Lexmark C925 Service Manual
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Lexmark C925 Service Manual

Led color printer
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Download this manual See also: Administrator's Manual, Maintenance Manual
Revised: December 17, 2013
™
Lexmark
C925
5041-030
• 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 C925

  • Page 1 Revised: December 17, 2013 ™ Lexmark C925 5041-030 • 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. PCL® is a registered trademark of the Hewlett-Packard Company.

  • Page 3: Table Of Contents

    5041-030 Notices and safety information ......... . . xi Safety information.
  • Page 4 5041-030 Paper jams ............... . . 2-12 Clearing and troubleshooting paper jams .
  • Page 5 5041-030 A. Collecting the history information from the SE menu ......2-40 B.
  • Page 6 5041-030 Tray Insert Message ............. . 3-9 SIZE SENSING .
  • Page 7 5041-030 Theory of operation ..............3-24 Print engine theory .
  • Page 8 5041-030 Transfer belt position sensor removal ..........4-32 Paper size sensor removal .
  • Page 9 5041-030 Pick roll removal ............. . 4-104 Paperfeed roll removal .
  • Page 10 5041-030 Assembly 9: Paperfeed ............. 7-18 Assembly 10: Electrical 1 .

  • Page 11: Notices And Safety Information

    5041-030 Notices and safety information Previous This device is a LED printer. The laser safety information does not apply to this device. Next Go Back Notices and safety information...
  • Page 12 5041-030 Previous Next Go Back Service Manual...

  • Page 13: Safety Information

    5041-030 Previous Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. Next •...
  • Page 14 5041-030 Previous Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Next • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 15 5041-030 Previous Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 16: Preface

    5041-030 Preface Previous This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

  • Page 17: Change History

    5041-030 Previous Change history Revision date Updates 2013/12/16 Removed the Reset color calibration topic from the Diagnostic information chapter. Next 2013/07/01 Added Steps before starting the 9yy.xx service checks. 2012/06/25 • Added “Safety feature notice” on page 2-1. • Updated and changed the Abnormal fuser temperature error service check to “ON / Go Back OFF switch automatically switching to the Off position service check”...

  • Page 18: Conventions

    5041-030 Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements: CAUTION Go Back A caution identifies something that might cause a servicer harm. CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working.

  • Page 19: General Information

    It prints both four-color and monochrome print jobs. Next The C925 represents the latest in Lexmark printer innovation, including a 4.3” full-color eTask touch screen with improved messaging and animation, enhanced security features, remote operator panel access and control, Go Back customizable reports, and access to the growing list of downloadable and customizable solutions.

  • Page 20: Printer Configurations

    Next input option, or more than one input option. If you purchased a multifunction printer (MFP) that scans, copies, and faxes, you may need additional furniture. For more information, see www.lexmark.com/multifunctionprinters. Go Back 4.3” touchscreen display Output bin...

  • Page 21: Options And Features

    5041-030 Previous Options and features Lexmark C925 printers support only Lexmark C925 paper-handling options. These options are not compatible with any other Lexmark printer. Next Some of the following options are not available in every country or region. Available internal options Go Back •...

  • Page 22: Printer Specifications

    5041-030 Previous Printer specifications This section varies by product type. It will be different in scanners, laser printers, and inkjet printers. Power specifications Next Average nominal power requirements for the base printer configuration. (Power levels are shown in watts.) Go Back Printing states Power Sleep Mode...

  • Page 23: Acoustics

    5041-030 Acoustics Previous All measurements are made in accordance with ISO 7779 and conform with ISO 9296. 1 meter average sound pressure Declared sound power level Status Bels Next Idle (Standby) 37 dBA Simplex printing 53 dBA Go Back Duplex printing 54 dBA Quiet Mode printing (Mono) 54 dBA...

  • Page 24: Performance

    5041-030 Performance Previous The C925 printers support up to 30 ppm (Letter) and 30 ppm (A4) maximum print speeds. Actual performance depends on: • Next Interface to host (parallel, serial, USB or network) • Host system and application • Complexity and content of the page •...

  • Page 25: Media Types

    5041-030 Previous Optional Multipurpose Paper size Dimensions Tray 1 Tray 2 550-sheet Duplex unit feeder tray Executive 184 x 267 mm (7.3 x 10.5 in.) Next Oficio 216 x340 mm (8.5 x 13.4 in>) Folio 216 x 330 mm Go Back (8.5 x 13 in.) Statement 140 x 216 mm...

  • Page 26: Media Weights

    5041-030 Media weights Previous Subsystem Size Type Weight Tray 1 All sizes supported Xerographic Long Grain 16lb to 34lb (60g/m2 to 128g/m2) by engine. and Bond Tray2 and Short Grain 16lb to 34lb (60g/m2 to 128g/m2) Excluding banner Next optional Recycled Long Grain 20lb to 34lb (75g/m2 to 128g/m2)

  • Page 27: Media Guidelines

    Paper characteristics The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. For detailed information, see the Card Stock & Label Guide available on the Lexmark Web site at http:// support.lexmark.com. Weight The printer can automatically feed paper weights from 60 to 220 g/m (16 to 58 lb bond) grain long.

  • Page 28: Unacceptable Paper

    5041-030 Moisture content Previous The amount of moisture in the paper affects both print quality and the ability of the printer to feed the paper properly. Leave the paper in its original wrapper until it is time to use it. This limits the exposure of the paper to moisture changes that can degrade its performance.

  • Page 29: Tools Required For Service

    5041-030 Previous Tools required for service Flat-blade screwdrivers, various sizes #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic Next #2 Phillips screwdriver, magnetic short-blade 7/32 inch (5.5 mm) open-end wrench 7.0 mm nut driver Go Back Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter...
  • Page 30 LASER Light amplification by stimulated emission of radiation Liquid crystal display Liquid Crystal Module Laser Diode Light emitting diode Long edge feed Lexmark Embedded Solution (applications) Low Voltage LVPS Low voltage power supply Magenta Megabyte Motor Driver Control Message handling...
  • Page 31 5041-030 Printer Job Language Previous Power-on reset POST Power-on self test PPDS Personal Printer Data Stream Pages per minute PQET Print Quality Enhancement Technology Next Peoples' Republic of China Parallel Synchronous Communications Position Sensing Device Go Back Participating Standards Organization Pulse Width Modulation Random access memory RFID...
  • Page 32 5041-030 Previous Next Go Back 1-14 Service Manual...

  • Page 33: Diagnostic Information

    5041-030 2. Diagnostic information Previous Start Next CAUTION Go Back Unplug the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

  • Page 34: Initial Check

    5041-030 Initial check Previous Before you start troubleshooting, check the following: Installation environment Next • The power supply line voltage is plus or minus 10% of the rated line voltage. • The machine is securely installed on a level surface in a well-ventilated place. •...

  • Page 35: Por (Power-On Reset) Sequence

    5041-030 Previous POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed. Next Power the machine on. Power supply fan rotates. Splashscreen with progress bar displayed. Go Back Printer controller initialized.

  • Page 36: Print Quality Issues

    5041-030 Previous Print quality issues Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photoconductor unit. Next Service tip: Before troubleshooting any print quality problems, do the following: Print a menu settings page, and then check the life status of all supplies.

  • Page 37: One Color Missing

    5041-030 One color missing Previous Step Action and questions Are the imaging units (photoconductors) properly Go to step 2. Reinstall the installed? imaging units. Next Is the photoconductor lock door properly closed on Go to step 3. Open and close both sides? photoconductor Go Back...

  • Page 38: Lowered Print Density

    5041-030 Lowered print density Previous Step Action and questions Check the paper for moisture. Is the paper moist? Replace the Go to step 2. paper. Next Check the LED printhead for dirt. Is the printhead dirty? Go to step 3. Go to step 4.

  • Page 39: Partial Dirt

    5041-030 Partial dirt Previous Step Action and questions Is there toner attached to the developer roll, especially Replace the Go to step 2. the lower part of the roll? imaging unit. Next Check the transfer belt for defects or foreign matter Remove the dirt Go to step 3.

  • Page 40: Unprinted Spots

    5041-030 Unprinted spots Previous Step Action and questions Check the paper in the tray for moisture. Is the paper Replace the Go to step 2. moist? paper in the tray. Next Check the LED print head for moisture on the imaging Wipe the LED Go to step 3.

  • Page 41: Black Page

    5041-030 Black page Previous Step Action and questions Inspect the contact points for the imaging unit and the Go to step 3 Go to step 2 printer. Are they clean and free of debris? Next Clean the contacts. Did this fix the issue? Problem resolved Go to step 3.

  • Page 42: Stain On Back Of Page

    5041-030 Stain on back of page Previous Step Action and questions Check for dirt on the transfer belt. Is there dirt on the Clean the transfer belt? transfer belt with Next a lint free cloth. Check for dirt along the paper path. Is there dirt on the Clean any dirty paper path? paper path...

  • Page 43: White Gaps Due To Poor Color Registration

    5041-030 White gaps due to poor color registration Previous Step Action and questions Ensure that the printer is level on a flat surface. Is the Go to step 3. Go to step 2. surface level? Next Level the printer. Did this fix the issue? Problem resolved Go to step 3.

  • Page 44: Paper Jams

    5041-030 Previous Paper jams Next Go Back User primary Location Explanation message 200.xx Paper jam in the transfer / carry area. 201.xx Paper jam in the fuser entry area. Paper jam at the paper exit area. Paper jam in the duplex. 231-39 Paper jam in the duplex.

  • Page 45: Clearing And Troubleshooting Paper Jams

    5041-030 Clearing and troubleshooting paper jams Previous 200 paper jam Open the right side cover. Pull the paper up and out to remove it from the paper path. Next Go Back Note: Make sure all paper fragments are removed. If the page is in the fuser, the fuser nip release lever should be lowered.

  • Page 46: Paper Jam

    5041-030 201 paper jam Previous Open the right side cover. Determine where the jam is located and remove it. If the paper is visible under the fuser, grasp it on each side and pull it out. Next Go Back If the paper is not visible, remove the fuser and remove the jam. See fuser removal. Remove the jammed paper.

  • Page 47: Paper Jam

    5041-030 230 paper jam Previous Open the right cover. Lift the duplexing unit mechanism away from the cover. Next Go Back Remove any jammed paper. Lower the mechanism. Close the right cover. Press Continue, jam cleared. 2-15 Diagnostic information...

  • Page 48: Paper Jam

    5041-030 231-39 paper jam Previous Open the right cover. Lift the duplexing unit mechanism away from the cover. Next Go Back Remove any jammed paper. Lower the mechanism. Close the right cover. Press Continue, jam cleared. 2-16 Service Manual...

  • Page 49: 24X Paper Jam

    5041-030 24x paper jam Previous Jam in tray 1 Open the right cover, and pull any jammed pages out. Next Go Back Open Tray 1, and pull the jammed pages up and out. Close Tray 1. Press Continue, jam cleared. 2-17 Diagnostic information...

  • Page 50: Paper Jam

    5041-030 Jam in the optional trays Previous Open the side affected tray’s access door, and remove the jammed pages. Note: Make sure all paper fragments are removed. Open the affected tray, and remove the jammed pages. Next Go Back Close the tray. Press Continue, jam cleared.

