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Lexmark C500n Service Manual
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Lexmark C500n Service Manual

Lexmark C500n Service Manual

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Lexmark
C500n
5023-110
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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Summary of Contents for Lexmark C500n

  • Page 1 ™ Lexmark C500n 5023-110 • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms is a trademark of Lexmark International, Inc.
  • Page 3 5023-110 Table of contents Laser notices ................ix Preface .
  • Page 4 5023-110 Control system structure .............1-35 Electrical system and function .
  • Page 5 5023-110 Paper feed service checks ............2-44 Printer paper feed service check .
  • Page 6 5023-110 Fuser assembly removal ............4-7 Waste toner bottle removal .
  • Page 7 5023-110 RIP board ..............5-13 Engine controller board .
  • Page 8 5023-110 viii Service Manual...
  • Page 9 5023-110 Laser notices The following laser notice labels may be affixed to this printer as shown: Laser advisory label Laser notices...
  • Page 10 5023-110 Class 1 Laser statement label XXXXXXXX2004 Service Manual...
  • Page 11 5023-110 Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 12 5023-110 Avis relatif à l’utilisation de laser Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.
  • Page 13 5023-110 Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 14 5023-110 Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770- 795 nanometer.
  • Page 15 5023-110 Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 16 5023-110 Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
  • Page 17 5023-110 Chinese laser notice Korean laser notice -xvii Laser notices...
  • Page 18 5023-110 -xviii Service Manual...
  • Page 19 5023-110 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 20 5023-110 Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 21 5023-110 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 22 5023-110 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
  • Page 23 5023-110 1. General information This Lexmark™ C500 color laser printer is the ideal printer for presentations, business graphics, line art, and text. It uses laser diode electrophotographic technology to deliver remarkable quality print images and text. The printer can be used as a shared network or desktop printer.
  • Page 24 5023-110 Serial number Look for the serial number information on the right cover and the inside of the front cover of the printer. XXXXXXXX2004 Service Manual...
  • Page 25 5023-110 Acronyms ASIC Application-Specific Integrated Circuit Dots Per Inch DRAM Dynamic Random Access Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage HVPS High Voltage Power Supply Intergrated circuit Local Area Network LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...
  • Page 26 The following table contains the dimensions and weights for each printer model and option. This does not include packaging but does include the print cartridge that ships with the printer. Width Depth Height Weight inch inch inch Printers Lexmark C500n 18.9 16.5 15.2 66.0 29.0 Paper options 530-Sheet drawer 18.1 18.5 13.3...
  • Page 27 5023-110 Operating clearances Printer sides C500n C500n with 530-sheet tray Left side 8 in (203 mm) 8 in (203 mm) Right side 20 in (508 mm) 20 in (508 mm) Front 28 in (711 mm) 28 in (711 mm) Rear...
  • Page 28 Capacity may vary and is subject to media specifications and printer operating environment. The capacities listed are based on plain paper at 75 g/m Sources and capacities C500n Input sources Number of standard sources Number of optional input drawers...
  • Page 29 5023-110 Media input types and weights Source Type Standard tray 530-Sheet tray Printer menu Item Legal tray Paper Paper type weight Paper Xerographic or bond 60-74 60-74 Plain paper Light (grain long) paper (16-19 lb) (16-19 lb) Xerographic or bond 75-120 75-120 Plain paper...
  • Page 30 5023-110 Media sizes Media sizes Dimensions Input Output 210 x 297 8.27 x 11.7 148 x 210 5.83 x 8.27 JIS B5 182 x 257 7.17 x 10.1 Letter 216 x 279.4 8.5 x 11 Legal 216 x 356 8.5 x 14 Executive 184.2 x 266.7 7.25 x 10.5...
  • Page 31 Transparencies are only supported in tray 1 (standard or legal trays). Labels • Labels should be selected using guidelines found in the User's Reference, Complete Printer Reference, or the Card stock & Label Guide (located at www.lexmark.com), and tested for acceptability. • Vinyl labels are not supported.
  • Page 32 This printer is compatible with applications running under the following operating systems for either local or network connections: Apple Macintosh • Mac OS 8.6, 9.x, OS X Download the latest Lexmark printer PPD files or printer drivers from the Lexmark Web Site. Microsoft Windows • Microsoft Windows 98 2nd Edition •...
  • Page 33 5023-110 Internal Print Servers The standard Ethernet connection and optional N2100 Series print servers support the following protocols: • TCP/IP–The TCP/IP standard set of application services are supported including DHCP, BOOTP, WINS, SNMP (mib-2, host resources MIB, printer MIB, enterprise MIB, SNMP traps), HTTP, LPR/LPD, FTP, IPP1,SLP, DDNS •...
  • Page 34 5023-110 Power and electrical specifications Printing states C500n Average power while printing Continuous printing 670 W Power consumption, standby Power saver on 35 W Power saver off 200 W Maximum current while printing 115 Volts 11 A 230 Volts Average current while printing 115 Volts 6.5 A...
  • Page 35 5023-110 Printer identification Top cover assembly Operato panel/cover Rear cover assembly Paper Release stopper lever Release lever Front cover Right cover Paper tray Front view Left cover Power switch AC input inlet Back view 1-13 General information...
  • Page 36 5023-110 Printer theory of operation The following diagram shows the major parts of the printer and paper path. 1-14 Service Manual...
  • Page 37 5023-110 Printer paper path The following illustration shows the paper path and the associated paper jam messages for jams at specific points in the paper path. The printer depicted in the illustration has a duplex unit and secondary paper feed assembly installed: Top Cover Paper Exit Roller...
  • Page 38 5023-110 Printer systems description See the illustration “Printer component systems” on page 1-17, for more information. Basic principles of color printing Color printing is made through the subtractive process of combining the three primary colors: yellow, magenta, and cyan. Mechanical and electrical structures This color laser printer consists of five engineering systems: print, transfer, optical, paper transport, and control system.
  • Page 39 5023-110 Printer component systems 1-17 General information...
  • Page 40 5023-110 Basic process of color printing 1. This printer has a toner cartridge for each color – yellow, magenta, cyan, and black. 2. The toner image is developed with primary colors and then transferred to the transfer belt for color combination.
  • Page 41 5023-110 Print system and transfer system This illustration shows the basic structure of the print system having the OPC belt as a main function, and the transfer system including the transfer belt. A color print is accomplished by actuating each process in the print system and the transfer system.
