—Coarse exceeds margin limits • AA Result 12—Coarse corrections applied •...
Page 238 5028 Action Step 2 The problem is Go to step 3. solved. Perform the blank or white pages service check or missing color service check. See “Blank or white pages check” on page 37 “Missing color check” on page Enter the Diagnostics menu, and then navigate to: Printer setup >...
Page 239 5028 Action Step 6 Go to step 7. The problem is solved. Check the cables on the sensor (auto alignment) and on the JTPSAA1 connector on the controller board for proper connection, and reseat if necessary. Does the problem remain? Step 7 The problem is Contact the next...
Page 240 5028...
Page 241: Service Menus
5028 Service menus Understanding the printer control panel Using the control panel Use the Display • View the printer messages and supply status. • Set up and operate the printer. Home button Go to the home screen. Keypad Enter numbers or symbols in an input ﬁeld. Power button •...
Page 242: Understanding The Status Of The Power Button And Indicator Light
5028 Understanding the status of the power button and indicator light Indicator light Printer status The printer is off or in Hibernate mode. Blue The printer is ready or processing data. The printer requires user intervention. Power button light Printer status The printer is off, ready, or processing data.
Page 243: Menus List
Bin Conﬁguration AirPrint Alert Types Job Accounting Ethernet Anti‑Spam Logic Description Image TCP/IP Suppressing Duplicate Alerts IPv6 Power Management SNMP Information Sent to Lexmark HTML 802.1x Accessibility PostScript IPSec Restore Factory Defaults LPD Conﬁguration Maintenance PPDS HTTP/FTP Settings Remote Operator Panel...
Page 244: Diagnostics Menu
5028 Security Option Card Menu Reports Help Login Methods Note: This setting appears Menu Settings Page Print All Guides only when an optional card is Certiﬁcate Management Print Quality Pages Color Quality Guide installed. Schedule USB Devices Device Connection Guide Security Audit Log Print Information Guide...
Page 245: Reports
5028 Print Log Summary This setting lists a brief summary of the various printer events. Enter the Diagnostics menu, and then navigate to: Event Log > Print Log Summary Touch Start. Note: The events that appear in the report vary depending on the operational history of the printer. Mark Log This setting allows you to create a service, maintenance, or custom log entry.
Page 246: Printer Setup
5028 Select whether to print a single or continuous test page, and then touch Start. Printer Setup Printed page count (mono) This setting displays the amount of pages printed in mono. Enter the Diagnostics menu, and then touch Printer Setup. View the printed page count for mono.
Page 247 5028 Processor ID This setting indicates the ID of the processor on the controller board. Enter the Diagnostics menu, and then touch Printer Setup. View the processor ID. Serial number This setting displays a read-only value of the serial number. Enter the Diagnostics menu, and then touch Printer Setup.
Page 248: Printer Diagnostics And Adjustments
5028 Printer diagnostics and adjustments Sensor tests Enter the Diagnostics menu, and then touch Printer diagnostics & adjustments. From the Sensor tests section, touch Start. A dialog listing the sensor tests appears. Find, and then manually toggle the sensor. Notes: •...
Page 249 5028 Color alignment adjust This setting allows you to adjust the color alignments and to print or reset the default settings. Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Color alignment adjust Select a setting. Supply reset The setting resets the fuser and ITM counter values to zero.
Page 250: Additional Input Tray Diagnostics
5028 Additional input tray diagnostics Sensor tests Enter the Diagnostics menu, and then touch Additional input tray diagnostics. From the Sensor tests section, touch Start. A dialog listing the sensor tests appears. Find, and then manually toggle the sensor. Notes: •...
Page 251: General Se
5028 General SE This setting allows you to save a log ﬁle to a USB drive. Enter the Service Engineer (SE) menu, and then navigate to: General SE > Capture Logs to USB Drive Network SE Enter the Service Engineer (SE) menu, and then touch Network SE. Note: Use these settings as directed by the next level of support.
Page 252 5028...
Page 253: Repair Information
5028 Repair information Removal precautions CAUTION—SHOCK HAZARD: To avoid the risk of electrical shock and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and computers or peripherals.
Page 254: Handling Esd‑Sensitive Parts
5028 To erase the hard disk memory: From the home screen, touch Settings > Device > Maintenance > Out of Service Erase. Select the Sanitize all information on hard disk check box, and then touch ERASE. Follow the instructions on the display. Notes: •...
Page 255: Restoring The Printer Conﬁguration After Replacing The Controller Board
Note: The software bundle contains the latest version of the ﬁrmware, applications, and software licenses from the Lexmark Virtual Solutions Center (VSC). The printer ﬁrmware may be at a different level from what was used before replacing the controller board.
Page 256 5028 Save the zip ﬁle. Note: Make sure that the serial number in the zip ﬁle matches the serial number of the printer being restored. Extract the contents of the zip ﬁle, open the Readme ﬁle, and then follow the instructions in the ﬁle. Notes: •...
Page 257 5028 After performing the installation instructions in the Readme ﬁle, conﬁrm from the customer if all the eSF apps have been installed. Notes: • If you are unable to access the administrative menus to verify that the printer is restored, then ask the customer for access rights.
Page 258: Restoring Solutions, Licenses, And Conﬁguration Settings
5028 Restoring solutions, licenses, and conﬁguration settings To load the zip ﬁles that are extracted from the Service Restore Tool, do the following: Open a Web browser, and then type the printer IP address. Click Apps. Click Import Conﬁguration. Select the zip ﬁle from the expanded Service Restore Tool package. Repair information...
Page 259: Updating The Printer Firmware
5028 Click Import. Repeat steps 3 through 5 for the other zip ﬁles that are included in the expanded zip ﬁle. Updating the printer ﬁrmware Warning—Potential Damage: Before updating the printer ﬁrmware, ask the next level of support for the correct code.
Page 260: Backing Up Esf Solutions And Settings
5028 Using a network computer Using the File Transfer Protocol (FTP) Make sure that the printer is in ready state before ﬂashing. Turn on the printer. Obtain the IP address: • From the home screen • From the TCP/IP section of the Network/Ports menu From the command prompt of a network computer, open an FTP session to the printer IP address.
Page 261: Adjustments
5028 Adjustments Printhead alignment adjustment Printhead misalignment may cause crooked or skewed print. Perform this procedure after replacing the printhead or if there are skewed print issues. Checking the test page for alignment Enter the Diagnostics menu, and then navigate to: Printer diagnostics &...
Page 262 5028 Aligning a printhead skewed in the counterclockwise direction In most cases, the printhead is skewed counterclockwise, as shown in the following test page result. Remove the top cover. See “Top cover removal” on page 268. Loosen the three screws. Repair information...
Page 263: Registration Adjustment
5028 Adjust the printhead until the bottom left corner of the printhead touches the alignment pin (A). Print another test page, and then check if the printhead is aligned. Repeat steps 4 and 5 until the printhead is aligned. Tighten the three screws. Registration adjustment Image misalignments may occur after printhead replacement.
Page 264 5028 A test page showing the margins is generated. Right Left Bottom Adjusting the margins Note: The procedure may not work for old ﬁrmware versions. Make sure that the latest ﬁrmware version is installed. Refer to the test page generated for margin alignment. Check the arrows along the margin.
Page 265: Removal Procedures
5028 Enter the Diagnostics menu, and then navigate to: Printer diagnostics & adjustments > Color alignment adjust On the AA Adjustment row, touch Start. The Color alignment procedure is performed on the cyan, magenta, and yellow colors. Note: The procedure may not work for old ﬁrmware versions. Make sure that the latest ﬁrmware version is installed.
Page 266 5028 Remove the screw (B) securing the ground cables. Repair information...
Page 267 5028 Remove the two screws (C). Disconnect the cable (D), and then remove the screw (E). Remove the straps from the duplex outer guide. Remove the front cover from the duplex outer guide. See “Duplex outer guide removal” on page 289.
Page 268: Top Cover Removal
5028 Top cover removal Open the toner door cover. Remove the two screws (A) on the upper-left corner of the printer. Repair information...
Page 269 5028 Remove the two screws (B) on the top of the printer. Repair information...
Page 270 5028 Remove the screw (C) on the output bin. Disconnect the sensor cable (D), and then remove the cover. Repair information...
Page 271: Left Cover Removal
5028 Left cover removal Open the front door. Remove the two screws (A) on the front of the cover. Remove the three screws (B) on the left side of the cover. Repair information...