  • Page 51: Duplex Unit Service Check

    5041-030 Duplex unit service check Previous Action Feed roller belts Check for wear or damage to the feed roller belts. Replace as necessary. Next Duplex clutch Check the clutch cable for proper connection to CN13 on the engine board. If it is properly connected, replace the clutch. If this doesn't fix the problem, replace the engine board.
  • Page 52 5041-030 Paper has stopped at the registration roller or has not reached the fuser (Paper jams Previous 200, 250, 24x). Action Next • Registration roller Check these parts for wear or damage. Replace as necessary. Be clutch sure all guide surfaces in the paper path are free of dirt. •...
  • Page 53 5041-030 Paper has entered the duplex unit (Paper jam 230, 231-9). Previous Action Feed rollers Check for wear or damage to feed rollers and belts. Next Belts Duplex unit Be sure the duplex unit is properly installed and that all connections on the engine board (CN 28, 29, 13, 14) are correct.

  • Page 54: Paperfeed Unit Service Check

    5041-030 Paperfeed unit service check Previous Note: These tests can also be performed on the expansion paper-feed units. Action Next Door open interlock switch • Turn the printer on. • Open the door. • Check the operator panel for “Close Door” message. Go Back Paper tray level motor •...
  • Page 55 5041-030 Previous Action Relay sensor • Bypass the turn guide door open sensor*. • Turn the printer on while holding down the paper relay sensor. - If the operator panel does not display “Paper Jam”, check for a dirty paper relay sensor. Next - If the paper relay sensor is clean, or the actuator for the paper relay sensor is broken, replace the sensor.

  • Page 56: Mpf Service Check

    5041-030 MPF service check Previous Action MPF tray paper guides Check the guides to ensure they are not binding. Also, check the guides to ensure they are correctly adjusted for the paper in the Next tray. MPF roll cover Make sure the MPF roll cover is properly installed, and not obstructing the paperpath.

  • Page 57: Expansion Paper Feeder Service Check

    5041-030 Expansion paper feeder service check Previous Action Sensors • Check the sensors for dirt. Clean if needed. • Check the actuators for binding. Next • Check the sensor cables for proper connection to the sensors and interface controller board. •...

  • Page 58: Error Codes

    5041-030 Previous Error codes Note: In addition to the 1xx and 9xx error codes, this device displays a symptom where the device shuts down repeatedly. The main symptom of this error is the switch going to the off position automatically when the device PORs.

  • Page 59: Abnormal Eeprom

    5041-030 Previous 9xx error codes Action 900.xx Unrecoverable RIP “Steps before starting the 9yy service checks” on page 2-40. software error / illegal trap Next “900.xx System software error” on page 2-42. 910.xx Unrecoverable engine Turn off printer for 10 seconds and restart. If error re-occurs, replace RIP firmware error board.

  • Page 60: Service

    5041-030 Previous 9xx error codes Action 975.xx Standard network or Call your second level support. Network Card X 976.xx Standard network or Next Network Card X 982.xx Service <device> Go Back 990.xx Service <device> 991.xx Service <device> Card 2-28 Service Manual...

  • Page 61: 1Xx / 9Xx Error Code Service Checks

    5041-030 Previous 1xx / 9xx Error code service checks 111.01 Black printhead error Next Step Action and questions Is the ribbon cable connecting CN4 on the printhead Go to step 2. Properly connect controller board to the black LED head securely the ribbon cable Go Back connected?

  • Page 62: Thermistor 1 Error

    5041-030 121.01 Thermistor 1 error Previous Note: If the error is 121.05, the fuser is at the end of life. Step Action and questions Next Is the fuser properly installed? Make sure that it is Go to step 2. Reinstall the properly seated.

  • Page 63: Thermistor 3 Error

    5041-030 121.03 Thermistor 3 error Previous Note: If the error is 121.05, the fuser is at the end of life. Step Action and questions Next Is the fuser properly installed? Make sure that it is Go to step 2. Reinstall the properly seated.

  • Page 64: Fuser - Fuser Heater Error

    5041-030 121.05 Fuser - fuser heater error Previous Step Action and questions Is the fuser installed and seated properly? Go to step 2. Properly install the fuser. Next Are CN02 and CN04 on the LVPS, and CN16 on the Go to step 3. Properly connect printhead controller board properly connected? all the cables.

  • Page 65: Density Sensor Error

    5041-030 132.00 Density sensor error Previous Step Action and questions Is the density sensor cleaner stuck in place? Go to step 2 Release the cleaner. Replace Next if damaged. Is the cable connecting the density sensor to CN14 on Go to step 3. Securely connect the printhead controller board connected securely on the cable.

  • Page 66: Abnormal Theta Sensor

    5041-030 132.xx Abnormal theta sensor Previous Step Action and questions Is the reference pattern for the color plane alignment Go to step 4. Go to step 2. printing properly on the transfer belt? Next Did all the colors print on the test pattern? Go to step 4.

  • Page 67: Temperature Humidity Sensor Error

    5041-030 136.xx Temperature humidity sensor error Previous Step Action and questions Is CN4 on the engine board securely connected? Go to step 2 Connect the cable securely. Next Replace the humidity sensor cable. Does this fix the Problem solved. Go to step 3. problem? Go Back Replace the temperature humidity sensor.

  • Page 68: Tray1Error

    5041-030 146.01 Tray1error Previous Note: This is the service check for the standard paper tray. Step Action and questions Next Check the cable connecting the paper tray lift motor to Go to step 3 Go to step 2 CN 6 on the engine board. Is the cable properly connected at both ends? Go Back Connect the cable properly at both ends.

  • Page 69: Tray 4 Error

    5041-030 Previous Step Action and questions Replace the paper full sensor cable. Did this fix the Problem solved. Go to step 12. problem? Replace the paper full sensor. Did this fix the issue? Problem solved. Go to step 13. Next Replace the expansion paper feeder controller board.

  • Page 70: Tray 5 Error

    5041-030 146.05 Tray 5 error Previous Note: This is the third expansion tray. Step Action and questions Next Check CN 121 on the second expansion paper Go to step 3. Go to step 2. feeder’s expansion feeder controller board for proper connectivity.

  • Page 71: Power Supply Unit Fan Error

    5041-030 172.01 - Power supply unit fan error Previous Step Questions/actions Next Is there anything obstructing the fan’s movement? Clear the Go to step 2. obstruction. Check connector CN22 on the MDCONT board, and Go to step 3 Reconnect the Go Back CN04 and CN05 on the LVPS.

  • Page 72: Steps Before Starting The 9Yy Service Checks

    5041-030 Steps before starting the 9yy service checks Previous Before starting the service checks in this section, you will need to retrieve certain information. This will aid your next level of support in diagnosing the problem before replacing the controller board. Warning: Do not replace the controller board unless directed by your next level of support.

  • Page 73: Collecting The Settings From The Menu Settings Page

    5041-030 C. Collecting the settings from the menu settings page Previous Note: The menu settings page is different for each printer. For more information see the User’s Guide. Your next level of support will tell you which page they want to see. Copying the menu settings page from the Embedded Web Server (EWS) Next Note: Make sure your printer is connected to a network or to a print server.

  • Page 74: System Software Error

    • Determine the operating system used when the error occured. If possible determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device.
  • Page 75 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.

  • Page 76: Sdram R/W Error

    5041-030 Previous Step Action and questions Replace the faulty ISP option. Restart the device. Go to step 31. Go to step 26. Does the 900.xx error reoccur? Are there any more ISP options to install? Go to step 27 Problem Next resolved.
  • Page 77 5041-030 Previous Step Action and questions Are the cables connecting CN24 on the engine board, Go to step 3. Go to step 2. CN5 on the printhead controller, and CN03 in the Next LVPS properly connected? Re connect the cables. Did this fix the problem? Problem resolved Go to step 3.

  • Page 78: Cpu Error

    5041-030 941.03 CPU error Previous Step Action and questions POR the printer. Problem resolved Go to step 2. Next Does the problem go away? Replace the printhead controller. Does this fix the Problem resolved Go to step 3. problem? Go Back Replace the RIP board.

  • Page 79: 950.29-Eprom Mismatch Failure

    5041-030 950.00–950.29—EPROM mismatch failure Previous Warning: When replacing any of the following components, replace only one component at a time or the printer will be rendered inoperable: • System board • Flatbed scanner assembly Next • Scanner interface card Replace the required component, bring the printer up in Diagnostics mode (see “Diagnostics mode”...

  • Page 80: Service Invalid Firmware Error

    5041-030 959.xx Service invalid firmware error Previous Step Action and questions POR the printer a few times. Does the problem re- Go to step 2. Problem occur? resolved. Next Put the machine into recovery mode and update the Problem resolved Go to step 3.

  • Page 81: User Attendance Messages

    5041-030 User attendance messages Previous User prompts Error code Action Next Adjusting color Wait until the process is completed. Change <src><custom This message allows the user to override the source for the remainder of a job. The page will Go Back type name>...
  • Page 82 5041-030 Previous Error code Action Close Front Door Close the front door securely. Disk Corrupted, The printer has attempted a disk recovery and cannot repair the disk. The disk must be Reformat? formatted to use. Next Warning: All files stored on the disk will be lost. Held Jobs May Not Be The printer has attempted to restore Held jobs, but not all were restored.
  • Page 83 5041-030 Previous Error code Action Load Manual <type> If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, <size> pressing Select indicates to the printer it should search for a source with the proper type and size.

  • Page 84: User Attendance Messages (0-99)

    5041-030 User attendance messages (0–99) Previous Error code Action 30 Toner cartridge • Reseat the specified print cartridge. missing Next • Use different cartridge. • Check contacts on the photodeveloper. • Check the ribbon cable connecting the printhead and printhead controller board. Go Back •...
  • Page 85 5041-030 Previous Error code Action 37 Insufficient memory • Select Continue to stop the defragment operation and continue printing. for Flash Memory • Delete fonts, macros, and other data in printer memory. Defragment operation • Install additional printer memory. Next •...
  • Page 86 5041-030 Previous Error code Action 54 Serial option <x> • Make sure the serial link is set up correctly and the appropriate cable is in use. error • Make sure the serial interface parameters (protocol, baud, parity, and data bits) are set correctly on the printer and host computer.
  • Page 87 58 Too Many Trays 1. Turn off and unplug the printer. Attached 2. Remove options until the supported number of options for that model. Models C925 supports three additional trays. 3. Plug in the printer, and turn it on. 61 Defective Disk •...
  • Page 88 5041-030 Previous Error code Action 80 Fuser Missing Remove power from the printer before continuing or use caution if the product must be energized during this procedure. The heat sink transformer core presents risk of electric shock. Test before touching. Next •...
  • Page 89 5041-030 Previous Error code Action • Show Me, View Supplies, and Tell Me More displays additional information. 88.xx <color> Cartridge Nearly Low • Replace the specified toner cartridge. • Select Continue to clear the message and continue printing. • If the problem persists, replace the system board. See “Printhead controller board Next removal”...