  • Page 42 5023-110 Structure of OPC belt (photo developer cartridge) The OPC belt consists of a surface layer having an optical photoconductor (OPC) of organic material, the inner layer consists of an insulator material (PET), and the aluminum deposit layer in between. The OPC belt is a main part of the print system.
  • Page 43 5023-110 Basic structure of the print system The print system process consists of the following: 1. The OPC belt is biased to the -CBV(V) by power supply CBV. 2. The OPC belt is then evenly charged to the negative high voltage by the OPC charging system. The charging system consists of a charging brush that is biased by power supply CHV and a discharge roller that is biased by power supply DCV.
  • Page 44 5023-110 5. Variation of the OPC belt potential: a. The OPC belt is biased to -CBV(V). b. The OPC belt surface is evenly charged to -Vo(V) during the charging process. c. During the exposing process, the optical unit emits a laser beam that strikes the OPC belt surface forming an electrostatic image.
  • Page 45 5023-110 Details of the print system Charging process In the charging process, the OPC belt is evenly charged by the charger. See “Printer theory of operation” on page 1-14 for charger unit location. The charger unit consists of a charging brush and a discharge roller. 1.
  • Page 46 5023-110 Exposing process In the exposing process, the OPC belt surface is exposed to the laser light which forms an electrostatic latent image. The luminous source of the laser is a semiconductor laser. See “Printer theory of operation” on page 1-14 for optical unit location. The laser light scans the OPC belt, forming an electrostatic latent image.
  • Page 47 5023-110 Developing process In the developing process, an electrostatic latent image attracts printer toner and becomes visible on the OPC belt. There are four toner cartridges. See “Printer theory of operation” on page 1-14 for toner cartridges location. The toner cartridges are located in the printer from top to bottom in the order of black, yellow, magenta, and cyan.
  • Page 48 5023-110 3. Developing is processed by toner adhering to the OPC belt due to the attraction between the toner and the -VR(V) charge at the exposed area of OPC belt. The toner image becomes visible on the OPC belt. Note: No developing takes place on the non-exposed area because the potential of toner and that of the non-exposed area of the OPC belt is an identical pole and therefore, repels.
  • Page 49 5023-110 4. The toner image is then transferred to paper. Belt discharge (erase lamp) process Electrical belt cleaning is accomplished by an erase lamp radiating on the OPC belt. Radiation discharges the residual charge -VR(V) remaining on the belt after the first transfer process. Electrical cleaning occurs after each toner color transfer.
  • Page 50 5023-110 The residual toner is collected in a waste toner container located by the waste toner feeder. OPC belt OPC belt cleaning (blade) OPC belt discharging First transfer (erase lamp) 1-28 Service Manual...
  • Page 51 5023-110 Details of the transfer system Second transfer (paper) process In the second transfer process, the toner image on the transfer belt is transferred to paper. See “Printer theory of operation” on page 1-14 for second transfer roller location. The transfer roller, normally separated from the transfer belt, is positively biased by the power supply THV. The transfer roller contacts the transfer belt as paper passes between the transfer roller and the transfer belt.
  • Page 52 5023-110 Transfer belt cleaning process The residual toner on the surface of the transfer belt is removed after the paper transfer process. See “Printer theory of operation” on page 1-14 for transfer belt cleaner unit location. The belt cleaner brush is a semiconductor-type fur brush. The cleaning roller is charged by voltage FCBV. The resistance of the cleaning brush against the cleaning roller charges the brush.
  • Page 53 5023-110 Details of the optical system In the optical system process, the printer utilizes a semiconductor laser diode as a light source. This laser diode is controlled by fast switching which matches the transmitted image data (video signal). The generated laser light scans the OPC belt through a polygon mirror and lens. The electrostatic latent images are formed on the OPC belt.
  • Page 54 5023-110 Details of the paper transportation system In the paper transportation process, paper is automatically fed by the pick-up roller and transported to the registration roller. The registration roller synchronizes with the transfer belt. The registration roller transports the paper to the transfer roller. During the transfer process, the transfer roller forwards the paper to the fuser rollers.
  • Page 55 5023-110 Fusing unit The fusing unit utilizes a thermal fusing system that contains a heated fusing roller and a belt-like backup roller. The heated roller contains an inner heating element. The backup roller contains three pressure members located behind the belt. Paper carrying a toner image passes between the rollers where heat and pressure are applied to the paper to fuse the toner to the paper.
  • Page 56 5023-110 Fusing process 1. When the paper reaches the fuser, the toner image is transferred on the paper, but not yet fused to the paper. 2. The transported paper passes between the heated roller and the back-up roller. The heated roller’s temperature is approximately 338°F (170°C).
  • Page 57 5023-110 Control system structure Electrical system and function The engine board controls most of the main electrical parts in this printer. Control process Function Print process control Controls print process from paper feed through paper exit. Laser output control Automatically controls laser output to the default. Fuser temperature control Controls fuser heater, allowing heated roller to reach default temperature.
  • Page 58 5023-110 Print sequence diagram 1-36 Service Manual...
  • Page 59 5023-110 Laser drive control circuit The laser drive control circuit (LDC) consists of a video signal input circuit, laser drive circuit, laser diode, output sensing circuit, and output control circuit. See the illustration. 1. When the video signal is received, the laser drive control circuit switches the laser diode switch on and radiates according to the video signal.
  • Page 60 5023-110 1-38 Service Manual...
  • Page 61 5023-110 2. Diagnostic information Start CAUTION: Remove power from the printer before you connect or disconnect any cable, electronic board or assembly, for personal safety and to prevent damage to the printer. Always use the hand grips on the side of the printer and be sure your fingers are not under the printer when you set the printer down.
  • Page 62 5023-110 Service error codes Error code Action “Engine controller board removal” on SVC 110 ERROR Replace the controller board. See page 4-34. Memory Read/Write is abnormal SVC 111 ERROR Memory Read/Write is abnormal SVC 112 ERROR Memory Read/Write is abnormal SVC 113 ERROR Memory Read/Write is abnormal SVC 180 ERROR...
  • Page 63 5023-110 Error code Action SVC 32 ERROR Replace the RIP board. See“System board removal” on page 4-28. Or, replace the engine controller board. See“Engine controller board removal” on Download error (Flash ROM page 4-34 erasing/writing error) SVC 33 ERROR Download error (Other critical error) SVC 41 ERROR Pipeline processing system error...
  • Page 64 5023-110 Error code Action SVC E3 ERROR Unstable transfer belt rotation–color matching cannot be secured. “Transfer belt unit service check” on page 2-21. Transfer belt error (transfer unit) SVC E5 ERROR Improper transfer roller clutch cable connection or a shorted or cut cable. “Transfer roller clutch service check”...