Page 272: Right Cover Removal
5028 Remove the three screws (C) on the rear of the cover, and then remove the cover. Right cover removal Remove the motor cover. See “Motor cover removal” on page 273. Remove the waste toner bottle. Repair information...
Page 273: Motor Cover Removal
5028 Remove the ﬁve screws (A). Remove the right cover from the printer. Remove the right cover from the imaging unit cover. See “Imaging unit cover removal” on page 324. Motor cover removal Open the toner door. Open the imaging unit cover. Repair information...
Page 274 5028 Remove the three screws (A). Repair information...
Page 275 5028 Open the front cover, and then remove the screw (B) from the front of the cover. Disconnect the cable (C), and then remove the cover. Repair information...
Page 276: Toner Door Removal
5028 Toner door removal Open the toner door, and then remove the two outer screws (A) from the door bracket. Repair information...
Page 277 5028 Remove the two inner screws (B) from the door bracket. Gently pull the toner door away from the bracket to remove. Repair information...
Page 278: Toner Door Mount Bracket Removal
5028 Toner door mount bracket removal Remove the toner door. See “Toner door removal” on page 276. Remove the six screws (A), and then remove the bracket. Repair information...
Page 279: Toner Door Mount Removal
5028 Toner door mount removal Remove the toner door. See “Toner door removal” on page 276. Unhook the spring (A), and then remove the two screws (B) on the rear side. Unhook the spring (C), and then remove the two screws (D) on the front. Remove the toner door mount from the printer.
Page 280: External Air Filter Removal
5028 External air ﬁlter removal Firmly hold the air ﬁlter. Pull the air ﬁlter to remove. Control panel removals Upper control panel removal Remove the badge cover. See “Badge cover removal” on page 283. Remove the number pad cover. See “Number pad cover removal”...
Page 281 5028 Remove the ﬁve screws (A). Release the three tabs (B) securing the upper control panel. Repair information...
Page 282 5028 Disconnect the two cables (C). Warning—Potential Damage: Do not yank the ribbon cable. See “Disconnecting ribbon cables” on page 260. Remove the four screws (D), and then remove the control panel. Repair information...
Page 283: Badge Cover Removal
5028 Badge cover removal Carefully pull to detach the badge cover. Remove the cover Repair information...
Page 284: Number Pad Cover Removal
5028 Number pad cover removal Remove the badge cover. See “Badge cover removal” on page 283. Remove the number pad cover. Control panel arms removal Note: The control panel arms are two separate FRUs. This procedure shows how to remove both arms. Remove the fuser.
Page 285 5028 Disconnect the cable (A), and then remove the two screws (B). Remove the arm, and then route the cables (C) out of the right arm. Repair information...
Page 286: Speaker Removal
5028 Remove the left arm (D) from the mounting pin. Carefully remove the ribbon cable (E), and then route the control panel cable (F) and headphone cable (G) out of the arm. Speaker removal Remove the badge cover. See “Badge cover removal” on page 283.
Page 287: Control Panel Base Cover Removal
5028 Disconnect the speaker cable (A), remove the two screws (B), and then remove the speaker. Control panel base cover removal Remove the badge cover. See “Badge cover removal” on page 283. Remove the number pad cover. See “Number pad cover removal” on page 284.
Page 288 5028 Remove the headphone port (D). Repair information...
Page 289: Duplex Removals
5028 Remove the four screws (E), and then remove the cover. Duplex removals Duplex outer guide removal Remove the front cover. See “Front cover removal” on page 265. Remove the pivot shaft. See “Pivot shaft removal” on page 291. Remove the duplex inner guide. See “Duplex inner guide removal”...
Page 290 5028 Remove the ten screws (A). Remove the tray indicator (B), and then remove the duplex outer guide. Repair information...
Page 291: Duplex Inner Guide Removal
5028 Duplex inner guide removal Remove the front cover. See “Front cover removal” on page 265. Remove the pivot shaft. See “Pivot shaft removal” on page 291. Release the latch (A), and then slide the guide to remove. Pivot shaft removal Remove the front cover.
Page 292: Tensioner Belt Removal
5028 Tensioner belt removal Remove the front cover. See “Front cover removal” on page 265. Remove the duplex inner guide. See “Duplex inner guide removal” on page 291. Remove the pivot shaft. See “Pivot shaft removal” on page 291. Remove the six screws (A), and then remove the cover. Remove the belt.
Page 293: Sensor (Duplex) Removal
5028 Sensor (duplex) removal Remove the front cover. See “Front cover removal” on page 265. Remove the duplex inner guide. See “Duplex inner guide removal” on page 291. Remove the pivot shaft. See “Pivot shaft removal” on page 291. Remove the six screws (A). Repair information...
Page 294: Sensors (Fuser Buckle And Narrow Media) Removal
5028 Disconnect the sensor cable (B), and then remove the sensor (C). Sensors (fuser buckle and narrow media) removal Open the front cover. Remove the screw (A). Repair information...
Page 295 5028 Slide the paper guide to the right to remove. Disconnect the sensor cable (B), remove the screw (C), and then remove the sensors. Note: The left sensor is the sensor (fuser buckle). The right sensor is the sensor (narrow media). Repair information...
Page 296: Left Removals
5028 Left removals Motor (EP drive) removal This removal shows how to remove all three motors. The motors can be replaced individually. Remove the left cover. See “Left cover removal” on page 271. On each of the motor, disconnect the motor cable (A), remove the four screws (B), and then remove the motor.
Page 297: Power Cable Removal
5028 Power cable removal Remove the left cover. See “Left cover removal” on page 271. Disconnect the power cable from the LVPS. Remove the two screws (A). Remove the cable from the cable ties (B). Disconnect the cable from the LVPS. Motor (output) removal Remove the left cover.
Page 298 5028 Disconnect the motor cable (A). Remove the three screws (B), and then remove the motor. Repair information...
Page 299: Motor (Deskew) Removal
5028 Motor (deskew) removal Remove the left cover. See “Left cover removal” on page 271. Disconnect the motor cable (A). Remove the two screws (B), and then remove the motor. Fuser fan removal Remove the left cover. See “Left cover removal” on page 271.
Page 300 5028 Disconnect the fuser fan cable (A) from the controller board. Remove the two screws (B). Repair information...
Page 301: Main Fan Removal
5028 Route the fuser fan cable out of the retainers (C), and then remove the fan. Main fan removal Remove the left cover. See “Left cover removal” on page 271. Remove the controller board shield. See “Controller board shield removal” on page 356.
Page 302: Ep Gear Box Removal
5028 Remove the two screws (B), and then route the fan cable through the hole in the frame to remove the fan. EP gear box removal Remove the left cover. See “Left cover removal” on page 271. Route the cable out of the guides (A). Repair information...
Page 303 5028 Disconnect the three motor cables (B). Route the motor cables out of the guides (C) from under the gear box. Repair information...
Page 304 5028 Remove the two screws (D) from under the gear box. Repair information...
Page 305: Lvps Removal
5028 Remove the two screws (E) from the top-left and top-right corners of the EP drive, and then remove the gear box. LVPS removal CAUTION—SHOCK HAZARD: The LVPS may have residual voltage present. To avoid the risk of electrical shock, do not touch its circuit components. Only handle it by its outer edges. Open the front door.
Page 306 5028 Disconnect the cable (A) from the LVPS. Repair information...
Page 307 5028 Remove the seven screws (B). Disconnect the two cables (C), and then remove the LVPS. Repair information...
Page 308: Lvps Cage Removal
5028 LVPS cage removal Note: This is not a FRU. Remove the left cover. See “Left cover removal” on page 271. Remove the LVPS. See “LVPS removal” on page 305. Remove the two screws (A) from the right side of the cage. Repair information...
Page 309: Motor (Black Only Retract) Removal
5028 Remove the ﬁve screws (B) from the inside of the cage, and then remove the cage. Motor (black only retract) removal Remove the front cover. See“Front cover removal” on page 265. Remove the left cover. See “Left cover removal” on page 271.
Page 310 5028 Disconnect the black only retract motor cable (A). Remove the two screws (B). Repair information...
Page 311: Right Removals
5028 Remove the two screws (C), and then remove the motor. Right removals Sensor (weather station) removal Remove the waste toner bottle. Remove the motor cover. See “Motor cover removal” on page 273. Remove the right cover. See “Right cover removal” on page 272.