  • Page 90: Other Symptoms

    5041-030 Previous Other symptoms Symptom Action You cannot print color. Make sure the Color Correction menu item is not set to Black & White. Next Make sure the color print units are completely installed in the printer. Go to “Transfer belt up down check” on page 2-67.

  • Page 91: On / Off Switch Automatically Switching To The Off Position Service Check

    5041-030 Previous Symptom Action • Foggy print Go to “Print quality issues” on page 2-4. • Black pages • Blank print • White spots Next • Poor reproduction • Incorrect color image registration • Dirt on back of paper Go Back •...

  • Page 92: Other Service Checks

    Go Back electronic interference. 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. Step...

  • Page 93: Usb Port Service Check

    5041-030 Previous Step Questions / actions Is the device physically connected (ethernet Go to step 13. Go to step 15. cable) to the network? Try using a different ethernet cable. Problem resolved Go to step 14. Next Did this remedy the situation? Have the network administrator check the Replace the controller Contact the network...

  • Page 94: False Close Door Service Check

    5041-030 False close door service check Previous Step Action and questions Open and close the right cover. Does the message Problem solved Go to step 2. reset? Next Check the right door release lever. Does it operate Go to step 3. Replace the smoothly, and is the interlock actuator intact? faulty part on the...

  • Page 95: Insert Tray Service Check

    5041-030 Insert tray service check Previous Step Action and questions Remove the tray, and inspect the tray for any damaged Go to step 2. Go to step 3. or broken parts that would prevent it from being Next installed properly, or move around in the printer. Are there loose or damaged parts on the tray? Try a different tray.

  • Page 96: Imaging Unit (Photo Developer) Missing Service Check

    5041-030 Imaging unit (photo developer) missing service check Previous Step Action and questions Are the imaging units properly seated? Go to step 3. Go to step 2. Next Reseat the imaging units, and properly close the Problem solved. Go to step 3. photodeveloper lock.

  • Page 97: Flash Options

    5041-030 Flash options Previous Run a copy of the test page, and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Be sure the memory card assembly is installed correctly and is not broken or damaged.

  • Page 98: Power Supply (Dead Machine) Service Check

    5041-030 Power supply (Dead machine) service check Previous Note: Before proceeding, make sure that this is not an issue with the display. Turn the machine on. If the machine’s fans and motors start up, it could be an issue with the display. Next Step Action and questions...

  • Page 99: Printhead Service Check

    5041-030 Printhead service check Previous Step Action and questions Check the LED for any dirt or toner that may distort the Go to step 2. Go to step 3. image. Is the LED dirty? Next Clean the LED. Did this fix the problem? Problem solved Go to step 3.

  • Page 100: Unable To Print From Usb Thumb Drive Service Check

    5041-030 Unable to print from USB thumb drive service check Previous Step Action and questions Try a different thumb drive. Does that drive work? Problem solved Go to step 2. Next Verify that the USB cable is properly connected to the Go to step 4.

  • Page 101: Wrong Paper Size Service Check - Tray1

    5041-030 Wrong paper size service check - tray1 Previous Step Action and questions Check the size indicator on the front of the tray. Is it set Go to step 3. Go to step 2. to the correct size? Next Set the indicator to the correct size. Did this fix the Problem solved Go to step 3.
  • Page 102 5041-030 Previous Next Go Back 2-70 Service Manual...

  • Page 103: Diagnostic Aids

    5041-030 3. Diagnostic aids Previous This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Next Understanding the printer operator panel Go Back Item Description 1- Display Shows the status of the printer. 2 - Home Lets you navigate back to the home screen.

  • Page 104: Understanding The Homescreen Icons And Their Functions

    5041-030 Understanding the homescreen icons and their functions Previous Buttons appearing on the home screen may vary depending on home screen customization settings. Next Go Back Item Description Change Language Allows you to change the primary language and reports on the display, and will remain in effect until changed Bookmarks Allows you to create, organize, and save a set of bookmarks (URLs) into a...

  • Page 105: Using The Touch-Screen Buttons

    5041-030 Using the touch-screen buttons Previous Button Function Up arrow Scrolls up Next Go Back Delete folder Deletes a print job Drag print jobs to the folder to delete them. Left arrow Scrolls left Right arrow Scrolls right Right scroll increase Increases a value Left scroll decrease Decreases a value...

  • Page 106: Other Touch-Screen Icons

    5041-030 Other touch-screen icons Previous Icon Function Exit Exits from the current screen to the home screen Next Go Back Unselected radio Indicates that an item is not selected button Selected radio button Indicates a selection Index Displays information about the key functions of the printer, including instructions on how to operate it Search Lets you search for files and menus...

  • Page 107: Administrative Menus

    5041-030 Administrative menus Previous See the menu map for a brief overview of the printer menus available from the operator panel. Select a menu or menu item for more details. Next Supplies Menu Replace Supply Paper Menu Reports Go Back Cyan Cartridge Default Source Menu Settings Page...

  • Page 108: Accessing The Service Menus

    5041-030 Accessing the service menus Previous There are different test menus that can be accessed during POR to identify problems with the printer. Next Diagnostics menu 1. Turn off the printer. The Diagnostics menu group contains the settings and 2. Press and hold 3 and 6. operations used while manufacturing and servicing the Go Back...

  • Page 109: Configuration Menu

    5041-030 Previous Configuration Menu The Configuration menu contains a set of menus, settings, and operations which are infrequently used by a user. Generally, the options made available in this menu are used to configure a printer for operation. Next An asterisk (*) in the value list in the following menus indicates the default value. Entering Config Menu Go Back To enter the Configuration Menu:...

  • Page 110: Reset Separator Roll And Pick Assembly Counter

    5041-030 Configuration Menu Previous Disk Encryption “Disk Encryption” on page 3-12. Erase all information on Disks “Erase all information on Disks” on page 3-12. Wipe All Settings “Wipe All Settings” on page 3-12. Next Font Sharpening “Font Sharpening” on page 3-12.

  • Page 111: Print Quality Pages

    5041-030 Print Quality Pages Previous The Print Quality Test consists of five pages. Pages one and two contain a mixture of graphics and text. The remainder of the pages only contain graphics. Use this test to identify print quality problems. The Test Pages must be printed on A4, Legal, or Letter paper.

  • Page 112: Ppds Emulation

    5041-030 PPDS Emulation Previous This appears only if the PPDS interpreter is available. Download Emuls Next Warning: This setting should not be changed without specific instructions from the next level of support. This setting temporarily disables downloaded emulators for troubleshooting purposes. All downloaded Go Back emulators are re-enabled automatically after two PORs.

  • Page 113: Color Alignment

    5041-030 Color Alignment Previous When you enter Color Alignment, the printer generates four alignment pages that are used to set the color alignment on the print engine. This needs to be run whenever a toner cartridge of imaging unit is instaled on the print engine.

  • Page 114: Envelope Prompts

    5041-030 Envelope Prompts Previous Env Prompts controls which tray a change prompt is directed to when the envelopes are sensed to be the wrong size. Action for Prompts Next This setting enables users to have the printer resolve media change prompt situations automatically. Such prompts occur when the selected media for the job is not available when the job prints.

  • Page 115: Les Applications

    5041-030 LES Applications Previous This setting allows users to enable or disable the use of Lexmark Embedded Solutions (LES) applications. Key Repeat Initial Delay Next This setting determines the length of delay before a repeating key starts repeating. The default setting is 1 second.

  • Page 116: Diagnostics Mode

    5041-030 Previous Diagnostics mode To run the printer diagnostic tests described in this chapter, put the printer in Diagnostics mode. Entering Diagnostics mode Next To enter the Diagnostics Mode: Go Back Turn off the printer. Press and hold 3 and 6. Turn on the printer.
  • Page 117 5041-030 HARDWARE TESTS Previous Panel Test “Panel Test” on page 3-16 Button Test “Button Test” on page 3-17 DRAM Test “DRAM Test” on page 3-17 Serial 1 Wrap (if installed) “Serial Wrap Test” on page 3-18 Next USB HS Test Mode “USB HS Test Mode”...

  • Page 118: Print Tests

    5041-030 PRINT TESTS Previous Print Tests (input sources) This test determines if the printer can print on media from any of the paper input sources. Each of the installed sources is available within the Print Tests menu. Next The content of the test page varies depending on the media installed in the selected input source. •...

  • Page 119: Button Test

    5041-030 Button Test Previous This test verifies the operator panel button function. To run the Button Test: From the Diagnostics menu, navigate to: Next HARDWARE TESTS > Button Test With no buttons pressed, an image the operator panel buttons is displayed. Press each operator panel button one at a time, and the button in the illustration turns blue.

  • Page 120: Serial Wrap Test

    5041-030 Serial Wrap Test Previous Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. Note: this test is listed only if the serial option ISP card is installed. To run the Serial Wrap Test: Next Disconnect the serial interface cable, and install the wrap plug.

  • Page 121: Usb Hs Test Mode

    5041-030 USB HS Test Mode Previous 1. From the Diagnostics menu, navigate to: HARDWARE TESTS > USB HS Test Mode 2. Select the desired Port. The test begins immediately for the Single Stop tests. 3. Select the desired Test. Next Ports Tests Go Back...

  • Page 122: Flash Test

    5041-030 Flash Test Previous This test causes the file system to write and read data on the flash to test the flash. Warning: This test destroys all data on the flash because the flash is reformatted at the end of the test. Select Flash Test from DEVICE TESTS From the Diagnostics menu, navigate to: Next DEVICE TESTS >...

  • Page 123: Page Counts

    5041-030 PAGE COUNTS Previous This menu lets you view the total page counts of the printer or the page counts broken down into color and mono pages printed. Unlike in previous printers, none of these values can be changed. Touch Back to return to the Diagnostics menu. Next Serial Number Go Back...

  • Page 124: Par 1 Strobe Adj

    5041-030 Par 1 Strobe Adj Previous Parallel Strobe Adjustment enables you to change the amount of time the strobe is sampled in order to determine if data is available on the parallel port. Increasing the value increases the amount of time by 50 ns per increment.

  • Page 125: Clear Log

    5041-030 The Clear Log operation clears out the errors that print in this report. The errors listed in the Display Log Previous operation do not necessarily match in number nor in order with the errors from the printer log. Note: This log can be printed from configuration menu, but the debug and secondary error codes are not printed on this log.

  • Page 126: Theory Of Operation

    5041-030 Previous Theory of operation Print engine theory Electrophotographic Process (EP Process) Next The method that all laser and LED printers use to print is called the electrophotographic process. These machines use differences in charge to manipulate and move toner from the toner cartridge to the printed page. Go Back Even though the basic EP process is the same for every laser and LED printer, the specifics for each printer are different.

  • Page 127: Step 1: Charge

    5041-030 Step 1: Charge Previous During the charge step, voltage is sent from the high-voltage power supply to the charge roller (A) beside each of the four photoconductors. The charge roller is part of the photoconductor unit. The charge roller (A) puts a uniform negative charge over the entire surface of the photoconductor to prepare it Next for the LED.