  • Page 65 5023-110 Error code Action SVC HA ERROR AC relay turned off due to an abnormal temperature. “Fuser assembly service check” on page 2-28. Fuser AC OFF error (relay off) SVC L1 ERROR Laser scanning beam is not detected by beam sensor. “Laser unit assembly service check”...
  • Page 66 5023-110 Parts replacement maintenance codes Operator panel code Recommended actions “Paper feed roller • Replace the tray 1 paperfeed roller (40X3414). See removal” on page 4-32. • Replace the separator pad (40X3415) in tray 1. “Paper feed roller • Replace the tray 2 paperfeed roller (40X3414). See removal”...
  • Page 67 5023-110 Operator panel code Recommended actions • Replace the transfer roller (40X3418). See “Transfer roller removal” on page 4-7. “Transfer belt cleaning roller • Replace the cleaning roller (40X3382). See removal” on page 4-5. “Paper feed roller • Replace the paperfeed roller (40X3414) in both trays. See removal”...
  • Page 68 5023-110 Operator messages Message Description Action Tray x: “paper size” The upper or lower paper Fill up the paper tray(s) or replace the media with Tray x Load “paper size” tray is empty or the media the correct type. If the problem persists, see in the trays is inconsistent.
  • Page 69 5023-110 Paper jam messages The following illustration lists paper jam messages indicating where the paper jam occurred. JAM-C JAM-B Tray1 JAM-A Tray2 JAM-A CAUTION: When clearing paper jams, inside of the printer may be hot. Allow printer to cool before touching any internal components.
  • Page 70 5023-110 Accessing jam areas Open doors and covers, and remove trays to access jam areas. The illustration shows the location of sources and possible jam areas. Rear door Standard tray (Tray 1) 530-sheet tray (Tray 2) Use the following table to locate instructions for a particular jam; however, to resolve any message, you must clear all media from the media path.
  • Page 71 5023-110 JAM-A tray, rear (tray 1) A JAM-A Tray, Rear message indicates the media is jammed in either tray 1 or tray 2. The affected tray is indicated by the Tray x message. Tray x could be the 250-sheet letter size tray or the optional 250- sheet legal size tray (Tray 1), or the optional 530-sheet tray (Tray 2).
  • Page 72 5023-110 JAM-A tray, rear(tray 2) A JAM-A Tray, Rear message indicates the media is jammed in either tray 1 or tray 2. The affected tray is indicated by the Tray x message. To clear a jam from the optional 530-sheet tray (Tray 2): 1.
  • Page 73 5023-110 JAM-B rear A JAM-B Rear message indicates the media is jammed behind the rear door. 1. Push the rear door release latch. 2. Gently lower the rear door. 2-13 Diagnostic information...
  • Page 74 5023-110 3. Pull the fuser pressure release levers to release tension on the media. 4. Grasp each side of the jammed media. Pull it to the rear of the printer and then out. Fuser pressure release lever Fuser pressure release lever Note: Gently pull the media out so you do not tear it.
  • Page 75 5023-110 JAM-C rear A JAM-C Rear message indicates the media is jammed behind the rear door above the fuser. 1. Push the rear door release latch and gently lower the rear door. 2. Pull the fuser pressure release levers to release tension on the media. 3.
  • Page 76 5023-110 Symptom tables Printer symptom table Symptom Action “Paper feed service checks” on page 2-44. Paper feed problems Close door displayed when all doors are closed “Operator messages” on page 2-8 and follow the action suggested. Paper jam messages do not reset after removing paper “Operator messages”...
  • Page 77 5023-110 Print quality symptom table Symptom Action “Background service check” on page 2-45. Background Missing image at edge “Missing image at edge service check” on page 2-53. “Jitter service check” on page 2-52. Jitter “Ribbing service check” on page 2-57. Ribbing Wrinkle and image migration “Wrinkle / image migration service check”...
  • Page 78 5023-110 Printer service checks Main motor service check Step Questions / actions Turn printer off and remove right cover. See Replace photodeveloper Go to step 2. “Right cover removal” on page 4-14. cartridge. Open top cover and override top cover interlock switch.
  • Page 79 5023-110 Step Questions / actions Disconnect cable from engine controller Replace engine controller Replace cable that board POCN. Check the following on board. See “Engine connects ACN1 on LVPS to controller board removal” disconnected cable connector: POCN on engine controller on page 4-34.
  • Page 80 5023-110 Developer drive assembly service check Step Questions / actions Is the error a D0, or D1 error Go to step 5. Go to step 2 if E0 or E1. Are there any unusual noises heard around Replace toner cartridge Go to step 5.
  • Page 81 5023-110 Step Questions / actions Reassemble and retest printer. Does error Problem solved. Contact next level of clear? support. Transfer belt unit service check Step Questions / actions Open rear cover assembly and check Clean belt marker area with Go to step 2. transfer belt unit markers for stains.
  • Page 82 5023-110 Transfer roller clutch service check Step Questions / actions Turn printer off and remove printer right Go to step 2. Properly connect cable. If cover. See “Right cover removal” on problem persists, go to step page 4-14. Is cable properly connected to transfer roller clutch? Disconnect transfer roller clutch from cable.
  • Page 83 5023-110 Paper feed clutch service check Step Questions / actions Turn printer off and remove printer right Go to step 2. Properly connect cable. If cover. See “Right cover removal” on problem persists, go to step page 4-14. Is cable properly connected to paper feed clutch? Disconnect paper feed clutch from cable.
  • Page 84 5023-110 OPC belt marker sensor service check Step Questions / actions Remove photodeveloper cartridge and Go to step 2. Replace photodeveloper check for defects. Does photodeveloper cartridge. appear ok? Observe markers on side. Are belt markers Clean marker area with Go to step 3.
  • Page 85 5023-110 Erase lamp service check Step Questions / actions Turn printer off and remove toner cartridges Go to step 2. Properly connect erase and photodeveloper cartridge. Check erase lamp. Retest printer. If error lamp cable for proper connection. Is erase clears, problem solved, lamp cable properly connected? otherwise go to step 2.
  • Page 86 5023-110 Power supply fan service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board board shield. See controller board removal” on page 4-34 for steps to remove engine controller board shield.
  • Page 87 5023-110 High voltage power supply (HVPS) service check Step Questions / actions Remove photodeveloper cartridge Replace photodeveloper Go to step 2. and ensure charging unit on bottom cartridge. See “Photodeveloper cartridge of photodeveloper cartridge is not removal” on page 4-9. damaged.