Page 312: Sensor (Paper Size) Removal
5028 Remove the screw (A), disconnect the cable (B), and then remove the sensor. Sensor (paper size) removal Remove the waste toner bottle. Remove the motor cover. See “Motor cover removal” on page 273. Remove the right cover. See “Right cover removal” on page 272.
Page 313 5028 Pull the mounting assembly away from the printer. Disconnect the sensor cable (B). Repair information...
Page 314: Sensor (Waste Toner Contact) Removal
5028 Release the two tabs (C) from the mounting assembly, and then remove the sensor. Sensor (waste toner contact) removal Remove the waste toner bottle. Remove the motor cover. See “Motor cover removal” on page 273. Remove the sensor (paper size). See “Sensor (paper size) removal”...
Page 315: Tmc Card Removal
5028 TMC card removal Remove the imaging unit. Remove the two screws (A) securing the TMC cover. Disconnect the cable (B), and then remove the TMC card from the cover. Motor (duplex/MPF) removal Remove the right cover. See “Right cover removal” on page 272.
Page 316 5028 Disconnect the motor cable (A). Repair information...
Page 317 5028 Remove the four screws (B), and then remove the motor. Repair information...
Page 318: Motor (Fuser) Removal
5028 Motor (fuser) removal Remove the motor cover. See “Motor cover removal” on page 273. Disconnect the motor cable (A). Repair information...
Page 319: Hvps Removal
5028 Remove the four screws (B), and then remove the motor. HVPS removal Remove the transfer module. See “Transfer module removal” on page 334. Remove the controller board. See “Controller board removal” on page 357. Remove the retainer (A). Repair information...
Page 320 5028 Disconnect the cable (B). Remove the screw (C) securing the HVPS. Repair information...
Page 321 5028 Press the three toner contacts (D) from inside the printer, and then remove the power supply. Installation notes: • Make sure that the transfer module guide rail does not block the three toner contacts. • Make sure that the three toner contacts freely move and are fully extended. Repair information...
Page 322: Sensor (Mpf Paper Present) Removal
5028 • Make sure that the index pin (A) behind the transfer module retract arm is properly aligned. Sensor (MPF paper present) removal Remove the waste toner bottle. Remove the motor cover. See “Motor cover removal” on page 273. Remove the right cover. See “Right cover removal”...
Page 323 5028 Pull the sensor (MPF paper present) and cable out of the printer. Disconnect the sensor cable (A), and then remove the sensor. Repair information...
Page 324: Waste Toner Bottle Idler Gear Removal
5028 Waste toner bottle idler gear removal Remove the waste toner bottle. Remove the gear. Imaging unit cover removal Remove the waste toner bottle. Remove the motor cover. See “Motor cover removal” on page 273. Remove the right cover. See “Right cover removal”...
Page 325: Sensor (Tps) Removal
5028 Remove the two waste toner bottle stops (B), and then remove the toner door from the right cover assembly. Sensor (TPS) removal Remove the controller board shield. See “Controller board shield removal” on page 356. Remove the inner controller board shield. See “Inner controller board shield removal”...
Page 326 5028 Remove the two screws (B). Carefully pull the sensor while guiding the black thermistor cable through the hole at the rear of the printer. Disconnect the three cables (C) from the sensor. Warning—Potential Damage: Press the tab on the white cable while disconnecting it to avoid damage. Repair information...
Page 327: Tps Sled Removal
5028 Installation notes: After routing the thermistor cable through the hole at the rear of the printer, make sure that the sensor is placed behind the transfer module retract mechanism to avoid interference with the transfer module retract. After installing the sensor to the printer, restart the printer to test the cable connections to the sensor. A 128.xx error indicates a bad connection at the sensor.
Page 328: Toner Cartridge Contacts Removal
5028 Remove the two screws (C), and then remove the sled. Toner cartridge contacts removal Remove the imaging unit. Remove the controller board shield. See “Controller board shield removal” on page 356. Disconnect the toner cartridge contacts cable (A) from the controller board. Repair information...
Page 329 5028 Remove the screw (B), and then push the tab (C) to the right. Push the cartridge contacts assembly into the printer. Remove the cable from the retainer clips, and then remove the cartridge contacts. Repair information...
Page 330: Tps Wiper Mechanism Removal
5028 TPS wiper mechanism removal Remove the waste toner bottle. Remove the motor cover. See “Motor cover removal” on page 273. Remove the right cover. See “Right cover removal” on page 272. Remove the three screws (A). Repair information...
Page 331 5028 Unhook the spring (B) from the sled, and the remove the cord (C) from the pulley. Remove the clip (D). Repair information...
Page 332: Tps Wiper Removal
5028 Slide the shaft out, and then remove the TPS wiper. TPS wiper removal Remove the TPS sled. See “TPS sled removal” on page 327. Remove the three wipers (A) from the sled. Repair information...
Page 333: Front Removals
5028 Front removals Fuser removal Open the front cover. Raise the redrive guide. Turn the fuser lock counterclockwise. Repair information...
Page 334: Transfer Module Removal
5028 Remove the fuser. Transfer module removal Open the toner door. Open the imaging unit cover. Remove the waste toner bottle. Unlock the transfer module. Repair information...
Page 335 5028 Remove the imaging kit. Open the front cover. Remove the transfer module. Repair information...
Page 336: Transfer Module Guide Rail Removal
5028 Transfer module guide rail removal Remove the left cover. See “Left cover removal” on page 271. Remove the LVPS. See “LVPS removal” on page 305. Remove the screw (A). Remove the LVPS cage. See “LVPS cage removal” on page 308.
Page 337 5028 Remove the two screws (C), to release the ITU ground spring. Lift the rail, and then move it slightly to the right. Repair information...
Page 338 5028 Gently twist the rail to release the two tabs (D) from the frame, and then remove it. Installation notes: Make sure that ITM dog bone retract (A) and the spring (B) on the new rail are securely attached. Repair information...
Page 339 5028 When reinstalling the EP gear box, carefully insert the ITM drive shaft through the left side of the frame and rail to avoid damaging the ITM dog bone retract. Make sure that the tabs (C) are properly inserted into the frame. Make sure to place the rail below the thermistor wire tie (D).
Page 340: Sensor (Media Type) Removal
5028 Make sure that the three HVPS contacts (E) move freely and are fully extended. Sensor (media type) removal Remove the transfer module. See “Transfer module removal” on page 334. Open the front door. Remove the screw (A). Repair information...
Page 341: Sensor (Input) Removal
5028 Disconnect the sensor cable (B), and then remove the sensor. Sensor (input) removal Remove the transfer module. See “Transfer module removal” on page 334. Open the front door. Remove the sensor (media type). See “Sensor (media type) removal” on page 340.
Page 342: Deskew Rollers Removal
5028 Disconnect the sensor cable (B), and then remove the sensor. Deskew rollers removal Open the front door. Remove the right cover. See “Right cover removal” on page 272. Remove the left cover. See “Left cover removal” on page 271. Remove the LVPS.
Page 343 5028 On the right side of the printer, remove the gear (A), and then remove the screw (B). Remove the clip (C), and then remove the spacer. Warning—Potential Damage: Be careful not to over extend the clip when removing or installing to avoid damage.
Page 344 5028 Remove the bracket (D), and then unhook the spring (E). Remove the spacer (F). Repair information...
Page 345 5028 Remove the screw (G), and then remove the guide (H). Remove the clip (J), and then remove the bushing. On the left side of the printer, remove the three screws (K), and then remove the plate (L) from inside the LVPS cage.
Page 346 5028 Remove the clip (M), and then remove the spacer. Repair information...
Page 347 5028 Remove the screw (N) securing the nip release arm. Remove the spring (P), and then remove the spacer (Q). Repair information...
Page 348 5028 Remove the screw (R), and then remove the guide (S). Remove the clip (T), and then remove the bushing. Slide the front deskew roller to the right to remove. Note: Be careful not to drop or lose the washer on the left side of the shaft. Repair information...
Page 349 5028 Repair information...
Page 350: Diverter Removal
5028 Slide the rear deskew roller to the right to remove. Diverter removal Remove the badge cover. See “Badge cover removal” on page 283. Remove the number pad cover. See “Number pad cover removal” on page 284. Remove the upper control panel. See “Upper control panel removal”...