  • Page 128: Step 2: Expose

    5041-030 Step 2: Expose Previous During the expose step, the LED exposes the surface of each photoconductor (B) and writes an invisible image called a latent image or electrostatic image for each color. The LED actually discharges the surface only where the beam hits the photoconductor. This creates a difference Next in charge potential between the exposed area and the rest of the photoconductor surface.

  • Page 129: Step 3: Develop

    5041-030 Step 3: Develop Previous Once the laser exposes the photoconductor, the high-voltage power supply sends charge to the developer roll (C). For each color, the toner cartridge engages the photoconductor so it is in contact with the surface. Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser, the toner will attract to the photoconductor only where the laser exposed the surface.

  • Page 130: Step 4A: First Transfer

    5041-030 Step 4a: First transfer Previous When the latent images are developed on each Photoconductor, the high-voltage power supply sends voltage to the 1st Transfer Rollers inside the transfer belt unit. The charge difference between the developed toner image on the Photoconductor surface and the 1st Transfer Next Roller causes the images to transfer to the surface of the transfer belt for each color.

  • Page 131: Step 4B: Second Transfer

    5041-030 Step 4b: Second transfer Previous Once the four planes of color are transferred to the transfer belt from the photoconductors, the image is carried towards the transfer roll. This transfer roll is mounted on the duplex unit. The paper passes between the transfer belt and transfer roll when the image on the belt reaches the second transfer area.

  • Page 132: Step 5: Fuse

    5041-030 Step 5: Fuse Previous Once the image has been fully transferred to the media, the transfer roll helps move the paper into the fuser area. The fuser applies heat and pressure to the page to melt the tiny toner particles and bond them permanently to Next the media.

  • Page 133: Step 6: Clean/Erase

    5041-030 Step 6: Clean/Erase Previous There are two main cleaning processes that take place during the EP Process. One process cleans the transfer belt, and the other cleans the photoconductors. Transfer Unit Clean Next Once the toner image on the transfer belt has been transferred to the page, the transfer belt rotates around and is cleaned by the cleaning blade.

  • Page 134: Cleaning Blade

    5041-030 Photoconductor Clean/Erase Previous 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. This is the clean/erase process. Next Go Back Cleaning blade Now the photoconductor surface is prepared to begin the EP cycle once again.

  • Page 135: Paper Path Components

    5041-030 Paper path components Previous Paper feed The standard paper feed sources consist of a multi-paper cassette (Tray 1), a standard paper cassette (Tray 2), and an MPF Tray. The paper feed system on the paper cassettes uses a separation roll/torque limiter to prevent Next multiple feeds.
  • Page 136 5041-030 Tray 2 and optional trays (3-5) Previous Trays 2 through Tray 5 use a motorized lift mechanism to engage the media in the tray with the pickup roller. Tray 1 holds up to150 sheets of 20 lb. paper and the optional Trays (3-5) can hold up to 500 sheets of 20lb paper.

  • Page 137: Feeding Paper From A Tray

    5041-030 Feeding paper from a tray Previous The printer controller sends a signal to turn on the paper feed clutch; the pick roll grabs the top sheet of paper while the separator roll rotates backwards to prevent multiple sheets of paper from feeding. The paper moves to the feed roll and is fed into the paper path.

  • Page 138: Feeding Paper From The Mpf

    5041-030 Feeding paper from the MPF Previous To start the paper feed, the printer controller sends a signal to turn on the MPF feed clutch; the paper feed motor starts turning to feed the top sheet of paper in the MPF tray one by one. Once the duplex exit/MPF detection lever senses the leading edge of the media at the duplex exit roller, it engages the duplex re-feed clutch to transport the sheet of paper into the paper path.
  • Page 139 5041-030 Paper registration Previous As the media trips the Registration Sensor, it briefly stops at the Registration Rollers. Here, the leading edge is adjusted so it is parallel with the image on the Transfer Belt and synchronized with the Belt’s rotation. Next, the paper feed motor triggers the Registration Clutch to rotate the Registration Rollers to feed the paper toward the Transfer Belt and 2nd Transfer Roller.
  • Page 140 5041-030 Duplexing Previous If a page is two-sided, a signal is sent to the Printer Controller Board once the trailing edge of the paper passes the Fuser Exit Sensor. The leading edge of the paper partially feeds from the Exit Rolls and then reverses direction and feeds into the Duplex Unit.

  • Page 141: Color Theory

    5041-030 Color theory Previous 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 Next monitors create colors in this manner.

  • Page 142: My Color Transparencies Seem Dark When They Are Projected. Is There Anything I Can Do To Improve The Color

    5041-030 My color transparencies seem dark when they are projected. Is there anything I can Previous do to improve the color? This problem most commonly occurs when projecting transparencies with reflective overhead projectors. To obtain the highest projected color quality, transmissive overhead projectors are recommended. If a reflective projector must be used, then adjusting the Toner Darkness setting to 1, 2, or 3 will lighten the transparency.

  • Page 143: How Can I Match A Particular Color (Such As A Corporate Logo)

    5041-030 How can I match a particular color (such as a corporate logo)? Previous From the printer Quality menu, nine types of Color Samples sets are available. These are also available from the Color Samples page of the Embedded Web Server. Selecting any sample set generates a multiple-page printout consisting of hundreds of colored boxes.
  • Page 144 5041-030 Previous Next Go Back 3-42 Service Manual...

  • Page 145: Repair Information

    5041-030 4. Repair information Previous Warning: Read the following before handling electronic parts. Next Handling ESD-sensitive parts Go Back Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...

  • Page 146: Rip Board/Operator Panel Replacement

    5041-030 RIP board/operator panel replacement Previous This procedure should only be followed if both the RIP board and operator panel fail. If you only need to replace one of the FRUs follow the startup procedure described in the FRU’s removal procedure. CAUTION - POTENTIAL INJURY: There is danger of explosion if a lithium battery is incorrectly Next replaced.

  • Page 147: Esf Solutions Backup

    5041-030 eSF solutions backup Previous If a technician needs to replace the RIP board, the steps below should be taken to backup the eSF solutions and settings: POR the printer into invalid engine code mode. See “Accessing the service menus” on page 3-6.

  • Page 148: Removal Procedures

    5041-030 Previous Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable Next or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. Go Back Arrangement of removals in this chapter The removals in this chapter are arranged by area of printer.

  • Page 149: Cover Removals

    5041-030 Previous Cover removals Rear cover removal Remove the RIP card cover. Next Go Back Remove the option connector cover. Repair information...
  • Page 150 5041-030 Open the duplex and remove the screw (A). Previous Next Go Back Remove the three screws (B) on the rear side of the printer. Tilt the rear cover back. Service Manual...

  • Page 151: Operator Panel Bezel Removal

    5041-030 Using a flatblade screwdriver, release the tabs (C) fastening the option cable to the rear cover. Previous Next Go Back Operator panel bezel removal Open the front door. Remove the three screws (A) securing the operator panel bezel to the operator panel assembly. Lift the bezel up, and remove it from the operator panel assembly.

  • Page 152: Operator Panel Removal

    5041-030 Operator panel removal Previous Remove the operator panel bezel. See “Operator panel bezel removal” on page 4-7. Remove the two screws (A) securing the operator panel assembly to the printer frame. Next Go Back Turn the operator panel assembly over. Disconnect the RIP-UICC cable (B).

  • Page 153: Uicc Card Removal

    5041-030 UICC card removal Previous Remove the operator panel assembly. See “Operator panel removal” on page 4-8. Place the operator panel assembly face down on a non-marring surface. Carefully open the ZIF connector (A) and disconnect the display ribbon cable. Next Go Back Remove the five screws (B) that secure the UICC card to the operator panel assembly.

  • Page 154: Touchscreen Removal

    5041-030 Touchscreen removal Previous Remove the operator panel assembly. See “Operator panel removal” on page 4-8. Remove the UICC from the operator panel assembly. See “UICC card removal” on page 4-9. Remove the five screws (A) securing the TSP holder and TSP ground to the operator panel assembly. Next Go Back Remove the TSP ground and TSP holder (B).

  • Page 155: Top Cover Removal

    5041-030 Top cover removal Previous Remove the rear cover. See “Rear cover removal” on page 4-5. Remove the operator panel assembly. See “Operator panel removal” on page 4-8. Remove the two screws (A) securing the top cover to the rear EMI shield. Next Go Back Remove the screw (B) securing the top cover to the left EMI shield.
  • Page 156 5041-030 Remove the two screws (C) securing the top cover to the front of the printer frame. Previous Next Go Back Gently pry the right side of the top cover out to release the tabs securing the cover to the printer frame. 4-12 Service Manual...

  • Page 157: Left Cover Removal

    5041-030 Lift the top cover up and away. Previous Next Go Back Left cover removal Remove the rear cover. See “Rear cover removal” on page 4-5. Remove the top cover. See “Top cover removal” on page 4-11. Remove the rear screw (A) securing the left cover to the printer frame. 4-13 Repair information...
  • Page 158 5041-030 Remove the screw (B) securing the left cover to the left EMI shield. Previous Next Go Back Remove the two screws (C) securing the left shield to the frame. Remove the screw (D) securing the left cover to the printer frame. 4-14 Service Manual...
  • Page 159 5041-030 Slide the left cover back to release the tabs from the printer frame. Previous Next Go Back Pull the left cover away from the frame. 4-15 Repair information...

  • Page 160: Front Door Removal

    5041-030 Front door removal Previous Note: If you are replacing the front door, remove the front logo cover. See “Front logo cover removal” on page 4-17. Open the front door. Next Remove the screws (A) securing the front door hinge to the front door. Go Back Slide the door to the left, and pull the front door away from the printer.

  • Page 161: Front Logo Cover Removal

    5041-030 Front logo cover removal Previous Open the front door. Remove the nine screws (A) securing the front logo cover to the front door. Next Go Back 4-17 Repair information...

  • Page 162: Top Removals

    5041-030 Previous Top removals Output bin full sensor actuator removal Remove the top cover. See “Top cover removal” on page 4-11. Next Use a flatbed screwdriver to gently pry the tab (A) holding the actuator in place. Go Back Carefully lift the actuator up. Be careful to avoid dislodging the exit sensor. 4-18 Service Manual...

  • Page 163: Led Assembly Removal

    5041-030 LED assembly removal Previous Remove the transfer belt. See “Transfer belt CRU removal” on page 4-31. Remove the top cover. See “Top cover removal” on page 4-11. Remove the rear EMI shield. See “Rear EMI shield removal– Not a FRU” on page 4-82.
  • Page 164 5041-030 Press up on the green touchpoint, Previous Next Go Back Pull the LED assembly towards the front of the print engine. Note: Use two hands when removing the unit. This is to prevent the LED assembly from dropping down and damaging the LED unit in the assembly.

  • Page 165: Led Print Head Removal

    5041-030 LED print head removal Previous Remove the LED assembly. See “LED assembly removal” on page 4-19. Using a screw driver, pull the plastic casing (A) on the rear of the holder away from the tab on the printhead, releasing it from the printhead holder. Next Go Back Repeat the previous step for the front of the printhead assembly.