  • Page 88 5023-110 Fuser thermistor service check Step Questions / actions Remove and reinstall fuser assembly. See Problem solved. Go to step 2. “Fuser assembly removal” on page 4-7. Does error clear? Check fuser connector for damage. Problem solved. Go to step 3. Replace if necessary.
  • Page 89 5023-110 Laser unit assembly service check Step Questions / actions Check LCN connection on laser assembly Go to step 2. Properly connect LCN LDU board. Is connector properly cable. If error clears, connected? problem solved, otherwise go to step 2. Check LCN connection on engine controller Go to step 3.
  • Page 90 5023-110 Toner empty sensor (sender-TPD) service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board board shield. See Retest printer. If error controller board removal” on page 4-34 clears, problem solved, for steps to remove engine controller board otherwise go to step 2.
  • Page 91 5023-110 Toner empty sensor (receiver-TTR) service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board board shield. See Retest printer. If error controller board removal” on page 4-34 clears, problem solved, for steps to remove engine controller board otherwise go to step 2.
  • Page 92 5023-110 Lower feed unit (secondary paper assembly) service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board shield. See Retest printer. If error controller board removal” on page 4-34 clears, problem solved, for steps to remove shield.
  • Page 93 5023-110 Tray empty service check Step Questions / actions Remove paper tray from printer. Press Go to step 2. Replace paper tray. bottom of spring platform latches located in rear corners of paper tray. This releases spring platform of paper tray. Ensure tray is raising paper after insertion.
  • Page 94 5023-110 Paper tray missing service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board shield. See controller board removal” on page 4-34 for steps to remove engine controller board shield.
  • Page 95 5023-110 Toner low/empty service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board board shield. See controller board removal” on page 4-34 for steps to remove engine controller board shield.
  • Page 96 5023-110 Missing toner cartridge service check Step Questions / actions Remove toner cartridge in question. Holding Replace toner cartridge. Go to step 2. toner cartridge with developer roller away from you, check toner present sensor actuators located on left rear of toner cartridge.
  • Page 97 5023-110 Missing photodeveloper cartridge service check Step Questions / actions Check photodeveloper cartridge for proper Go to step 2. Install properly. installation. Is cartridge installed properly? Check printer contacts (A) and Replace photodeveloper Replace photodeveloper cartridge. See cartridge. See photodeveloper cartridge contacts (B) for “Photodeveloper “Photodeveloper dirt and damage.
  • Page 98 5023-110 Transfer roller missing service check Step Questions / actions Turn printer off and check transfer roller Go to step 2. If contact A has slipped off contacts. Are contacts present and not frame, put it back on. If you damaged? cannot see it, remove “HVPS...
  • Page 99 5023-110 Cover open service check Step Questions / actions Turn printer off and remove right cover. See Go to step 2. Replace appropriate “Right cover removal” on page 4-14. actuator: Check all interlock switch (top, rear and Front cover for front cover front) actuators for proper operation.
  • Page 100 5023-110 OPC belt (photodeveloper) cartridge drive service check Step Questions / actions Check photodeveloper cartridge for proper Go to step 2. Install properly. installation. Is cartridge installed properly? Check photodeveloper cartridge for Replace photodeveloper Go to step 3. cartridge. See damage.
  • Page 101 5023-110 Paper size sensing service check Step Questions / actions Turn printer off and remove engine Go to step 2. Properly connect cable. “Engine controller board shield. See controller board removal” on page 4-34 for steps to remove engine controller board shield.
  • Page 102 5023-110 Printer no power service check Note: If secondary paper feed assembly or duplex unit is installed, disconnect or remove before checking base printer operation. Step Questions / actions Reset printer and listen for any activation of Go to step 2. Go to step 3.
  • Page 103 5023-110 Toner feed service check Step Questions / actions Check toner cartridge for damage. Check to Replace toner cartridge. Go to step 2. see if toner cartridge moves easily into and out of printer. Is toner cartridge damaged or is there resistance moving in and out of printer? Is developer motor damaged? Replace developer drive...
  • Page 104 5023-110 Paper feed service checks Printer paper feed service check Problem area Action Check for recommended paper Ensure paper being used is recommended. Ensure paper is stored in an area free from high humidity. Note: Disconnect secondary paper assembly, if installed, to help isolate a paper transport problem.
  • Page 105 5023-110 Print quality service checks Background service check Background is smeared due to toner spread. Problem area Action Toner cartridge Too small charging amount in the development process. Check developer high voltage contact points. Insufficient contact of developer roller's primary or secondary high voltage contact points.
  • Page 106 5023-110 Back stain service check Backside of paper is stained. Problem area Action Fuser assembly • Fuser roller and back-up roller are stained. • Fusing offset error occurred. “Fuser assembly removal” on Replace fuser assembly. See page 4-7. Note: Fuser assembly is a customer order supply. Transfer roller Transfer roller is stained.
  • Page 107 5023-110 Banding service check A banding line appears in horizontal direction. Problem area Action Photodeveloper (OPC) cartridge Transfer failure due to uneven rotational speed caused by a shock which occurs when the seam of the OPC belt passes over the cleaning blade. Replace photodeveloper cartridge.
  • Page 108 5023-110 Black line service check A fine black line appears in printer image. Problem area Action Toner cartridge Toner cartridge blade is deformed. Replace toner cartridge. Photodeveloper (OPC) cartridge OPC belt’s surface is damaged. Replace photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-9.
  • Page 109 5023-110 Color misregistration service check Color misregistration between two colors. Problem area Action Transfer roller and transfer belt cleaning roller Transfer belt fails to maintain regular and proper rotation due to impact caused when transfer roller or transfer belt cleaning roller contacts transfer belt.
  • Page 110 5023-110 Insufficient fusing service check Printed image is partially missing. Problem area Action Fuser tension release lever Fuser tension release lever is open. Check fuser and remove shipping pieces if still installed. Close release lever. Driver media settings Driver media setting is wrong. Ensure proper media setting is selected for specific media in use.
  • Page 111 5023-110 Insufficient gloss service check Gloss on paper is not sufficient. Problem area Action Driver media settings Driver media setting is wrong. Ensure proper media setting is selected for specific media in use. Fuser Fuser roller is deteriorated. Fuser temperature is not properly controlled. Replace fuser.
  • Page 112 5023-110 Jitter service check Uneven optical density appears periodically in horizontal direction. Problem area Action Photodeveloper cartridge Replace faulty photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-9. Note: Photodeveloper cartridge is a customer order supply. Main motor assembly • Irregular rotation of main motor assembly •...