Page 351 5028 Disconnect the speaker cable (A) and sensor cable (B), and then remove the two screws (C). Remove the headphone port (D). Repair information...
Page 352 5028 Remove the four screws (E). Route the control panel cables, speaker cable, and redrive sensor cable through the tub. Repair information...
Page 353 5028 Remove the three screws (F), and then remove the diverter. Installation note: Make sure that the headphone cable is routed properly through its cable guide. Repair information...
Page 354: Redrive Guide Removal
5028 Redrive guide removal Remove the fuser. See “Fuser removal” on page 333. Remove the four screws (A). Hold the redrive deﬂector up, and then remove the redrive guide. Sensor (redrive) removal Remove the badge cover. See “Badge cover removal” on page 283.
Page 355 5028 Remove the screw (A). Remove the retainer (B), and then remove the sensor from the bracket. Installation note: Use the retainer of the old sensor when installing the new sensor. Repair information...
Page 356: Rear Removals
5028 Rear removals Controller board shield removal Note: This is not a FRU. Remove the eight screws (A). Remove the controller board shield. Repair information...
Page 357: Inner Controller Board Shield Removal
5028 Inner controller board shield removal Note: This is not a FRU. Remove the controller board shield. See “Controller board shield removal” on page 356. Remove the four screws (A), and then remove the inner controller board shield. Controller board removal Warning—Potential Damage: The controller board may contain a secure element SIM card that must be transferred from the old controller board to the new controller board.
Page 358 5028 Using a hex wrench or pliers, remove the four hex standoffs (A). Remove the ﬁve screws (A), and then remove the controller board. Repair information...
Page 359: Tps Cables Removal
5028 TPS cables removal Remove the controller board shield. See “Controller board shield removal” on page 356. Remove the inner controller board shield. See “Inner controller board shield removal” on page 357. Remove the controller board. See “Controller board removal” on page 357.
Page 360: Secure Element Sim Card Removal
5028 Secure element SIM card removal Warning—Potential Damage: The controller board may contain a secure element SIM card that must be transferred from the old controller board to the new controller board. This SIM card contains software and security settings that are unique to the printer. Remove the controller board shield.
Page 361: Top Removals
5028 Remove the SIM card. Top removals Printhead removal Remove the top cover. See “Top cover removal” on page 268. Remove the control board shield. See “Controller board shield removal” on page 356. Disconnect the ribbon cable (A) and printhead cable (B). Warning—Potential Damage: Do not yank the ribbon cable.
Page 362 5028 Remove the screw (C) from the printhead. Remove the rear right screw (D) from the printhead. Repair information...
Page 363: Developer Hold Down Removal
5028 Remove the rear left screw (E) from the printhead. Installation note: When installing the printhead, replace the screws but do not tighten them right away. After installing the screws, turn the printhead clockwise until it stops before tightening the screws fully. After performing these steps, you may need to align the printhead if there is skew.
Page 364: Output Roll Removal
5028 Pull the bell crank (B) and spring (C) off the mounting pin. Output roll removal Remove the left cover. See “Left cover removal” on page 271. Remove the fuser. See “Fuser removal” on page 333. Remove the redrive guide. See “Redrive guide removal”...
Page 365 5028 Remove the e-clip (C), and then remove the gear. Remove the e-clip (D) from inside the frame. Repair information...
Page 366 5028 Slide the output shaft to the left, and then remove from the printer. Remove the e-clip (E). Note: Use the e-clips and bushings on the new shaft. Repair information...
Page 367: Output Bin Exit Cover Removal
5028 Output bin exit cover removal Remove the top cover. See “Top cover removal” on page 268. Disengage the tab (A), and then remove the cable from the tabs. Remove the cover. Output bin ﬂag removal Remove the top cover. See “Top cover removal”...
Page 368: Bottom Removals
5028 Slide the ﬂag to the left to remove. Bottom removals Front cover hinges removal Warning—Potential Damage: Remove the waste toner bottle and imaging kit ﬁrst before removing the hinges. Failure to do this can lead to toner spillage and damage to the printer. Note: This procedure is applicable to the left and right front cover hinges.
Page 369: Tray Rail Removal
5028 Remove the three screws (A) securing the hinge, and then remove the hinge. Tray rail removal Remove the motor cover. See “Motor cover removal” on page 273. Remove the waste toner bottle. Remove the right cover. See “Right cover removal” on page 272.
Page 370: Aligner Idler Gears Removal
5028 Hold the tab in place, and then slide the rail toward the front of the printer to remove. Disconnect the spring (B) from the rail. Aligner idler gears removal Remove the imaging kit. Remove the media feeder. See “Media feeder removal” on page 373.
Page 371: Isolation Unit Removal
5028 Remove the E‑clip (A), and then remove the outer gear (B). Installation note: Use the washer in the new gear. Remove the E‑clip (C), and then remove the inner gear (D). Installation note: Use the washer in the new gear. Isolation unit removal Warning—Potential Damage: Remove the waste toner bottle and imaging kit ﬁrst before removing the isolation unit.
Page 372 5028 Remove the three screws (A) securing the isolation unit. Remove the biasing screw (B). Repair information...
Page 373: Media Feeder Removal
5028 Installation note: Make sure to replace this screw ﬁrst before replacing the three screws to secure the unit. Disconnect the motor cable (C) and sensor cable (D). Tilt the right portion of the isolation unit to the front, and then remove the unit. Route the isolation unit cables out of the printer.
Page 374 5028 Remove the four screws (A), and then remove the media feeder. Repair information...
Page 375: Sheet Tray Removals
5028 550-sheet tray removals 550-sheet tray right cover removal Remove the tray insert. Remove the three screws (A). Remove the right cover. Repair information...
Page 376: Motor (550-Sheet Tray Pass‑Through) Removal
5028 Motor (550-sheet tray pass‑through) removal Remove the tray insert. Remove the three screws (A). Remove the right cover. Remove the motor cover. Repair information...
Page 377 5028 Remove the two screws (B). Disconnect the cable (C). Remove the motor. Repair information...
Page 378: Sheet Tray Paper Feeder Removal
5028 550‑sheet tray paper feeder removal Remove the tray insert. Remove the four screws (A), and then release the two latches (B). Repair information...
Page 379: Sensor (550-Sheet Tray Pass-Through) Removal
5028 Disconnect the cable (C). Remove the paper feeder. Sensor (550-sheet tray pass-through) removal Remove the tray insert. Remove the screw (A), and then disconnect the cable (B). Remove the sensor. Repair information...
Page 380: Sensor (550-Sheet Tray Trailing Edge) Removal
5028 Sensor (550-sheet tray trailing edge) removal Remove the tray insert. Remove the pick roller. Remove the screw (A), and then disconnect the cable (B). Remove the sensor. Sensor (550-sheet tray paper size) removal Remove the tray insert. Remove the right cover. See “550-sheet tray right cover removal”...
Page 381 5028 Release the latch (A), and then remove the sensor cover. Release the two latches (B). Repair information...
Page 382: Sheet Tray Controller Board Assembly Removal
5028 Disconnect the cable (C), and then remove the sensor. 550-sheet tray controller board assembly removal Remove the tray insert. Remove the right cover. See “550-sheet tray right cover removal” on page 375. Disconnect all cables from the assembly, and then remove the two screws (A). Remove the controller board assembly.
Page 383: Sheet Tray Interface Cable Removal
5028 550-sheet tray interface cable removal Remove the tray insert. Remove the right cover. See “550-sheet tray right cover removal” on page 375. Disconnect the two cables (A), and then remove the screws (B). Squeeze, and then push the latches into the tray base to release the cable. Repair information...
Page 384: Sheet Tray Empty Sensor Actuator Removal
5028 Squeeze, and then push the latches into the tray base to release the cable. 550-sheet tray empty sensor actuator removal Remove the tray insert. Turn over the tray base. Remove the pick roller. Pull out the actuator to release, and then remove the actuator. Installation note: Make sure that the actuator is properly installed as shown.
Page 385: Sensor (550-Sheet Tray Empty) Removal
5028 Sensor (550-sheet tray empty) removal Remove the tray insert. Remove the paper feeder. See “550-sheet tray right cover removal” on page 375. Disconnect the cable (A), and then remove the sensor. Repair information...
Page 386: Sensor (550-Sheet Tray Index) Removal
5028 Sensor (550-sheet tray index) removal Remove the tray insert. Remove the paper feeder. See “550-sheet tray right cover removal” on page 375. Remove the screw (A). Disconnect the two cables (B), and then cut the zip tie (C). Repair information...