  • Page 166: Op Panel Paper Exit Guide Removal

    5041-030 Op panel paper exit guide removal Previous Remove the top cover. See “Top cover removal” on page 4-11. Remove the two screws (A) on the rear. Next Go Back Remove the two screws (B) at the front of the printer. 4-22 Service Manual...
  • Page 167 5041-030 Gently pull the lower op panel cover back, and lift the op panel guide up. Previous Next Go Back Remove the screw (C) securing the ground wire to the printer frame. 4-23 Repair information...

  • Page 168: Paper Exit Guide Removal

    5041-030 Paper exit guide removal Previous Remove the top cover. Remove the op panel paper exit guide. See “Op panel paper exit guide removal” on page 4-22. Disconnect the paper exit / bin full sensor cable from CN7 on the printhead controller board. Thread the cable (A) through the fuser fan duct.
  • Page 169 5041-030 Lift the unit up and remove it from the printer. Previous Next Go Back Note: When reinstalling the unit, line up the slots (D) on the paper exit unit with the tabs (E) on the sub drive unit before pushing the unit down in place. 4-25 Repair information...

  • Page 170: Bin Full Sensor Removal

    5041-030 Bin full sensor removal Previous Remove the paper exit guide. See “Paper exit guide removal” on page 4-24. Release the tabs (A) securing the black exit guide. Next Go Back Open the guide, exposing the bin full sensor. Release the tabs (B) securing the bin full sensor to the paper exit guide. Disconnect the blue cable from the sensor.

  • Page 171: Paper Exit Sensor Removal

    5041-030 Paper exit sensor removal Previous Remove the paper exit guide. See “Paper exit guide removal” on page 4-24. Release the tabs (A) securing the paper exit sensor to the paper exit guide. Next Go Back Disconnect the purple cable from the sensor. 4-27 Repair information...

  • Page 172: Printhead Controller Board Removal

    5041-030 Printhead controller board removal Previous Warning: When replacing any one of the following components: • Printhead controller board • Engine) board Next Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.

  • Page 173: Speaker Removal

    5041-030 Speaker removal Previous Remove the top cover. See “Top cover removal” on page 4-11. Turn the top cover over. Remove the two screws (A). Next Go Back Lift the speaker and frame out of the top cover. 4-29 Repair information...

  • Page 174: Top Emi Sheild Removal

    5041-030 Remove the speaker from the frame. Previous Next Go Back Top EMI sheild removal Remove the top cover. See “Top cover removal” on page 4-11. Remove the seven screws securing the sheild (A) to the top of the printer. There are five screws on the rear and two screws on the front.

  • Page 175: Front Removals

    5041-030 Previous Front removals Transfer belt CRU removal Open the front cover. Next Go Back Open the right cover. Lower the transfer belt door. 4-31 Repair information...

  • Page 176: Transfer Belt Position Sensor Removal

    5041-030 Using the handle (A) on the transfer belt, pull the belt outward until two handles appear on the top of the Previous unit. Next Go Back Use the two handles to pull the unit all the way out. Transfer belt position sensor removal Remove the transfer belt.

  • Page 177: Paper Size Sensor Removal

    5041-030 Paper size sensor removal Previous This is the paper size sensor for the top MPF tray. Remove the standard tray. Remove the MPF tray. Next Remove the 15 screws (A) securing the sensor support frame to the print engine frame. Go Back Remove the paper size sensors.

  • Page 178: Photoconductor Lock Removal

    5041-030 Photoconductor lock removal Previous Remove the standard paper tray. Remove the two screws (A) that secure the front metal cover to the printer frame. Next Go Back Remove the photoconductor lock. 4-34 Service Manual...

  • Page 179: Cassette Stopper Removal

    5041-030 Cassette stopper removal Previous Remove the standard and MPF trays. Disengage the tabs (A) securing the cassette stopper to the left side of the printer frame. Next Go Back Twist the stopper downward to release the two pawls (B). Insert a flat-blade screwdriver at point (C).

  • Page 180: Left Side Removals

    5041-030 Previous Left side removals ISP option board removal Next CAUTION Go Back Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.
  • Page 181 5041-030 Unplug the ISP cable from the RIP board and remove the ISP and RIP cage cover. Previous Next Go Back Remove the screws securing the ISP cover to the RIP cage cover. Tilt the ISP cover down and disconnect the ISP cable from the old ISP board. Remove the thumbscrews securing the ISP solution card to the ISP cage.
  • Page 182 5041-030 Remove the ISP from the cage. Previous Next Go Back Remove the tee from the old ISP card. 4-38 Service Manual...

  • Page 183: Left Emi Shield Removal (Not A Fru)

    5041-030 Left EMI shield removal (not a FRU) Previous Remove the top cover. Remove the left cover. Remove the RIP -USB, and RIP -UICC cables from the cable guides (A) on top of the shield. Next Go Back Remove the ten screws (B) on the top side of the shield. 4-39 Repair information...
  • Page 184 5041-030 Remove the eight screws (C) on the left side of the shield. Previous Next Go Back Remove the screw (D) on the lower rear side. Remove the screw (E) fastening the shield to the RIP board USB connector. 4-40 Service Manual...
  • Page 185 5041-030 Remove the screw (F) behind the main fan. Previous Next Go Back Use a flatblade screwdriver to gently pull the shield away, and disengage it from the tab (G) on the power box. Pull the shield away from the printer. 4-41 Repair information...

  • Page 186: Low Volt Power Supply Removal

    5041-030 Low volt power supply removal Previous CAUTION-SHOCK HAZARD Remove power from the printer before continuing or use caution if the product must be energized during this procedure. The heat sink transformer core presents risk of electric Next shock. Test before touching. Go Back Remove the left side EMI shield.

  • Page 187: Main Fan Removal

    5041-030 Remove the three screws (B) securing the bottom of the power supply to the power supply cage. Previous Next Go Back Main fan removal Remove the HVPS. Remove the rear fan. See “Rear fan removal” on page 4-78. Disconnect the engine board fan cable from the engine board. Disconnect the main fan cable from CN22 on the engine board.
  • Page 188 5041-030 Remove the screw (B) fastening the main fan stay to the rear of the printer frame. Previous Next Go Back Thread the fan cable through the cable stay. Lift the fan up and pull the main fan stay away from the printer. 4-44 Service Manual...

  • Page 189: Power Supply Fan Removal

    5041-030 Power supply fan removal Previous Note: Fan needs to be mounted with label pointed outwards. Remove the left side EMI shield. Remove the fan’s wiring harness from the connector (A) on the shield. Next Note: The harness must be routed in this matter when the fan is reinstalled. Go Back Turn the shield over, and remove the four screws (B) securing the fan to the shield.

  • Page 190: Rip Board Removal

    RIP board removal Previous Note: Before replacing the RIP board, ask the customer if there are any Lexmark E-task applications installed on the machine. If there are applications installed and the machine can be accessed by a Web browser, connect to the machine via Web browser and export the application and application settings.
  • Page 191 5041-030 Remove the three standoffs (A) that secure the RIP board to the RIP cage. Previous Next Go Back Carefully remove the RIP board from the RIP cage. Video board removal Remove the rear cover. See “Rear cover removal” on page 4-5.

  • Page 192: Theta Sensor Removal

    5041-030 Theta sensor removal Previous Remove the LVPS. See “Low volt power supply removal” on page 4-42. Remove the 7 screws (A) securing the power box shield to the printer frame. Next Go Back Disconnect the theta sensor harness from the theta sensor. Remove the one screw (B) securing the theta sensor mounting plate to the printer frame.

  • Page 193: Density Sensor Removal

    5041-030 Density sensor removal Previous Remove the LVPS. See “Low volt power supply removal” on page 4-42. Remove the 7 screws securing the power box shield to the printer frame. Next Go Back Disconnect the density sensor harness from the density sensor. Remove the two screws (D) fastening the density sensor to the frame.

  • Page 194: Main Switch Removal

    5041-030 Main switch removal Previous Remove the main power switch cable. Disconnect both harnesses (A) from the power switch. Next Go Back 4-50 Service Manual...

  • Page 195: Right Side Removals

    5041-030 Previous Right side removals Fuser removal Open the right side door. Next Go Back Grab the handles on the fuser, and gently pull the fuser out of the print engine. 4-51 Repair information...

  • Page 196: Handle Cover Removal

    5041-030 Handle cover removal Previous Remove the two screws (A) securing the handle covers to the printer frame. Next Go Back Remove the handle cover. 4-52 Service Manual...

  • Page 197: Duplex Removal

    5041-030 Duplex removal Previous Remove the high voltage power supply. See “HVPS removal” on page 4-87. Remove the handle covers. See “Handle cover removal” on page 4-52. Open the right cover, and remove the transfer roll. Warning: Avoid damaging the transfer roll. Next Go Back While holding the right cover, lift the duplex unit.
  • Page 198 5041-030 Disconnect the two springs from the right cover. Previous Next Go Back Disconnect the left and right link arms from the white locks on the right cover. 4-54 Service Manual...
  • Page 199 5041-030 Disconnect the duplex clutch and sensor cables from the connectors (B) on the engine controller board. Previous Next Go Back Disconnect the duplex ground wire from the frame. 4-55 Repair information...
  • Page 200 5041-030 Route the duplex cables through the frame. Previous Next Go Back Slide the duplex to the right, freeing it from the left hinge. 4-56 Service Manual...
  • Page 201 5041-030 Pull the duplex away from the printer while carefully routing the cables through the right hinge on the Previous printer. Next Go Back Remove the screws securing the duplex unit to the right cover. Note: See “Duplex unit component removals” on page 4-89 for instructions to remove the duplex sub- components.

  • Page 202: Paper Feed Unit Removal

    5041-030 Paper feed unit removal Previous Note: Remove the main tray paper guide and the multi-purpose feed tray paper guide. These will be used on the new paper feed unit. See “Main tray paper guide removal” on page 4-95 “Multi-purpose feed tray paper guide removal”...

  • Page 203: Transfer Roll - Cru Removal

    5041-030 Transfer Roll - CRU removal Previous Open and lower the right side cover / duplex unit. Turn the transfer roll fasteners to the unlocked position. Next Go Back 4-59 Repair information...

  • Page 204: Rear Removals

    5041-030 Previous Rear removals Drive Unit removal Remove the HVPS. See “HVPS removal” on page 4-87. Next Remove the plastic drive unit cover. Disconnect the drive motor wiring harnesses from the engine board. Disconnect the harness from the printhead controller board. Go Back Remove the three screws (A) in the upper left corner of the drive unit.
  • Page 205 5041-030 Remove the screw (C) on top of the drive unit. Previous Next Go Back Remove the two screws (D) in the upper right corner of the drive unit. 4-61 Repair information...
  • Page 206 5041-030 Remove the screw (E) in the lower right corner of the drive unit. Previous Next Go Back Remove the two screws (F) on the bottom of the drive unit. 4-62 Service Manual...

  • Page 207: Drive Unit Motor C/M/Y/K Removal

    5041-030 Remove the two screws (G) in the lower left corner of the drive unit. Previous Next Go Back Drive unit motor C/M/Y/K removal Note: All four motors use this procedure. Remove the drive unit. Place the drive unit with the motors down on a table. Remove the two screws (A) securing the motor to the drive unit.