  • Page 113 5023-110 Missing image at edge service check Image has missing or peeling toner at edge. Problem area Action Toner cartridge Too small a toner mass amount and charging amount in the development process. Replace toner cartridge. Photodeveloper cartridge OPC belt is deformed and wavy. Replace photodeveloper cartridge.
  • Page 114 5023-110 Mixed color image service check Mixed color image appears. Problem area Action Toner cartridge Ensure toner cartridge moves in and out of printer without a lot of resistance. Compare toner cartridge in question with one of the other known working cartridges. Replace toner cartridge if defective.
  • Page 115 5023-110 Mottle service check Variation of optical density is found in image. Problem area Action Rear cover assembly Rear cover assembly is not fixed in place. Open rear cover assembly and close properly. Transfer roller Transfer roller is not properly installed. Remove and reinstall transfer roller.
  • Page 116 5023-110 Residual image service check Image of preceding page appears on every other page. Problem area Action Transfer unit cleaning roller Cleaning roller is not installed properly. Remove and reinstall. Ensure left side of cleaning roller is making good contact with HVPS contact.
  • Page 117 5023-110 Ribbing service check Light print occurs in right or left side of image. Problem area Action Printer is not level Table printer is sitting on is slightly tilted. Tilt should be less than 1/2 inch. Confirm the printer table is large enough and the printer is level.
  • Page 118 5023-110 Toner drop service check A toner spot stain on paper is caused by ambient toner within printer engine. Problem area Action Waste toner feed system Toner drops on the transfer drum due to a breakdown of the waste toner feed system. •...
  • Page 119 5023-110 Vertical line service check A vertical line appears in printed image. Problem area Action Photodeveloper cartridge (OPC belt) and Foreign particles (dust and so on) adhere to parts located transfer belt around photodeveloper cartridge and transfer belt unit which consequently contact toner image on transfer belt unit.
  • Page 120 5023-110 Vertical staggering image service check Printed image staggers in vertical direction. Problem area Action Printer vibration Check for printer vibrations or shock to printer. Laser unit assembly (printhead) Optical unit failure caused by vibration from scanner motor rotation. Replace laser unit assembly. See “Laser unit assembly (printhead) removal”...
  • Page 121 5023-110 Vertical white band service check White band appears in vertical direction of printed image. Problem area Action Toner cartridge Replace faulty toner cartridge. Photodeveloper cartridge Replace faulty photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-9. Transfer belt unit Replace faulty transfer belt unit.
  • Page 122 5023-110 White band service check Horizontal white banding creates missing portion of image. Problem area Action Transfer roller • Transfer roller bias pole is not making proper contact with high voltage spring contact. Remove and reinstall transfer roller. Ensure spring contact on left side (looking from front of printer) is not damaged.
  • Page 123 5023-110 White line I service check Vertical white line appears in a specific color area when print quality test print is run. Problem area Action Test print Print the maintenance page. See “Maintenance page printout” on page 3-2. White line appears on specific color. Toner cartridge •...
  • Page 124 5023-110 White spot / black spot service check A white spot and black spot appear on paper. Problem area Action Photodeveloper cartridge There are foreign particles adhering to photodeveloper OPC belt. Remove photodeveloper cartridge (see “Photodeveloper cartridge removal” on page 4-9).
  • Page 125 5023-110 White print service check Blank page (no print at all) is printed or a specific color is missing. Problem area Action Solid white print Optical Unit (Printhead) Laser light path is blocked by paper or other material stuck at the opening of the optical unit.
  • Page 126 5023-110 Wrinkle / image migration service check Banding shadows of different optical density appear due to wrinkle, image migration, and color misregistration occurring on paper. Problem area Action Non-recommended paper Paper being used is not recommended for printer. Replace paper with recommended paper. Rear cover assembly Open rear cover assembly and reclose, ensuring that both sides properly latch.
  • Page 127 5023-110 Uneven density (right and left) Optical density is different between right and left side of printed image. Problem area Action Rear cover assembly Open rear cover assembly and reclose, ensuring that both sides properly latch. If rear cover assembly will not properly latch, ensure that white door actuators located at top of rear cover assembly are not damaged.
  • Page 128 5023-110 Spacing table Roller specifications Repeating defect on Diameter Number of rotation Name of roller print (mm) (rpm) (mm) Registration assembly rubber roller ø 14 Registration assembly steel roller ø 12 Transfer roller ø 20 Developer roller ø 18 Transfer belt drive roller (part of transfer ø...
  • Page 129 5023-110 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and to verify repairs have corrected the problem. Understanding the printer operator panel The display panel is a two line, gray scale display that shows text. The Go and Stop buttons are located below the display panel, and the Back, Navigation, and Select buttons are located below the Go and Stop buttons.
  • Page 130 5023-110 Button Function Back Press the Back button to return to the last screen viewed. Note: Changes made on a screen will not be applied if you press the Back button. Navigation buttons The Left and Right buttons are used to move within a screen, such as moving from one menu index item to another.
  • Page 131 5023-110 Saving NVRAM settings for hardware replacement Before replacing the RIP or engine controller board, it is important to save the settings contained on each FRU. Saving the engine controller board settings 1. Press and hold the right navigation button down. Simultaneously press the Stop button three times.
  • Page 132 5023-110 Service Manual...
  • Page 133 5023-110 4. Repair information Removal and cleaning precautions Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer, reverse the order of removal unless otherwise specified. •...
  • Page 134 5023-110 Handling the printed circuit boards with MOS ICs The following precautions must be observed when handling circuit boards with MOS (Metal Oxide Semiconductor) ICs. During transportation/storage: • Do not remove the new circuit board from it’s protective conductive bags until they are needed. •...
  • Page 135 5023-110 Photodeveloper cartridge The following precautions must be observed when handling the photodeveloper cartridge or commonly called the OPC (optical photo conductor). The photodeveloper cartridge is a supply item you will have to remove during some of the repair procedures: During transportation/storage Use the specified carton whenever moving or storing the photodeveloper cartridge.
  • Page 136 5023-110 CRU/FRU and supplies removals There are FRU/CRUs and supply items that will need to be removed prior to some of the removal procedures. The removal procedure will specify when the part must be removed. Service Manual...
  • Page 137 5023-110 Cleaning roller cover removal 1. Open the top cover. 2. Depress the tabs and remove the cleaning roller cover. Transfer belt cleaning roller removal 1. Remove the cleaning roller cover. See “Cleaning roller cover removal” on page 4-5. 2. Lift and remove the transfer belt cleaning roller. Repair information...