Page 387 5028 Squeeze, and then push the latches into the tray base to release the cable. Remove the sensor. Repair information...
Page 388 5028...
Page 389: Component Locations
CAUTION—TIPPING HAZARD: Installing one or more options on your printer or MFP may require a caster base, furniture, or other feature to prevent instability causing possible injury. For more information on supported conﬁgurations, see www.lexmark.com/multifunctionprinters. CAUTION—TIPPING HAZARD: To reduce the risk of equipment instability, load each tray separately.
Page 390: Controller Board Connectors
5028 Controller board connectors JSPKR1 JCVR1 JUIPWR1 JCTM1 JDSNS1 JMIRR1 JPHONE2 JPH1 JLCD1 JFPUSB1 JFSNS JFAN2 JFAN1 JFUSED1 JETH1 JOUTDC1 JBOR1 JBUSB1 JLVPS1 JUSB1 JCARTP1 JVIPER1 JISP1 JCARTS1 JCARTK1 JTPSAA1 JSC1 JPKSNS1 JWTH1 JSP1 JMTR1 JWT1 JMSNS1 JPSZ1 JHVPS1 JBOPT1 JSHUT1 JTHM1 Connector...
Page 391 5028 Connector Connects to Pin no. Signal JFUSED Fuser motor HALLF_A_IN HALLF_B_IN HALLF_C_IN FG_F_IN +5V_SW V45_FUSER_W V45_FUSER_V V45_FUSER_U JOUTDC1 Output motor VS10_OUT_LED S_OUT_ENC V30_OUT_MT- V30_OUT_MT+ JBOR Black only retract VS10_BOR_LED S_BOR_ENC V30_BOR_MT- V30_BOR_MT+ Component locations...
Page 392 5028 Connector Connects to Pin no. Signal JLVPS1 LVPS PS_ZERO_X PS_HEAT2_ON PS_HEAT1_ON V15_RELAY_DRIVE PS_25V_ON PS_PM_TX PS_PM_RX +6.5V +6.5V +25V_RAW +25V_RAW +25V_RAW +25V_RAW +25V_RAW +25V_RAW JCARTP1 CM cartridge motor V45_CM_CART_W V45_CM_CART_V V45_CM_CART_U V45_Y_CART_W V45_Y_CART_V V45_Y_CART_U Component locations...
Page 393 5028 Connector Connects to Pin no. Signal JCARTS1 Y cartridge motor CM_FG CM_HALL_U +5V_SW CM_HALL_V CM_HALL_W Y_HALL_U +5V_SW Y_HALL_V Y_FG Y_HALL_W JCARTK1 K cartridge motor K_HALL_U K_HALL_V K_HALL_W K_FG +5V_SW V45_K_CART_W V45_K_CART_V V45_K_CART_U Component locations...
Page 394 5028 Connector Connects to Pin no. Signal JHVPS1 HVPS +5V_HVPS_REF M_DEV_PWM_OUT K_DEV_PWM_OUT C_DEV_PWM_OUT CMY_CHG_PWM_OUT Y_DEV_PWM_OUT K_CHG_PWM_OUT K_TX_PWM_OUT CMY_TX_PWM_OUT ITM_TX_PWM_OUT CMY_SRVO_OUT K_SRVO_OUT ITM_SRVO_OUT GD_HVPS_ID V_25V_HVPS Component locations...
Page 395 5028 Connector Connects to Pin no. Signal JMTR1 Isolation unit motor and pick motor and VS10_BA_LED sensors V30_BA+ S_BA_ENC V30_BA- VS10_ISO_LED V30_ISO- S_ISO_ENC V30_ISO+ VS10_MPF_LED S_MPF_ENC V40_MPF+D V40_MPF-M VS10_PE_LED S_PE_ENC V40_PE-M V40_PE+D VS10_ELEV S_ELEV_IN VS10_EMP S_T1_EMP JTHM1 Thermistor S_TT_IN Component locations...
Page 396 5028 Connector Connects to Pin no. Signal JTPSAA1 TPS and auto align sensors VS10_TPS1_VDD TPS1_DIFF TPS1_SPEC TPS1_SPEC_G TPS1_LED_G I2C_DATA_TPS I2C_CLK_TPS VS10_TPS1_VDD AA1_ADC AA1_PWM VS10_TPS1_VDD AA2_ADC AA2_PWM JSHUT1 Media sensor VS10_SHTR S_SHTR JPKSNS1 Isolation unit sensors VS10_S1 S_S1_IN VS10_S1_ALT S_S1_ALT_IN VS10_BAN S_BAN_IN VS10_S2 S_S2_IN...
Page 397 5028 Connector Connects to Pin no. Signal JSC1 Imaging V_FUSE_5V I2CDATA_AR_R I2CCLK_AR_R JBOPT1 Option trays VS45_INOPT_PWR S1_OPTION RXD_PTR_IN BUMPA_ENC_OPT TXD_PTR_BTM_OUT JPSZ1 Paper size sensor PSIZE0 PSIZE1 PSIZE2 PSIZE3 JMSNS1 MFP paper present sensor, bubble / VS10_MPP narrow media sensors, and duplex VS10_MPM staging sensor S_MPP_IN...
Page 398 5028 Connector Connects to Pin no. Signal JWT1 Waste toner SENSE WT_VREF JISP1 ISP connector USBOUT+ USBOUT- USB_HD1_D+ USB_HD1_D- +3.3V ISP_RST_R +5V_RIP I2C_DAT_ISP_L +5V_RIP I2C_CLK_ISP_L +5V_RIP Hard drive JCTM1 +5V_SW -CART_METER_C_IN -CART_METER_M_IN -CART_METER_Y_IN -CART_METER_K_IN JSNS1 Bin full / duplex entry sensor JMIRR1 Mirror motor MM_REF_CLKC...
Page 399 5028 Connector Connects to Pin no. Signal JLCD1 LCD display LED_DRV_YLW2 +5VL GSPI_TXD MIR_SPI_CS PWR_BUTTON_R2 NC_SPICS_EXPN1 NC_SPICS_EXPN2 GSPI_RXD V15_UI GSPI_CLK_UIC I2CDATA_PANEL I2CCLK_PANEL V15_UI UIPIN24 OP_IRQ_R2- LVDS_UI_D3R+ LVDS_UI_D3R- V15_UI LVDS_UI_CLK_L+ LVDS_UI_CLK_L- LVDS_UI_D2R+ LVDS_UI_D2R- V15_UI LVDS_UI_D1R+ LVDS_UI_D1R- LVDS_UI_D0R+ LVDS_UI_D0R- V15_UI MTG1 MTG2 Component locations...
Page 400 5028 Connector Connects to Pin no. Signal JUIPWR1 V15_UI V15_UI JSPKR1 Speaker SPEAKER1 SPEAKER2 JPHONE2 Headphone jack HEADPHONE_DET HPL_C HPR_C JCVR1 Interlock switches +25V_RAW +25V_HVPS Component locations...
Page 401 5028 Connector Connects to Pin no. Signal JPH1 Printhead LADJ_D4_OUT I2CDATA_PH I2CCLK_PH SHADE_Y_R2 LADJ_D2_OUT SHADE_C_R2 LENA_CMY-_OUT LPOW_Y_OUT LPOW_C_OUT BOOST_OUT SHADE_M_R2 LADJ_D1_OUT SHADE_K_R2 LPOW_M_OUT LPOW_K_OUT LENA_K-_OUT PH_THERM_ADC HSYNC_IN YDATA2- YDATA2+ YDATA1- YDATA1+ Component locations...
Page 402: Lvps Controller Board Connectors
5028 Connector Connects to Pin no. Signal JPH1 Printhead MDATA2- MDATA2+ MDATA1- MDATA1+ CDATA2- CDATA2+ CDATA1- CDATA1+ KDATA2- KDATA2+ KDATA1- KDATA1+ LADJ_D3_OUT MTG1 MTG2 LVPS controller board connectors CN 1 CN 201 AC 1 Component locations...
Page 403 5028 Connector Connects to Pin no. Signal CN201 Controller board +25V +25V +25V +25V +25V +25V +25V +25V Zero_Cross Heat_On2 Heat_On1 Main_On_Off Tx_PwrMtr Relay_Drive Ground +6.5V +6.5V +6.5V Rx_PwrMtr Heat_On3 Fuser AC Common AC Out 3 AC Out 2 AC Out 1 Component locations...