  • Page 208: Sub Drive Unit Removal

    5041-030 Sub drive unit removal Previous Open the right cover and remove the fuser. Remove the rear cover. See “Rear cover removal” on page 4-5. Remove the top cover. See “Top cover removal” on page 4-11. Remove the rear EMI shield. See “Rear EMI shield removal–...
  • Page 209 5041-030 Disconnect the fuser / paper exit motor cable (B). Previous Next Go Back Remove the two black plastite screws (C) securing the sub drive cover to the sub drive unit. Remove the black plastic sub drive cover. 4-65 Repair information...
  • Page 210 5041-030 Remove the screw (D) at the bottom of the sub drive unit. Previous Next Go Back Remove the screw (E) at the middle of the sub drive unit above the fuser / paper exit motor. 4-66 Service Manual...
  • Page 211 5041-030 Remove the screw (F) at the top of the sub drive unit. Previous Note: If you are replacing the unit, place the ground wire on the new unit. Next Go Back Pull the portion of the unit with the motor, and sensors out of the machine. Disconnect the fuser entry sensor cable.

  • Page 212: Door Interlock Switch Removal

    5041-030 Lift and remove the gear train portion of the sub drive unit out of the printer. Previous Next Go Back Door interlock switch removal Remove the sub drive unit. See “Sub drive unit removal” on page 4-64. Remove the two screws (A) securing the door interlock switch to the sub drive unit. 4-68 Service Manual...

  • Page 213: Duplex Solenoid Removal

    5041-030 Duplex solenoid removal Previous Remove the sub drive unit. See “Sub drive unit removal” on page 4-64. Remove the left screw (A) securing the solenoid to the sub drive unit. Next Go Back Remove the right screw (B) securing the solenoid to the sub drive unit. 4-69 Repair information...

  • Page 214: Fuser Entry Sensor Removal

    5041-030 Fuser entry sensor removal Previous Remove the sub drive unit. See “Sub drive unit removal” on page 4-64. Depress the tabs (A) fastening the fuser entry sensor to the sub drive unit. Next Go Back 4-70 Service Manual...

  • Page 215: Engine Board (Mdcont) Removal

    5041-030 Engine board (MDCONT) removal Previous Warning: When replacing any one of the following components: • Printhead controller board • Engine board Next Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.

  • Page 216: Fuser Exit Drive Unit Motor Removal

    5041-030 Fuser exit drive unit motor removal Previous Remove the rear EMI shield.See “Rear EMI shield removal– Not a FRU” on page 4-82. Disconnect the cable from the connector (A) exit drive unit motor. Next Go Back Remove the two screws (B) that secure the exit drive unit motor to the fuser motor damper. Note: The ground wire (C) is connected with one of the screws.

  • Page 217: Papertray Lift Motor Removal

    5041-030 Papertray lift motor removal Previous Remove the HVU. See “HVPS removal” on page 4-87. Remove the rear fan. See.“Rear fan removal” on page 4-78. Disconnect the cable (A) from the DC Geared motor. Next Go Back Remove the three screws (B) securing the paper tray lift motor to the frame. 4-73 Repair information...

  • Page 218: Toner Sensor Removal

    5041-030 Toner sensor removal Previous Remove the drive unit. See “Drive Unit removal” on page 4-60. Remove the printhead controller board.“Printhead controller board removal” on page 4-28. Remove the three screws (A) securing the board stay to the printer frame. Next Go Back Remove the five screws (B) securing the head pin plate to the printer frame.
  • Page 219 5041-030 Remove the ten screws (C) securing the top support rail (not a FRU) to the top frame. Previous Next Go Back Remove the four printhead assemblies. See “LED assembly removal” on page 4-19. 4-75 Repair information...
  • Page 220 5041-030 Remove the twelve screws (D) securing the top frame to the printer. Previous Next Go Back Remove the four screws (E) securing the plastic body back to the left and right printer frames. 4-76 Service Manual...

  • Page 221: Transfer Belt Motor Removal

    5041-030 Remove the screws (F) securing the toner sensors to the top frame. Previous Next Go Back Transfer belt motor removal Remove the HVPS. Disconnect the motor harness (A) from the transfer belt. Remove the two screws (B) securing the motor to the frame. 4-77 Repair information...

  • Page 222: Temperature And Humidity Sensor Removal

    5041-030 Temperature and humidity sensor removal Previous Remove the rear cover. Disconnect the sensor cable (A) from the sensor. Next Go Back Remove the screw (B) securing the sensor to the printer frame. Rear fan removal Remove the high volt power supply. See “HVPS removal”...
  • Page 223 5041-030 Route the high volt power supply cable through the fan mounting duct. Previous Next Go Back Disconnect the fan cable (B) from the MDCONT (engine) board. 4-79 Repair information...

  • Page 224: Sub Frame Unit Removal

    5041-030 Sub frame unit removal Previous Remove the drive unit. Disconnect the belt up down sensor harness (A) if it is connected. Next Go Back Remove the four screws (B) securing the sub unit to the head in plate. 4-80 Service Manual...

  • Page 225: Paper Size Switch Removal

    5041-030 Paper size switch removal Previous Remove the HVPS. See “HVPS removal” on page 4-87. Disconnect the three cables. Next Go Back Remove the two screws (A) securing the sensor mount to the printer frame. 4-81 Repair information...

  • Page 226: Rear Emi Shield Removal- Not A Fru

    5041-030 Depress the tabs holding the sensor in place. Previous Next Go Back Rear EMI shield removal– Not a FRU Remove the rear cover. Remove the three screws (A) on the top rear of the shield. 4-82 Service Manual...
  • Page 227 5041-030 Remove the five screws (B) securing the upper shield to the rear shield. Previous Next Go Back Remove the three screws (C) above the fuser fan. 4-83 Repair information...
  • Page 228 5041-030 Remove the twelve screws (D) on the rear of the shield. Previous Next Go Back Remove the two screws (E) on the bottom of the rear side of the shield. 4-84 Service Manual...
  • Page 229 5041-030 Remove the two screws (F) next to the MPF tray. Previous Next Go Back 4-85 Repair information...

  • Page 230: Paper Feed Motor Removal

    5041-030 Paper feed motor removal Previous Note: The paperfeed unit does not need to be removed for this procedure. Remove the rear cover. Remove the top cover. Next Remove the rear EMI shield. Disconnect the cable (A) from the paper feed motor. Go Back Remove the two screws (B) securing the paper feed motor to the paper feed unit.

  • Page 231: Hvps Removal

    5041-030 HVPS removal Previous Remove the rear cover. See “Rear cover removal” on page 4-5. Remove the top cover. See “Top cover removal” on page 4-11. Remove rear shield. See “Rear EMI shield removal– Not a FRU” on page 4-82. Remove three screws (A) attaching the HVU to the frame.

  • Page 232: Waste Toner Sensor Removal

    5041-030 Disconnect the power cable (C) from the HVU. Previous Next Go Back Waste toner sensor removal Remove the rear fan. See “Rear fan removal” on page 4-78. Depress the tabs (A) securing the waste toner sensor to the frame and push the sensor in. After the sensor is detached, pull it out of the frame.

  • Page 233: Duplex Unit Component Removals

    5041-030 Previous Duplex unit component removals Duplex clutch removal Remove the duplex unit. See “Duplex removal” on page 4-53. Next Remove the two screws (A) securing the duplex cover to the duplex unit. Go Back Disconnect the duplex clutch harness from the duplex clutch. Remove the e-clip (B) that fastens duplex clutch to the carrying shaft.

  • Page 234: Duplex Timing Belt Removal

    5041-030 Duplex timing belt removal Previous Remove the duplex unit. See “Duplex removal” on page 4-53. Remove the duplex clutch. See “Duplex clutch removal” on page 4-89. Remove the timing belts. Next Duplex exit / MPF sensor removal Remove the duplex unit. See “Duplex removal”...

  • Page 235: Mpf Clutch Removal

    5041-030 MPF clutch removal Previous Remove the duplex unit. See “Duplex removal” on page 4-53. Remove the two screws (A) securing the MPF clutch cover to the duplex unit. Next Go Back Remove the e-clip (B) securing the clutch to the MPF shaft. Remove the MPF shaft (C).

  • Page 236: Mpf Tray Assembly Removal

    5041-030 MPF tray assembly removal Previous Open the MPF tray. Slide the MPF arm up to the opening on the tray (A). Next Go Back Pull the arm out of the tray. Repeat steps 1 and 2 for the other arm. Remove the MPF roller cover.
  • Page 237 5041-030 Lift and pull the tray away from the printer. Previous Next Go Back 4-93 Repair information...

  • Page 238: Paperfeed Unit Component Removals

    5041-030 Previous Paperfeed unit component removals Note: The paperfeed, separator, and pick rolls are part of the 300,000 page maintenance kit. See the “Paperfeed maintenance kit removals” on page 4-104 for removal instructions. Next Separating the MPF tray and main tray paperfeed units Remove the paperfeed unit from the printer.

  • Page 239: Main Tray Paper Guide Removal

    5041-030 Remove the twelve screws (C) securing the paperfeed connect frame to the paperfeed units. Previous Next Go Back Remove the eight screws (D) securing the paperfeed connect frame to the paperfeed units. Main tray paper guide removal Note: This is not a FRU. Remove the paper feed unit.
  • Page 240 5041-030 Use a flatblade screwdriver to depress the tab that holds the outer paper guide to the paper feed unit. Previous Next Go Back With the tab depressed, gently lift the paper guide up. Use a flatblade screwdriver to gently remove the guide spring from the paper feed unit. Note: The spring should remain on the paper guide.

  • Page 241: Multi-Purpose Feed Tray Paper Guide Removal

    5041-030 Use a flatblade screwdriver to depress the tab on the inner main paper guide. Previous Next Go Back Gently lift and remove the inner main paper guide from the paper feed unit. This guide will be used on the new paper feed unit.
  • Page 242 5041-030 Use a flatblade screwdriver to re-route the registration sensor cables around the guide on the outer paper Previous guide. Next Go Back Carefully disconnect the cable from the registration sensor. Route the sensor cable around the two remaining cable guides on the outer paper guide. 4-98 Service Manual...
  • Page 243 5041-030 Use a flatblade screwdriver to depress the tab that holds the outer paper guide to the paper feed unit. Previous Next Go Back With the tab depressed, gently lift the paper guide up. Use a flatblade screw driver to gently remove the guide spring from the paper feed unit. Note:The spring should remain on the paper guide.

  • Page 244: Paperfeed Unit Clutch Removal

    5041-030 Use a flat blade screwdriver to depress the tab on the inner multi-purpose paper guide. Previous Next Go Back Gently lift and remove the inner multi-purpose paper guide from the paper feed unit. This guide will be used on the new paper feed unit. Paperfeed unit clutch removal Note: This procedure applies to all the clutches on the paperfeed unit.

  • Page 245: Registration Sensor (Mpf Tray) Removal

    5041-030 Registration sensor (MPF tray) removal Previous Open the right cover door. Pull the cassette guide down. Pinch the tabs (A) that secure the sensor to the cassette guide, releasing the sensor. Next Go Back Disconnect the sensor from the sensor wire harness (B). Registration sensor actuator removal Note: The paperfeed unit does not need to be removed from the printer.