  • Page 138 5023-110 Transfer belt unit removal 1. Open the rear cover assembly. 2. Rotate the two captive screws (A) counterclockwise until they are loose. Warning: Take great care when removing the transfer belt unit to prevent scratching the transfer belt. Do not touch or hit the belt during removal.
  • Page 139 5023-110 Transfer roller removal 1. Open the rear cover assembly. 2. Rotate the transfer roller to release; lift and remove. Fuser assembly removal 1. Push the rear cover assembly latch and the lower rear cover assembly. 2. Turn the two green fuser release levers (A). Repair information...
  • Page 140 5023-110 3. Lift the fuser straight up and away from the printer. Waste toner bottle removal 1. Open the front cover. 2. Remove the waste toner bottle. Warning: Ensure that the waste toner bottle is secured and not allowed to tip over during repair process. Failure to adhere to this warning may result in toner spillage.
  • Page 141 5023-110 Photodeveloper cartridge removal Warning: Follow the precautionary procedures (see “Photodeveloper cartridge” on page 4-3) when removing photodeveloper cartridge. 1. Open the top cover assembly. 2. Depress the release levers (A). 3. Lift and remove the photodeveloper cartridge. 4. Lay the photodeveloper cartridge as shown in a clean area. 5.
  • Page 142 5023-110 Secondary paper feed assembly removal 1. Remove the left secondary paper feed assembly cover. Repeat for the right side. 2. Loosen the thumbscrew (A) on left bracket and the remove bracket. Repeat for right side. 3. With aid from another person, lift the printer by the recessed handholds and remove it from the secondary paper feed assembly.
  • Page 143 5023-110 Cover removals Top cover assembly Operato panel/cover Rear cover assembly Paper Release stopper lever Release lever Front cover Right cover Paper tray Front view Left cover Power switch AC input inlet Back view 4-11 Repair information...
  • Page 144 5023-110 Top cover assembly removal 1. Remove the cleaning roller cover. See “Cleaning roller cover removal” on page 4-5. 2. Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-9. 3. Open the rear cover assembly. 4. Open the top cover. 5.
  • Page 145 5023-110 Front cover assembly removal 1. Open the front cover assembly. 2. Remove the 8 screws (A) from the inner front cover. 3. Disengage the support strap from the printer. 4. Release the tabs on the front cover. 5. Remove the front cover from the inner front cover. 6.
  • Page 146 5023-110 7. Rotate the support pin away from the printer and slide it towards the center of the printer to remove. Repeat for the other support pin. 8. Remove the front inner cover from the printer. Right cover removal 1. Remove the waste toner bottle. See “Waste toner bottle removal”...
  • Page 147 5023-110 Rear cover assembly removal 1. Remove the fuser assembly. See “Fuser assembly removal” on page 4-7. 2. Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-6. “Right cover removal” on page 4-14. 3. Remove the right cover. See 4.
  • Page 148 5023-110 Left cover removal 1. Remove the rip board. See “System board removal” on page 4-28. 2. Remove the top cover assembly. See “Top cover assembly removal” on page 4-12. 3. Remove the two screws (A) from the bottom of the left cover. 4.
  • Page 149 5023-110 6. Unlatch and remove the laser unit assembly cover. 7. Remove the four screws (B) from the laser unit assembly. 8. Remove the laser unit assembly from the printer. 9. Disconnect the connector from the laser unit assembly. 4-17 Repair information...
  • Page 150 5023-110 Erase lamp removal 1. Remove all the toner cartridges. 2. Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-9. “Transfer belt unit removal” on page 4-6. 3. Remove the transfer belt unit. See 4. Remove the two screws (A). 5.
  • Page 151 5023-110 Right side removals Front door interlock Transfer roller Cleaning switch clutch roller clutch Developer drive assembly Waste toner holder assembly Waste toner Paper Main motor Registration feeder feed assembly clutch clutch 4-19 Repair information...
  • Page 152 5023-110 Front door interlock switch with bracket 1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-12. 2. Remove the right cover. See “Right cover removal” on page 4-14. 3. Disconnect the interlock switch cable (A) from the interlock switch. 4.
  • Page 153 5023-110 3. Remove the three screws (B) from the waste toner bottle holder. The bottom screw is longer than the other screws. 4. Remove the waste toner bottle holder from the printer. Developer drive assembly removal 1. Remove the main motor assembly. See “Main motor assembly removal”...
  • Page 154 5023-110 Toner sensor (sender) removal 1. Remove the developer drive assembly. See “Developer drive assembly removal” on page 4-21. 2. Remove the two screws (A) from the toner sensor. Note: The bottom screw is longer than the top screw. 3. Pull the toner sensor away from the printer, disconnect the cable, and remove the sensor. 4-22 Service Manual...
  • Page 155 5023-110 Cleaning roller clutch removal 1. Remove the transfer belt cleaning roller. See “Transfer belt cleaning roller removal” on page 4-5. 2. Remove the right cover. See “Right cover removal” on page 4-14. 3. Using a flat tip tool, pry and remove the cleaning roller clutch gear from the inside of the printer. 4.
  • Page 156 5023-110 Main motor assembly removal 1. Remove the right cover. See “Right cover removal” on page 4-14. 2. Disconnect the main motor assembly cable (A) from the main motor. 3. Remove the 4 screws (B) from the the main motor assembly. 4.
  • Page 157 5023-110 Clutch removal Note: This procedure applies to the transfer roller clutch, the registration clutch, and the paper feed clutch. Shown is the transfer clutch removal. This removal is typical for the others. “Right cover removal” on page 4-14. 1. Remove the right cover. See 2.
  • Page 158 5023-110 Main drive gear assembly removal 1. Remove the cleaning roller clutch. See “Toner sensor (sender) removal” on page 4-22. 2. Remove the main motor assembly. See “Main motor assembly removal” on page 4-24. Note: If you are removing the main drive gear assembly to get to the waste toner feeder you do not have to remove the fuser, transfer roller, registration, or paper feed clutch.
  • Page 159 5023-110 Waste toner feeder removal 1. Remove the main drive gear assembly. See “Main drive gear assembly removal” on page 4-26. 2. Loosen the two screws (A) on the sensor base to allow free movement of the waste toner feeder. 3.
  • Page 160 5023-110 Rear removals Paper guide Toner density Paper feed assembly sensor roller Separator Paper guide (C) Paper exit assembly Registration assembly contains: assembly Registration sensor Tray empty sensor System board removal Warning: Before replacing the system board, save the onboard settings. See “Saving the system (RIP) board settings”...