Page 404: Motor Locations
5028 Connector Connects to Pin no. Signal AC line in Phase Neutral Motor locations Part Description Motor (fuser) Motor (duplex/MPF) Motor (isolation) Motor (pick/elevator) Motor (deskew) Motor (BOR) Motor (K developer) Motor (ITM) Component locations...
Page 405: Sensor Locations
5028 Part Description Motor (CM developer) Motor (Y developer) Motor (output) Sensor locations Component locations...
Page 406 5028 Part Description Sensor (TPS) Sensor (weather station) Sensor (media out) Sensor (pick roller index) Sensor (MPF paper present) Sensor (input) Sensor (tray 1 pick) Sensor (MPF pass‑through) Sensor (duplex path 2) Sensor (narrow media) Sensor (fuser buckle) sensor (fuser exit) sensor (duplex path 1) sensor (bin full) Component locations...
Page 407: Maintenance
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 Use the following tables to determine when speciﬁed parts should be Inspected: Lexmark CS720, CS725, and...
Page 408: Scheduled Maintenance
5028 Scheduled maintenance The control panel displays an 80.xx error when it reaches certain page counts. It is necessary to replace the appropriate maintenance kit to maintain print quality and printer reliability. Reset the maintenance counter after replacing the maintenance kit. Maintenance kits The printer may stop printing when the fuser rated life is reached.
Page 409: Identifying The Type Of Fuser Used In The Printer
5028 Identifying the type of fuser used in the printer Open the front cover. Locate the identiﬁcation number on the fuser. Maintenance...
Page 410: Cleaning The Printer
5028 Cleaning the printer Cleaning the printer CAUTION—SHOCK HAZARD: To avoid the risk of electrical shock when cleaning the exterior of the printer, unplug the power cord from the electrical outlet and disconnect all cables from the printer before proceeding. Notes: •...
Page 411: Cleaning The Main Tray Duplex Turnaround
5028 Cleaning the main tray duplex turnaround Remove the two screws (A). Open the turnaround cover. Remove the debris in the duplex turnaround area. Close the cover, and then replace the screws. Maintenance...
Page 412: Parts Catalog
5028 Parts catalog Legend The following column headings are used in the parts catalog: • Asm‑index—Identiﬁes the item in the illustration • P/N—Identiﬁes the part number of a FRU • Units/mach—Refers to the number of units in a printer • Units/opt—Refers to the number of units in an option •...
Page 413: Assembly 1: Covers 1
5028 Assembly 1: Covers 1 Parts catalog...
Page 414 5028 Assembly 1: Covers 1 Asm-index Units/opt Units/FRU Description Removal procedure 41X0773 Output bin exit cover “Output bin exit cover removal” on page 367 41X0772 Output bin ﬂag “Output bin ﬂag removal” on page 367 41X0410 Bin extender 41X0424 Rear handle cover 41X0408 Rear tray cover 41X0419...
Page 415: Assembly 2: Covers 2
5028 Assembly 2: Covers 2 Parts catalog...
Page 416 5028 Assembly 2: Covers 2 Asm-index Units/mach Units/FRU Description Removal procedure 41X0414 Toner door “Toner door removal” on page 276 41X0558 Toner door mount “Toner door mount bracket removal” on bracket page 278 41X0415 Toner door mount “Toner door mount removal” on page 279 41X0412 Left cover...
Page 417: Assembly 3: Control Panel
5028 Assembly 3: Control panel Parts catalog...
Page 418 5028 Assembly 3: Control panel Asm-index Units/mach Units/FRU Description Removal procedure 41X0416 Upper control panel “Upper control panel removal” on cover page 280 41X0871 C620 badge cover “Badge cover removal” on page 283 41X0872 C720 badge cover “Badge cover removal” on page 283 41X0873 C4150 badge cover “Badge cover removal”...
Page 419: Assembly 4: Fuser
5028 Assembly 4: Fuser Parts catalog...
Page 420 5028 Assembly 4: Fuser Asm-index Units/mach Units/FRU Description Removal procedure 41X0251 CS72x fuser type 02, 100V “Fuser removal” on page 333 41X0252 CS72x fuser type 00, 110-120V “Fuser removal” on page 333 41X0253 CS72x fuser type 01, 220-240V “Fuser removal” on page 333 41X0254 CS72x fuser type 07, 100V “Fuser removal”...
Page 421: Assembly 5: Transfer Module
5028 Assembly 5: Transfer module Parts catalog...
Page 422 5028 Assembly 5: Transfer module Asm-index Units/mach Units/FRU Description Removal procedure 40X9929 Transfer module “Transfer module removal” on page 334 41X0683 Transfer module guide “Transfer module guide rail removal” rail on page 336 Parts catalog...
Page 423: Assembly 6: Paper Feed
5028 Assembly 6: Paper feed Parts catalog...
Page 424 5028 Assembly 6: Paper feed Asm-index Units/mach Units/FRU Description Removal procedure 40X7911 Sensor (paper size) “Sensor (paper size) removal” on page 312 41X0372 Tray rails “Tray rail removal” on page 369 41X0825 Support strap 41X0373 Paper size sensor actuators -- 41X0956 Pick roller (tray 1 and MPF) 41X0396...
Page 425: Assembly 7: Paper Path 1
5028 Assembly 7: Paper path 1 Parts catalog...
Page 426 5028 Assembly 7: Paper path 1 Asm-index Units/mach Units/FRU Description Removal procedure 41X0390 Output roll “Output roll removal” on page 364 ‑‑ 41X0395 Fuser drive gear 41X0001 Motor (fuser) “Motor (fuser) removal” on page 318 41X0757 Waste toner bottle idler “Waste toner bottle idler gear gear removal”...
Page 427: Assembly 8: Paper Path 2
5028 Assembly 8: Paper path 2 Parts catalog...
Page 428 5028 Assembly 8: Paper path 2 Asm-index Units/mach Units/FRU Description Removal procedure 41X0265 Printhead “Printhead removal” on page 361 41X0389 Diverter “Diverter removal” on page 350 41X0570 Sensor (duplex path 1 / MPF pass‑through) 41X0388 Redrive guide “Redrive guide removal” on page 41X0384 Isolation unit “Isolation unit removal”...
Page 429: Assembly 9: Duplex
5028 Assembly 9: Duplex Parts catalog...
Page 430 5028 Assembly 9: Duplex Asm-index Units/mach Units/FRU Description Removal procedure 41X0447 Sensor (fuser buckle / “Sensors (fuser buckle and narrow narrow media) media) removal” on page 294 41X0824 Static brush 41X0379 Guide spring 41X0378 Tensioner belt “Tensioner belt removal” on page 41X0446 Sensor (duplex staging) 41X0377...
Page 431: Assembly 10: Electrical
5028 Assembly 10: Electrical Parts catalog...
Page 432 5028 Assembly 10: Electrical Asm-index Units/mach Units/FRU Description Removal procedure 41X0267 Controller board “Controller board removal” on page 357 41X0394 TMC card “TMC card removal” on page 315 41X0785 Sensor (weather station) “Sensor (weather station) removal ” on page 311 41X0270 High voltage power supply “HVPS removal”...
Page 433 5028 Asm-index Units/mach Units/FRU Description Removal procedure 41X0413 Cable replacement pack: • Output roll motor cable • Paper path motors cable • CMY cartridge motors cable • Fuser motor cable • K cartridge ITM motor cable • Lower path sensors cable •...
Page 434 5028 Parts catalog...
Page 435: Assembly 11: 550‑Sheet Tray Option 1
5028 Assembly 11: 550‑sheet tray option 1 Parts catalog...
Page 436 5028 Assembly 11: 550‑sheet tray option 1 Asm-index Units/opt Units/FRU Description Removal procedure 41X0271 550-sheet tray 41X0361 550-sheet tray insert Parts catalog...
Page 437: Assembly 12: 550‑Sheet Tray Option 2
5028 Assembly 12: 550‑sheet tray option 2 Parts catalog...
Page 438 5028 Assembly 12: 550‑sheet tray option 2 Asm-index Units/opt Units/FRU Description Removal procedure 41X0471 550-sheet tray interface “550-sheet tray interface cable cable removal” on page 383 41X0331 550-sheet tray controller “550-sheet tray controller board board assembly removal” on page 382 41X0466 Motor (550-sheet tray “Motor (550-sheet tray...