  • Page 246: Static Discharge Brush Removal

    5041-030 Static discharge brush removal Previous Remove the paperfeed unit. See “Paper feed unit removal” on page 4-58. Remove the six screws (A) that secure the discharge brush plate to the paperfeed unit. Next Go Back Torque limiter removal Remove the separator roll. See “Separator roll removal”...
  • Page 247 5041-030 Remove the registration gears (A). Previous Next Go Back Remove the e-clips (B). Remove the registration bushings (C). Remove the registration springs (D). 4-103 Repair information...

  • Page 248: Paperfeed Maintenance Kit Removals

    5041-030 Previous Paperfeed maintenance kit removals Pick roll removal Remove the paperfeed unit. See “Paper feed unit removal” on page 4-58. Next Depress the tab (A) and remove the PE sensor actuator. Go Back Pull back the tab on the pick roll (B) and remove the pick roll. Paperfeed roll removal Remove the paperfeed unit.

  • Page 249: Separator Roll Removal

    5041-030 Separator roll removal Previous Lower the duplex unit to the down position. Remove the outer cassette guide (A.. Next Go Back Remove the inner cassette guide (B). Remove the plastic e-clip (C) that secures the separator roll to the shaft. Remove the separator roll.

  • Page 250: Registration Roll Removal

    5041-030 Registration roll removal Previous Note: This removal applies to both sets of registration rolls. To remove the lower roll, you will need to separate the MFP feed unit from the main feed unit. See “Separating the MPF tray and main tray paperfeed units” on page 4-94 for instructions.

  • Page 251: Mpf Roll Removal

    5041-030 MPF roll removal Previous Remove the MPF arms (A) from the MPF tray and right cover. Lower the MPF tray. Remove the MPF roller cover. Next Go Back Slide the MPF coupling to the left. 4-107 Repair information...
  • Page 252 5041-030 Take the MPF shaft out. Previous Next Go Back Remove the MPF roll. 4-108 Service Manual...

  • Page 253: Mpf Pad Removal

    5041-030 MPF pad removal Previous Remove MPF tray. See “MPF tray assembly removal” on page 4-92. Gently pull the right side of the pad holder cover and disconnect it from the mount (A). Next Go Back Gently pull the left side of the pad holder cover and disconnect it from the mount (B). 4-109 Repair information...
  • Page 254 5041-030 Remove the right screw (C) securing the outer pad holder to the MPF unit. Previous Next Go Back Remove the left screw (D) securing the outer pad holder to the MPF unit. 4-110 Service Manual...
  • Page 255 5041-030 Pull the outer pad holder away from the machine. Previous Next Go Back Carefully lift and remove the pad from the pad holder. Note: Reuse the spring that was between the pad and pad holder. 4-111 Repair information...

  • Page 256: Exit Guide (Paper Exit) Roll Removal

    5041-030 Exit guide (paper exit) roll removal Previous Note: You will need to remove the drive gear, spring, and washer on the paper exit roll and place it on the new paper exit roll. Remove the paper exit unit. See “Paper exit guide removal”...
  • Page 257 5041-030 Remove the e-clip (C) securing the drive gear to the shaft. Previous Next Go Back Remove the drive gear (D) from the shaft. 4-113 Repair information...
  • Page 258 5041-030 Remove the spring, washer, e-clip and bushing (E) from the shaft. Previous Next Go Back Release the tabs (F) that secure the black guide to the exit unit. 4-114 Service Manual...
  • Page 259 5041-030 Open the paper exit unit, exposing the rollers. Previous Next Go Back Pull back the tab (G) to release the roller. 4-115 Repair information...
  • Page 260 5041-030 Remove the screw (H) that fastens the roller holder to the paper exit unit frame. Previous Next Go Back Pull the roller holder back and away from the paper exit unit. Repeat steps 9 thru 11 for the remaining rollers. 4-116 Service Manual...
  • Page 261 5041-030 Move the paper exit guide roll to the left, lift it out of the frame and pull it to the lift, releasing it from the Previous paper exit unit. Next Go Back 4-117 Repair information...

  • Page 262: Option Paper Feed Removals

    5041-030 Previous Option paper feed removals Paper feed roll removal Remove the paper tray from the option paper feed unit. Next Remove the clip (A) securing the paper feed roll to the shaft. Go Back Slide the paper feed roll (B) off the shaft to remove it. Pick roll removal Remove the paper tray from the option paper feed unit.

  • Page 263: Separator Roll Removal

    5041-030 Separator roll removal Previous Remove the paper tray from the option paper feed unit. Remove the clip (A) securing the separator roll to the shaft. Next Go Back Slide the separator roll (B) off the shaft to remove it. Paper size switches removal Remove the paper tray from the option paper feed unit.

  • Page 264: Paper Level Sensor Removal

    5041-030 Paper level sensor removal Previous Remove the tray from the option paperfeed unit. Remove the rear cover. Disconnect the paper level sensor cable. Push the tabs securing the paper level sensor to the rear of the tray. Next Remove the sensor from the option paperfeed drawer. Go Back Transport sensor removal Take the main printer unit off of the option paper feed unit.

  • Page 265: Paper Empty Sensor Removal

    5041-030 Paper empty sensor removal Previous Take the main printer unit off of the option paper feed unit. Remove the paper empty sensor from the frame by pressing the tabs (A) on the sensor together and pulling it away from the frame. Next Go Back Disconnect the sensor from the harness.

  • Page 266: Option Controller Board Removal

    5041-030 Option controller board removal Previous Remove the rear cover. Disconnect all the cables from the option controller board. Remove the four screws (A) securing the controller board to the rear frame. Next Go Back Stepper motor removal Remove the rear cover. Remove the stepper motor cable from the controller board.

  • Page 267: Tray Lift Motor Removal

    5041-030 Remove the two screws (B) securing the stepper motor to the bracket. Previous Next Go Back Tray lift motor removal Remove the rear cover. Disconnect the tray lift cable from the tray lift motor. Remove the three screws (A) securing the tray lift motor to the frame. 4-123 Repair information...

  • Page 268: Option Door Inter Lock Switch Removal

    5041-030 Option door inter lock switch removal Previous Remove the rear cover. Disconnect the interlock cable from the interlock switch. Remove the one screw (A) securing the bracket to the frame. Next Go Back Remove the one screw (B) securing the interlock switch to the bracket. 4-124 Service Manual...

  • Page 269: Paper Feed Clutch Removal

    5041-030 Paper feed clutch removal Previous Remove the screw (A) securing the right front cover. Next Go Back Remove the screw (B) securing the right rear cover. Remove the screw (C) securing the right rear switch cover. Remove the two screws (D) securing the vertical transport guide rail. Remove the vertical transport cover.
  • Page 270 5041-030 Remove the two screws (G) securing the rear cover to the option feeder. Previous Next Go Back Remove the left and right drum stays (H). Remove the clutch. 4-126 Service Manual...

  • Page 271: Locations

    5041-030 5. Locations Previous Locations Next Exterior Go Back Front 4.3” touchscreen display Output bin Numeric keypad Operator panel USB input Duplex / Right cover handle MPF tray Carrying handles Tray 1 Tray 2 (Standard tray) Locations...

  • Page 272: Left Front

    5041-030 Left front Previous Next Go Back Paper exit RIP / Video board access cover Left handle Main power switch Service Manual...

  • Page 273: Interior

    5041-030 Interior Previous Next Go Back Callout no. Part name Charge roll LED head Developer roll Primary transfer roll Drum cleaning blade Photoconductor Doctor blade Supply roll Toner cartridge Secondary transfer roll Transfer belt cleaning blade Fuser heater Locations...
  • Page 274 5041-030 Previous Callout no. Part name Hot roll Fuser belt Fuser roll Next Press roll Transfer belt Go Back Transfer belt drive roll Pickup roll (MP feeder) Feed roll (MP feeder) Separator roll (MP feeder) Pickup roll (Std tray) Feed roll (Std tray Separator roll (Std tray Registration roll (IN) MP feeder Registration roll (OUT) MP feeder...

  • Page 275: Print Engine Diagram

    5041-030 Print engine diagram Previous Paper Print Density Sensor Paper Exit Sensor Exit Bin full Sensor Theta Sensor Unit Next Imaging unit(Y) T oner Sensor (TN) Board (Y) LED HEAD(Y) SFP Video Go Back Board UICC Board Imaging unit(M) 4.3” Touchscreen T oner Sensor (TN) Board (M) Display LED HEAD(M)

  • Page 276: Printer Motors

    5041-030 Printer motors Previous Next Go Back Callout Motor Fuser/paper exit Paperfeed Y drive unit M drive unit C drive unit K drive unit Transfer belt Service Manual...

  • Page 277: Printer Boards

    5041-030 Printer boards Previous Reference to wiring and block diagrams goes here. RIP board Next Go Back Locations...

  • Page 278: Video Board

    5041-030 Video board Previous Next Go Back Service Manual...

  • Page 279: Printhead Controller Board

    5041-030 Printhead controller board Previous Next Go Back Locations...

  • Page 280: Engine Board

    5041-030 Engine board Previous Next Go Back 5-10 Service Manual...

  • Page 281: Lvps

    5041-030 LVPS Previous Next Go Back 5-11 Locations...

  • Page 282: Hvps

    5041-030 HVPS Previous Next Go Back 5-12 Service Manual...