  • Page 161 5023-110 Bracket assembly removal 1. Remove the erase lamp. See “Erase lamp removal” on page 4-18. 2. Remove the two screws (A). 3. Disconnect the connector (B) from the transfer belt marker sensor. 4. Disconnect the connector (C) from the toner density sensor. 5.
  • Page 162 5023-110 Paper guide assembly removal 1. Remove the lower cover from the rear cover assembly. 2. Remove the two screws (A) that attach the paper guide assembly to the printer. The screws are located in the holes. 3. Open the rear cover assembly. 4-30 Service Manual...
  • Page 163 5023-110 4. Lift and remove the paper guide assembly (B) from the printer. Paper guide (C) assembly removal “Paper guide assembly removal” on page 4-30. 1. Remove the paper guide assembly. See “Transfer belt unit removal” on page 4-6. 2. Remove the transfer belt unit. See 3.
  • Page 164 5023-110 Paper feed roller removal 1. Remove the paper guide (C) assembly. See “Paper guide (C) assembly removal” on page 4-31. 2. Slide the paper feed roller off of the shaft to remove. Paper exit assembly removal 1. Remove the two screws (A). 4-32 Service Manual...
  • Page 165 5023-110 2. Disconnect the cable (B). 3. Remove the two screws (C). 4. Remove the paper exit (D). Registration assembly removal “Transfer roller removal” on page 4-7. 1. Remove the transfer roller. See 2. Remove the three metal screws (A) and the three plastic screws (B). 3.
  • Page 166 5023-110 Left side removals Engine controller Engine board controller shield board HVPS System board cage LVPS Toner HVPS sensor cage Toner present sensor Engine controller board removal Warning: Before replacing the engine controller board, save the onboard settings. See “Saving the engine controller board settings”...
  • Page 167 5023-110 4. Disconnect all the connectors from the engine controller board. 5. Remove the five screws (B) from the engine controller board, and remove the engine controller board. Note: When reinstalling flat cables, ensure the blue side of the cable is opposite of the pins on the connectors.
  • Page 168 5023-110 System board cage removal 1. Remove the engine controller board. See “Engine controller board removal” on page 4-34. 2. Remove the screw (A) from the power supply fan. 3. Lay the power supply fan to the side. 4. Remove the ducting. 4-36 Service Manual...
  • Page 169 5023-110 5. Remove the three screws (B) from the system board cage. 6. Remove the system board cage. High voltage power supply (HVPS) removal 1. Remove the RIP board cage. See “System board cage removal” on page 4-36. 2. Disconnect all the connectors from the HVPS. Note: When reinstalling flat cable, ensure blue side of cable is opposite pins on connector.
  • Page 170 5023-110 Low voltage power supply (LVPS) with cage removal 1. Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-6. 2. Remove the RIP board cage. See “System board cage removal” on page 4-36. 3. Remove the grounding terminal screw (A). 4.
  • Page 171 5023-110 7. Remove the three metal screws (E) and the 3 plastic screws (F) that attach the LVPS with cage; remove the LVPS with cage. HVPS cage removal “High voltage power supply (HVPS) removal” on page 4-37. 1. Remove the HVPS. See 2.
  • Page 172 5023-110 Toner present sensor removal 1. Remove the HVPS cage. See “HVPS cage removal” on page 4-39. 2. Remove the two screws (A), and remove the toner present sensor. 4-40 Service Manual...
  • Page 173 5023-110 Toner sensor (receiver) removal Note: The toner sensor is comprised of two separate parts: the sender and receiver. The sender portion of the toner sensor is located on the right side of the printer. See “Toner sensor (sender) removal” on page 4-22 for removal.
  • Page 174 5023-110 Left tray guide assembly removal 1. Remove the marker sensor. See “Marker sensor assembly removal” on page 4-43. 2. Remove the HVPS cage. See “HVPS cage removal” on page 4-39. 3. Reroute the cable (A) to allow sufficient cable length for removing the left tray guide assembly from the frame.
  • Page 175 5023-110 Top removals Waste toner Marker Waste toner agitator sensor assembly auger Marker sensor assembly removal 1. Remove all the toner cartridges. “Photodeveloper cartridge removal” on page 4-9. 2. Remove the photodeveloper cartridge. See 3. Remove the transfer belt unit. See “Transfer belt unit removal”...
  • Page 176 5023-110 Waste toner auger removal 1. Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-9. 2. Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-6. “Top cover assembly removal” on page 4-12. 3. Remove the top cover assembly. See “Transfer belt cleaning roller removal”...
  • Page 177 5023-110 Power supply fan removal 1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-12. 2. Remove the screw (A) from the power supply fan. 3. Disconnect the cables from the interlock switches and the remove power supply fan. 4-45 Repair information...
  • Page 178 5023-110 4-46 Service Manual...
  • Page 179 5023-110 5. Locations and connectors Printer Top cover assembly Operato panel/cover Rear cover assembly Paper Release stopper lever Release lever Front cover Right cover Paper tray Front view Left cover Power switch AC input inlet Back view Locations and connectors...
  • Page 180 5023-110 Part name Description Paper stopper Stopper for exited papers. Operator panel/cover Displays the status of the printer’s operation. Top cover assembly Upper enclosure and also the paper exit tray. Rear cover assembly Printer rear enclosure that opens allowing the clearing of internal paper jams or maintenance work.
  • Page 181 5023-110 Electronic components Sensor locations Name Code Function Paper size sensor Detects paper size. Registration sensor Detects whether paper is fed from the paper drawer. Fuser exit sensor Detects when paper exits from the rear cover assembly. Tray empty sensor Detects if paper is loaded in the paper drawer.
  • Page 182 5023-110 Printer circuit board locations Name Function Engine controller board Controls the following printer processes Fuser temperature control Laser output control Operator panel indication Toner empty sensing control Error processing control Interface control Operator panel Displays the printer operation status and supports the manual input switch. Erase lamp Discharges the OPC belt located in the photodeveloper cartridge.
  • Page 183 5023-110 Fan/motor locations Name Code Function Main motor Drives the OPC belt and the paper transport system. Developer motors Drives the toner cartridge and the developing system. Scanner motor Drives the laser beam scanning in the optical unit Power supply fan Exhausts heat from the power PSFAN supply unit and the interface controller.