Page 439: Assembly 13: Adjustable Stand
5028 Assembly 13: Adjustable stand Parts catalog...
Page 440 5028 Assembly 13: Adjustable stand Asm-index Units/opt Units/FRU Description Removal procedure 41X0764 Locking caster 41X0775 Nonlocking caster 41X0774 Locking caster Parts catalog...
Page 441: Assembly 14: Miscellaneous Parts
5028 Assembly 14: Miscellaneous parts Asm-index Units/mach Units/FRU Description Removal procedure Adapter–N8360 ISP + NFC/BLE dual band ‑‑ 41X0015 ‑‑ 40X9652 Adapter–Fiber gigabit ISP ‑‑ 41X0028 DDR3 RAM, (G2) 2GB, 512Mx32, 204 SODIMM, Unbuffered Non‑ECC ‑‑ 41X1011 Font card, Hebrew ‑‑...
Page 442 5028 Parts catalog...
Page 443: Assembly 15: Power Cords
5028 Assembly 15: Power cords Asm-index Units/mach Units/FRU Description Removal procedure ‑‑ 40X7104 US, Canada, Latin America LV ‑‑ 40X0288 Argentina ‑‑ 40X0259 Brazil LV ‑‑ 40X0273 Chile, Uruguay ‑‑ 40X0297 Bolivia, Peru, Paraguay ‑‑ 40X0301 Australia, New Zealand ‑‑ 40X3609 Japan ‑‑...
Page 444 5028...
Page 445: Appendix A: Printer Speciﬁcations
Scan The product is scanning hard‑copy documents. Ready The product is waiting for a print job. Ready 1: 80 (CS720, CS725); 100 (CX725) Sleep Mode The product is in a high‑level energy‑saving mode. 4 (CS720de, CS720dte, CS725de, CS725dte) Hibernate The product is in a low‑level energy‑saving mode.
Page 446: Off Mode
5028 The Hibernate mode can be entered in any of the following methods: • Using the Hibernate Timeout • Using the Schedule Power modes • Using the Sleep/Hibernate button Factory default Hibernate Timeout for this product in all countries or regions 3 days The amount of time the printer waits after a job is printed before it enters Hibernate mode can be modiﬁed between one hour and one month.
Page 447: Noise Emission Levels
1-meter average sound pressure, dBA Printing 54 (one-sided); 55 (two-sided) Scanning Copying Ready Values are subject to change. See www.lexmark.com for current values. Temperature information Ambient operating temperature 10 to 32.2°C (50 to 90°F) Shipping temperature -40 to 43.3°C (-40 to 110°F) Storage temperature and relative humidity 1 to 35°C (34 to 95°F)
Page 448 5028...
Page 449: Appendix B: Options And Features
Application cards • Forms and Bar Code • PRESCRIBE • IPDS • Lexmark Internal Solutions Port (ISP) – MarkNet N8360 (802.11 b/g/n/a wireless print server bundled with LEX‑M06‑001 Mobile Solutions Module) – IEEE 1284‑B Parallel Card – RS‑232C Serial Card Installing optional trays CAUTION—TIPPING HAZARD: Installing one or more options on your printer may require a caster base,...
Page 450: Adding Available Options In The Print Driver
5028 Align the printer with the optional tray, and then lower the printer until it clicks into place. Connect the power cord to the printer, and then to the electrical outlet. CAUTION—POTENTIAL INJURY: To avoid the risk of ﬁre or electrical shock, connect the power cord to an appropriately rated and properly grounded electrical outlet that is near the product and easily accessible.
Page 451 5028 Apply the changes. Appendix B: Options and features...
Page 452 5028...
Page 453: Appendix C: Theory Of Operation
5028 Appendix C: Theory of operation Paper path and transport components For an image to be printed, the paper or specialty media has to be moved from an input source (such as a tray) into the printer and eventually exit into an output source. The most important component in this process is this paper itself.
Page 454: Mpf Section
5028 MPF section The MPF has a sensor (MPF empty) which detects if paper is present. The motor (duplex/MPF) drives the MPF pick assembly. The pick assembly feeds the paper from the MPF tray into the printer through the sensor (MPF/pass‑through) and isolator nip at tray 1.
Page 455: Isolation Unit Section
5028 Isolation unit section The paper enters the isolation unit through one of two paths, each path having its own isolation roller. If the paper is fed from tray 1, the tray 1 isolation nip moves the paper through the isolation housing and into the aligner roller.
Page 456: Aligner Section
5028 Description Sensor (MPF/pass‑through) Aligner section After the paper reaches the sensor (input), or the sensor (MPF/pass‑through), a count is started. The paper is pushed up against the aligner rollers to align the leading edge of the paper and form a bubble. After a predetermined count from the sensor (input) is reached, the motor (aligner) turns and moves the paper through the aligner rollers and the sensor (input).
Page 457 5028 Description Transfer belt Sensor (input) Aligner roller Transfer roller Appendix C: Theory of operation...
Page 458: Fuser Section
5028 Fuser section After the second transfer, the paper is fed to the fuser. The paper passes through the sensor (fuser buckle) located before the fuser. The sensor detects the buckle in the paper when it hits the fuser rollers. If the buckle is too great, the motor (fuser) speeds up to avoid causing a paper jam.
Page 459: Duplex Section
5028 Description Decurl roller Fuser Sensor (fuser buckle) / Sensor (narrow media) Sensor (fuser exit) Sensor (paper exit) / Sensor (duplex entry) Duplex section After the ﬁrst side of the paper is printed and the trailing edge of the paper clears the diverter, the diverter drops and the motor (output) engages in reverse.
Page 460 5028 After passing the sensor (duplex staging), the duplex aligner roller drives the paper to the isolation nip and to the sensor (MPF/pass‑through) where the leading-edge position of the paper is again updated. When the paper reaches the sensor (MPF/pass‑through) in the isolation unit, the paper is pushed to the deskew rollers. As the paper reaches the sensor (input) after the registration process, the motor (aligner) adjusts its speed to line up the leading edge exactly with the belt image at the second transfer.
Page 461: Print Engine Theory
5028 Description Duplex feed roller Sensor (duplex staging) Duplex aligner roller Sensor (duplex entry) Print engine theory Electrophotographic process The method that all laser and LED printers use to print is called the electrophotographic (EP) process. These machines use differences in charge to manipulate and move toner from the print cartridge to the printed page. Even though the basic EP process is the same for every laser and LED printer, the speciﬁcs for each printer are different.
Page 462 5028 The transfer belt carries the four-colored image towards the transfer rolls. Paper is picked up from the tray and carried to the transfer roll where the image is transferred from the transfer belt to the paper. The timing of the paper pick is determined by the speed of the transfer belt.
Page 463 5028 The laser beam only discharges the surface where the beam hits the photoconductor. This creates a difference in charge potential between the exposed area and the rest of the photoconductor surface. Service tips • The laser beam passes through a glass lens as it exits the laser unit. If this lens gets contaminated with toner or other debris, vertical streaking of white/lightness on the page occurs.
Page 464 5028 This process is similar to using glue to write on a can and then rolling it over glitter. The glitter sticks to the glue but will not stick to the rest of the can. Service tips • Never touch the surface of the developer roller with your bare hand. The oil from your skin may cause a charge differential on the surface, and the toner will not stick properly.
Page 465 5028 The charge difference between the developed toner image on the photoconductor surface and the ﬁrst transfer roller causes the images to transfer to the surface of the transfer module belt for each color. This takes place by a direct surface-to-surface contact between the photoconductors and the transfer module belt. Service tips •...
Page 466 5028 The HVPS sends voltage to the transfer roll to create a positive charge. When the image on the transfer belt reaches the transfer roll, the negatively charged toner clings to the paper and the entire image is transferred from the transfer belt to the paper. Service tips •...
Page 467 5028 The fuser applies heat and pressure to the page to melt the toner particles and bond them permanently to the paper. The fuser moves the paper to the redrive rolls which move the paper to the output bin. Service tips •...
Page 468 5028 After the toner is moved to the cleaning blade, the toner is moved to the waste toner area using an auger system. Photoconductor clean/erase After each plane of color has been transferred to the transfer belt from the photoconductors, a cleaning blade scrapes the remaining toner from the surface of each photoconductor.