  • Page 184 5023-110 Interlock switch locations Name Code Function Front cover interlock DSW1 switch Rear cover assembly DSW2 Safety interlock switches that break power when a cover is opened. interlock switch Top cover interlock DSW3 switch Service Manual...
  • Page 185 5023-110 Clutch locations Name Code Function Paper feed clutch Feeds paper by coupling the feed roller to the main gear unit at PCLU the time of a paper feed. Registration clutch Transports paper by coupling the registration roller to the main RECL gear unit as synchronized with rotation of the transfer belt.
  • Page 186 5023-110 Symbol and part name table Symbol Part name Symbol Part name Back-up roller MCTL Main engine (MCTL P.W.B.) board CTFAN Control fan motor (cooling fan Main motor Developer motor Optical unit Optical unit Drum jam sensor PANEL Operator panel P.W.B. DSW1 Interlock switch (front) Belt sensor...
  • Page 187 5023-110 Wiring diagram 1 of 4 Locations and connectors...
  • Page 188 5023-110 Wiring diagram 2 of 4 5-10 Service Manual...
  • Page 189 5023-110 Wiring diagram 3 of 4 5-11 Locations and connectors...
  • Page 190 5023-110 Wiring diagram 4 of 4 5-12 Service Manual...
  • Page 191 5023-110 RIP board Engine controller board MCN9 MCN8 MCN7 MCN6 PACN MCN5 MCN10 FBCN HVCN 1FCN MCN4 MCN3 MCN2 MCN1 LVCN POCN FUCN 5-13 Locations and connectors...
  • Page 192 5023-110 Low voltage power supply (LVPS) board High voltage power supply (HVPS) board 5-14 Service Manual...
  • Page 193 5023-110 6. Preventive maintenance There is no preventive maintenance for this printer. Preventive maintenance...
  • Page 194 5023-110 Service Manual...
  • Page 195 5023-110 7. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
  • Page 196 5023-110 Assembly 1: Base printer Service Manual...
  • Page 197 5023-110 Assembly 1: Base printer Index Units Description 40X3383 Cover, cleaning roller 40X3382 Roller, cleaning 40X3412 Transfer unit 40X3418 Transfer roller assembly 40X3425 Paper tray, standard 40X0297 Power cord, USA 40X1766 Power cord, LV, USA, APG, Bolivia, Canada, Columbia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Peru, Venezuela 40X0301 Power cord, HV, Argentina...
  • Page 198 5023-110 Assembly 2: Covers Service Manual...
  • Page 199 5023-110 Assembly 2: Covers Index Units Description 40X3384 Cover assembly, top 40X3428 Assembly, paper exit (contains fuser exit sensor and flag) Packet, parts P/N 40X3420 40X3430 Assembly, registration 40X3417 Rear cover assembly 40X3385 Cover, right 40X3388 Cover, front 40X3387 Cover, inner front 40X3386 Cover, left 40X3424...
  • Page 200 5023-110 Assembly 3: Front Service Manual...
  • Page 201 5023-110 Assembly 3: Front Index Units Description 40X3441 Cover, laser unit assembly lens 40X3400 Laser unit assembly (printhead) 40X3431 Left tray guide assembly with cable (includes paper size sensor and temperature thermistor) 40X3401 Right tray guide 40X3416 Lamp, erase Parts catalog...
  • Page 202 5023-110 Assembly 4: Right Service Manual...
  • Page 203 5023-110 Assembly 4: Right Index Units Description 40X3395 Gear assembly, main drive 40X3391 Clutch, registration 40X3393 Clutch, transfer roller 40X3394 Clutch, cleaning roller Packet, parts P/N 40X3420 40X3390 Clutch, paper feed 40X3397 Drive assembly, developer 40X3389 Motor assembly, main 40X3398 Assembly, waste toner holder 40X3396 Waste toner feeder...
  • Page 204 5023-110 Assembly 5: Rear 7-10 Service Manual...
  • Page 205 5023-110 Assembly 5: Rear Index Units Description 40X3429 Assembly, bracket (includes marker sensor (transfer belt unit), toner density sensor) 40X3433 Paper guide assembly 40X3413 Paper guide (C) assembly with cable (includes registration sensor, tray empty sensor) 40X3414 Roller, paper feed 40X3415 Pad, separator 7-11...
  • Page 206 5023-110 Assembly 6: Left 7-12 Service Manual...
  • Page 207 5023-110 Assembly 6: Left Index Units Description 40X3436 Board, Network RIP (US) 40X3440 Board, Network RIP (EC) 40X3405 Power supply, high voltage 40X3399 Sensor, toner, receiver TTR (This is a two-piece sensor system. Ordering of this part number includes both the right and left side.) 40X3410 Sensor, toner present...
  • Page 208 5023-110 Assembly 7: Top 7-14 Service Manual...
  • Page 209 5023-110 Assembly 7: Top Index Units Description 40X3402 Auger, waste toner 40X3403 Agitator, waste toner 40X3434 Assembly, marker sensor (OPC) (includes bracket) 40X3409 Fan, power supply (includes top cover and rear cover assembly interlock switches) 7-15 Parts catalog...
  • Page 210 5023-110 Assembly 8: Miscellaneous/Options 7-16 Service Manual...
  • Page 211 5023-110 Assembly 8: Miscellaneous/Options Index Units Description 40X3421 Assembly, secondary paper feed 40X3426 Paper tray, legal 40X3419 Parts packet, harness 40X3442 Cable, 120V fuser 40X3443 Cable, 240V fuser 40X3420 Parts packet, screw 7372640 Field relocation kit 14D0403 Cable, USB, 2-meter 7-17 Parts catalog...
  • Page 212 5023-110 7-18 Service Manual...
  • Page 213 5023-110 Index messages operator Navigation buttons acronyms NVRAM settings saving the engine controller board settings saving the system (RIP) board settings Back button button back 1-31 optical system stop panel 1-35 control system display 1-35 control of print process paper jam messages 1-35 electrical system and function 1-15...
  • Page 214 5023-110 4-30 paper guide assembly photodeveloper cartridge 4-44 power supply fan 4-28 rear 4-33 registration assembly 4-14 right cover 4-19 right side 4-10 second paper feed assembly 4-42 sensor assembly 4-28 system board 4-36 system board cage 4-39 toner present sensor 4-40 toner sensor (receiver) 4-42...
  • Page 215 5023-110 Part number index Description page 14D0403 Cable, USB, 2-meter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 40X0273 Power cord, HV, Chile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 40X0274...
  • Page 216 5023-110 40X3419 Parts packet, harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 40X3420 Parts packet, screw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 40X3421...

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5023-110