Page 469: Color Theory
5028 Color theory Color theory What is RGB color? Red, green, and blue light can be added together in various amounts to produce a large range of colors observed in nature. For example, red and green can be combined to create yellow. Televisions and computer monitors create colors in this manner.
Page 470 5028 What is manual color correction? When manual color correction is enabled, the printer employs user-selected color conversion tables to process objects. However, Color Correction must be set to Manual, or no user-deﬁned color conversion will be implemented. Manual color correction settings are speciﬁc to the type of object being printed (text, graphics, or images), and how the color of the object is speciﬁed in the software program (RGB or CMYK combinations).
Page 471 5028 By examining Color Samples sets, a user can identify the box whose color is the closest to the desired color. The color combination labelled on the box can then be used for modifying the color of the object in a software program.
Page 472 5028...
Page 473: Appendix D: Acronyms
5028 Appendix D: Acronyms Acronyms ASIC Application-speciﬁc integrated circuit BLDC Brushless DC motor Black only retract Cyan Charge coupled device Carbonless copy paper Cyclic redundancy check Customer setup CTLS Capacitance toner level sensing DIMM Dual inline memory module DRAM Dynamic random access memory Enhanced data out Electrophotography EPROM...
Page 474 5028 Multipurpose feeder MROM Masked read only memory Microswitch Nonvolatile memory NVRAM Nonvolatile random access memory Original equipment manufacturer Optical sensor Photoconductor pel, pixel Picture element Power-on reset POST Power-on self test Position sensing device Pulse width modulation Raster imaging processor Read only memory SDRAM Synchronous dual random access memory...
Page 475: Index
5028 Index emission notices 447 envelopes acronyms 473 tips on using 27 adding hardware options EP process 461 print driver 450 error codes adding internal options 100 error messages 166 print driver 450 102 error messages 167 additional input tray diagnostics 110 error messages 168 motor tests 250 120 error messages 168...
Page 476 5028 mark log 245 print log 244 labels, paper print log summary 245 tips 28 exterior of the printer locations cleaning 410 motor 404 sensor 405 ﬁnding serial number 25 maintenance kits 408 ﬁrmware card 449 memory card 449 fuser menus identifying the fuser type 409 diagram of 243...
Page 477 5028 tray section 453 printhead diagnostics 249 paper sizes registration adjust 248 supported 29 supply reset 249 paper types weather station 249 printer setup supported 30 enable edge‑to‑edge (copy) 246 paper weights enable edge‑to‑edge (printing) 246 supported 30 engine setting [x] 247 parts catalog legend 412 EP setup 247 POR sequence 33...
Page 478 5028 LVPS cage 308 reports main fan 301 device settings 245 media feeder 373 installed licenses 245 Motor (550-sheet tray pass‑through) 376 restoring conﬁguration ﬁle 258 motor (black only retract) 309 license ﬁle 258 motor (deskew) 299 ribbon cables 260 motor (duplex/MPF) 315 motor (EP drive) 296 motor (fuser) 318...
Page 479 5028 troubleshooting, print quality background or gray background 36 blank or white pages 37 blurred print or color misalignment 40 dark print 52 gapping or half color page 39 ghost images 46 horizontal colored lines or banding 41 image void process direction 51 image void scan direction 49 light print 57 mottled print and dots 43...
Page 480 5028 Index...
Page 481: Part Number Index
5028 Part number index Part name Page 40X0259 Brazil LV................................443 40X0271 Hong Kong..............................443 40X0271 Singapore, Malaysia, Pakistan, Sri Lanka, Myanmar, Brunei, India...........443 40X0271 UK, Saudi Arabia............................443 40X0273 Chile, Uruguay..............................443 40X0275 Israel................................. 443 40X0279 Philippines, Thailand.............................443 40X0288 Argentina................................. 443 40X0297 Bolivia, Peru, Paraguay..........................
Page 482 5028 Part name Page 41X0252 CS72x fuser type 00, 110-120V........................420 41X0253 CS72x fuser type 01, 220-240V........................420 41X0254 CS72x fuser type 07, 100V (narrow media).................... 420 41X0255 CS72x fuser type 05, 110-120V (narrow media)..................420 41X0256 CS72x fuser type 06, 220-240V (narrow media)................. 420 41X0264 EP gear box..............................428 41X0265...
Page 483 5028 Part name Page 41X0391 Output gear..............................426 41X0392 Output drive..............................426 41X0393 Motor (black only retract)..........................428 41X0394 TMC card................................. 432 41X0395 Fuser drive gear............................426 41X0396 550-sheet tray paper feeder........................438 41X0396 Media feeder..............................424 41X0397 Main fan................................432 41X0398 Fuser fan................................432 41X0399 Speaker................................418...
Page 484 5028 Part name Page 41X0448 Sensor (interlock assembly).........................414 41X0450 Sensor (media type)..........................426, 432 41X0451 Motor (output)..............................426 41X0466 Motor (550-sheet tray pass‑through).......................438 41X0468 Sensor (550-sheet tray trailing edge)...................... 438 41X0469 Sensor (550-sheet tray index)........................438 41X0470 Sensor (550-sheet tray empty)........................438 41X0471 550-sheet tray interface cable........................
Page 485 5028 Part name Page 41X0871 C620 badge cover............................418 41X0872 C720 badge cover............................418 41X0873 C4150 badge cover............................418 41X0897 Developer hold down arm.......................... 428 41X0956 550-sheet tray pick roller..........................438 41X0956 Pick roller (tray 1 and MPF)..........................424 41X1002 Forms bar code card............................. 441 41X1004 IPDS SCS TNE card............................441 41X1006...
Page 486 5028 Part number index...
Page 487: Part Name Index
5028 Part name index Part name Page 41X0050 4.3‑in. control panel............................418 41X0268 550-sheet tray..............................424 41X0271 550-sheet tray..............................436 41X0331 550-sheet tray controller board........................ 438 41X0472 550-sheet tray empty sensor actuator....................438 41X0361 550-sheet tray insert............................436 41X0471 550-sheet tray interface cable........................438 41X0396 550-sheet tray paper feeder........................438 41X0373...
Page 488 5028 Part name Page 41X0441 Control panel USB cable........................418, 432 41X0267 Controller board............................432 41X0252 CS72x fuser type 00, 110-120V........................420 41X0253 CS72x fuser type 01, 220-240V........................420 41X0251 CS72x fuser type 02, 100V.........................420 41X0255 CS72x fuser type 05, 110-120V (narrow media)..................420 41X0256 CS72x fuser type 06, 220-240V (narrow media).................
Page 489 5028 Part name Page 40X1767 Indonesia, Vietnam, Cambodia, Laos.......................443 41X1004 IPDS SCS TNE card............................441 41X0384 Isolation unit..............................428 40X0275 Israel................................. 443 40X3609 Japan................................443 40X1792 Korea.................................443 41X0561 Left control panel arm........................... 418 41X0412 Left cover................................416 41X0764 Locking caster..............................440 41X0774 Locking caster..............................440 41X0425 Low voltage power supply..........................432 41X0397...
Page 490 5028 Part name Page 41X1006 Prescribe card..............................441 41X0265 Printhead................................. 428 41X0424 Rear handle cover............................414 41X0408 Rear tray cover..............................414 41X0388 Redrive guide..............................428 41X0562 Right control panel arm..........................418 41X0419 Right cover............................... 414 41X0470 Sensor (550-sheet tray empty)........................438 41X0469 Sensor (550-sheet tray index)........................
Page 491 5028 Part name Page 41X0394 TMC card................................. 432 41X0382 Toner cartridge contact..........................432 41X0414 Toner door................................416 41X0415 Toner door mount............................416 41X0558 Toner door mount bracket........................... 416 41X0409 Top cover................................414 41X0575 TPS cable................................ 432 41X0686 TPS wiper mechanism...........................414 41X0578 TPS wipers..............................432 40X9929 Transfer module.............................422 41X0683...
Page 492 5028 Part name index...
Page 493: Wiring Diagram
INTERLOCK SWITCHES or incinerate a lithium battery. Discard used lit hium batteries according to the manufacturer's instructions and local regulations. CONTROL PANEL ASSEMBLY DUPLEX ENTRY THUMB DRIVE USB SENSOR PORT CS720 LCD / NFC PORT CS725 SPEAKER BIN FULL HEADPHONE SENSOR...

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