  • Page 283: Connector Values

    5041-030 Previous Connector values RIP / video boards Connector Connects to Pin no. Signal Next Video board connectors JBOOT1 +3.3V Go Back IM_DATA (7:0) J105 UI_RESET_NR CON_TX1- CON_TX1+ CON_TX2- CON_TX2+ CON_CLKTX- CON_CLKTX+ I2C_CLK_UI I2C_DATA_UI CON_TX0- CON_TX0+ V_UI WAKE LED_DRV_YELLEOW +5V_CONT PWR_BUTTON J101 USB_FRONT_P1+...
  • Page 284 5041-030 RIP / video boards Previous Connector Connects to Pin no. Signal IC2_DATA Next IC2_CLK Go Back USB_POR- PANEL_INT WAKE HIBERNATE PWR_BUTTON HUSB_D+ INA_RESET LED_DRV_YELLOW TG_BEEPER MVREF_VTX_SR- HUSB_D- +3.3V +3.3V +5V_CONT 3, 4, 15, 8, 60, 79, 80 7, 23, 30, 37, 44, 51, 59, 78...
  • Page 285 5041-030 RIP / video boards Previous Connector Connects to Pin no. Signal RIP board connectors VCLK_Y Next VCLK_M Go Back VCLK_C VCLK_K VSYN_Y VSYN_M VSYN_C VSYN_K HSYN_Y HSYN_M HSYN_C HSYN_K LEVELY-O0_CONN LEVELY-O1_CONN LEVELY-E0_CONN LEVELY-E1_CONN LEVELM-O0_CONN LEVELM-O1_CONN LEVELYM-E0_CONN LEVELM-E1_CONN LEVELC-O0_CONN LEVELC-O1_CONN LEVELC-E0_CONN LEVELC-E1_CONN LEVELK-O0_CONN...
  • Page 286 5041-030 RIP / video boards Previous Connector Connects to Pin no. Signal GND_RESET STATUS Next FDRDY CPRDY Go Back START CBSY PDRDY STCLK READY COMMAND Jser1 TG_RXD1 TG_TXD1 +3.3V JLOCK1 LOCK CAGE_FAN_DRV 3, 4, 15, 58, 60, 79, 80 7, 59, 23, 30, 37, 44, 51, 78...
  • Page 287 5041-030 RIP / video boards Previous Connector Connects to Pin no. Signal IC2_DATA Next IC2_CLK Go Back USB_POR PANEL_INT WAKE HYBERNATE PWR_BUTTON HUSB_D+ INA_RESET LED_DRV_YLW TG_BEEPER MVREF_VTX_SR HUSB_D- +3.3V +3.3V +5V_CONT NETWORK +5V_CONT GRN_RST_T +V_RTC PROC_XRTAL_1 PROX_XTAL_4 I2C DATA TERM IC2 CLK TERM CPU_GREEN_INT JCONF...
  • Page 288 5041-030 Previous Printhead controller board Connector Connects to Pin no. Signal Yellow printhead HD5V Next HD5V Go Back HD5V HD5V HD5V HD3V SO-Y SCK-Y STROBE-Y DATA_Y0 DATA_Y1 DATA_Y2 DATA_Y3 HSYNC-Y LOAD_Y CLOCK-N-Y CLOCK-P-Y 5-18 Service Manual...
  • Page 289 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal Cyan printhead USB +5 V dc USB D- Next HD5V Go Back HD5V HD5V HD5V HD5V HD3V SO-C SCK-C STROBE-C DATA_C0 DATA_C1 DATA_C2 DATA_C3 HSYNC-C LOAD_C CLOCK-N-C CLOCK-P-C 5-19 Locations...
  • Page 290 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal Magenta printhead USB +5 V dc USB D- Next HD5V Go Back HD5V HD5V HD5V HD5V HD3V SO-M SCK-M STROBE-M DATA_M0 DATA_M1 DATA_M2 DATA_M3 HSYNC-M LOAD_M CLOCK-N-M CLOCK-P-M 5-20 Service Manual...
  • Page 291 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal Black printhead HD5V Next HD5V Go Back HD5V HD5V HD5V HD3V SO-K SCK-K STROBE-K DATA_K0 DATA_K1 DATA_K2 DATA_K3 HSYNC-K LOAD_K CLOCK-N-K CLOCK-P-K Engine board MBUSY_IN SUBRXD SUBTXD MOTOR_CLK1 MOTOR_CLK2 MOTOR_CLK3 MOTOR_CLK4 HTNB1...
  • Page 292 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal Fuser entry sensor FUIN_SW Next LDPRG Paper exit, Go Back PEX_SW IDPRG Bin full sensors STACK_SW Theta sensor THETA CN 10 CN11 HVPS VCC24VFAN HV24V_2 HINB DACLK DASO DARIN DA_LAT CN12 CN13...
  • Page 293 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal CN14 Density sensor GLED VMON Next Go Back VOUT CN15 LVPS +5V_IN +5V_GND +24V_IN +24V_GND Engine board +24VSW CN16 LVPS +24V_GND HV25V SLEEP1 SLEEP2 ZEROCRS CN17 Toner sensor K TNSETK TSZANK Toner sensor C...
  • Page 294 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal CN21 VCLK-Y RIP board Next VCLK-M Go Back VCLK-C VCLK-K CN22 RIP board VSYN-Y VSYN-C VSYN-M VSYN-K HSYN-Y HSYN-C HSYN-M HSYN-K LEVELY-O0 5-24 Service Manual...
  • Page 295 5041-030 Printhead controller board Previous Connector Connects to Pin no. Signal CN22 - continued RIP Board - continued LEVELY-O1 LEVELY-E0 Next LEVELY-E1 LEVELM-O0 Go Back LEVELM-O1 LEVELM-E0 LEVELM-E1 LEVELC-O0 LEVELC-O1 LEVELC-E0 LEVELC-E1 LEVELK-O0 LEVELK-O1 LEVELK-E0 LEVELK-E1 FEED2 SBSY STATUS FDRDY CPRDY START CBSY...
  • Page 296 5041-030 Engine Board Previous Next Go Back 5-26 Service Manual...
  • Page 297 5041-030 Previous Engine board Connector Connects to Pin no. Signal Next Printhead Controller LDPRG PRGSW5V Go Back THETA LED /PCZCNG HTNB1 MOTOR CLK4 MOTOR CLK3 MOTOR CLK2 MOTOR CLK1 /MBUSY_IN Temp humidity sensor Temp S Humid S Paper size sensor (Std CPSIZE2 Cassette) PCZCNG C...
  • Page 298 5041-030 Engine board Previous Connector Connects to Pin no. Signal CN8 Paperfeed clutches Paperfeed clutches VCC24V /PF1CL Next VCC24V /TRCL Go Back VCC24V /MLTCL Waste toner HTONER Belt pos sensor BELT U/D CN10 Duplex solenoid DUPSOL CN12 Full sensor PFLIFTSW PE Sensor STD tray PP EMP PE Sensor MPF tray...
  • Page 299 5041-030 Engine board Previous Connector Connects to Pin no. Signal CN16 Paperfeed motor / Paperfeed motor 1A FEED Fuser motor 1B FEED Next 2A FEED 2B FEED Go Back Fuser / paper exit motor 1A FUSER 1B FUSER 2A FUSER 2B FUSER CN17 Motor Y Motor...
  • Page 300 5041-030 Engine board Previous Connector Connects to Pin no. Signal CN25 Power supply fan PSFAN PSFALM Next CN26 Rear fan REAFAN Go Back REAFALM CN27 Remote switch P OFF CN28 MPF clutch TMPCL CN29 t MPF paper out TMFDET 5-30 Service Manual...
  • Page 301 5041-030 LVPS Previous Next Go Back LVPS board Connector Connects to Pin no. Signal CN01 Main switch AC-L AC-N CN02 Fuser sensor 5-31 Locations...
  • Page 302 5041-030 LVPS board Previous Connector Connects to Pin no. Signal CN03 RIP Board +5V- Next Printhead controller board +5V- Go Back +24V Engine board +5V- +24V CN04 Printhead controller board ACXerox-P Heater3N Heater2N Heater1N Sleep2 Sleep1 HT24 Engine board FAN GND FAN ARM CN05 RIP Board...

  • Page 303: Option Feeder Locations

    5041-030 Previous Option feeder locations Option feeder layout Upper UL1 Interface Next Go Back Transport Motor Paper tray lift motor Paper full Transport Paper empty Paper volume Paper size detection Paper size detection Paper size detection Door interlock Lower UL2 Interface 5-33 Locations...

  • Page 304: Option Board Layout

    5041-030 Option board layout Previous Next Go Back ASSY NO CN121 IC100 IC103 IC Socket CN104 CN105 CN106 CN108 CN103 5-34 Service Manual...

  • Page 305: Option Board Connector Values

    5041-030 Option board connector values Previous Conne Connect Parts Signal Signal ctor Name VAA(24V) CN101 Next Transport Motor VAA(24V) VAA/SW Cover Open 3 N.C.( Cover Open CN102 VAA(24V) Go Back CGND CGND Paper Overload Paper Full Sensor Sensor VCC(5V) CGND Transport CN103 Transport Sensor...
  • Page 306 5041-030 Previous Next Go Back 5-36 Service Manual...

  • Page 307: Preventive 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 Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.

  • Page 308: Scheduled Maintenance

    40X6013, and the 220 V part number is 40X6093. The aproximate yield for the fusers is 120,000 cycles. Imaging units - There are separate imaging units for each color on the C925. The imaging unit is composed of the developer, and phohtoconductor rolls.

  • Page 309: Parts Catalog

    5041-030 7. Parts catalog Previous How to use this parts catalog Next The following legend is used in the parts catalog: Units/mach Go Back Asm- Part Units/ - OR - Description index number Units/option • Asm-index: Identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 and item number 1 in the table.

  • Page 310: Assembly 1: Cover1

    5041-030 Assembly 1: Cover1 Previous Next Go Back Service Manual...
  • Page 311 5041-030 Assembly 1: Cover 1 Previous Asm- Part Units/ Units/ Description index number mach 40X6126 Complete Duplex Next 40X6272 A/S link arm spring 40X6268 A/S link arm 40X6120 Paper size sensor cable Go Back 40X6114 Paper size sensor 40X6354 Sensor frame 40X6121 Tray stop 40X6169...

  • Page 312: Assembly 2: Cover 2

    5041-030 Assembly 2: Cover 2 Previous Next Go Back Service Manual...
  • Page 313 5041-030 Assembly 2: Cover 2 Previous Asm- Part Units/ Units/ Description index number mach 40X6379 Button kit parts pack 40X7115 UICC (user interface controller) card Next 40X6405 RIP - USB Cable 40X6431 RIP-Operator panel cable Go Back 40X7116 4.3” Touchscreen display 40X6284 Op panel bezel cover 40X6378...

  • Page 314: Assembly 3: Duplex Components 1

    5041-030 Assembly 3: Duplex components 1 Previous Next Go Back Service Manual...
  • Page 315 5041-030 Assembly 3: Duplex components 1 Previous Asm- Part Units/ Units/ Description index number mach 40X6419 MPF Clutch 40X6259 Duplex ground cable Next 40X1104 Photo interuptor 40X6416 MPF - Engine board cable Go Back 40X6982 MPF paper empty lever 40X6152 A/S Carrying roller 40X6147 Duplex roller bushing...

  • Page 316: Assembly 4: Duplex Components 2

    5041-030 Assembly 4: Duplex components 2 Previous Next Go Back Service Manual...
  • Page 317 5041-030 Assembly 4: Duplex components 2t Previous Asm- Part Units/ Units/ Description index number mach 40X6578 MPF roll 40X6457 MPF Maintenance kit Next 40X6412 MPF separator spring 40X6411 MPF pad holder Go Back 40X6415 MPF bottom cover 40X6414 MPF catch 40X6141 Sub tray 40X6136...

  • Page 318: Assembly 5: Paper Exit

    5041-030 Assembly 5: Paper exit Previous Next Go Back 7-10 Service Manual...
  • Page 319 5041-030 Assembly 5: Paper exit Previous Asm- Part Units/ Units/ Description index number mach 40X6579 Paper exit roller 40X1104 Photo interuptor Next 40X6168 Exit sensor cable 40X6167 Paper exit guide Go Back 7-11 Parts catalog...

  • Page 320: Assembly 6: Base 1

    5041-030 Assembly 6: Base 1 Previous Next Go Back 7-12 Service Manual...
  • Page 321 5041-030 Assembly 6: Base 1 Previous Asm- Part Units/ Units/ Description index number mach 40X6173 Main unit drive 40X6261 Photo interrupter cable Next 40X1104 Photo interrupter 40X6160 Sub frame Go Back 40X6162 Belt motor 40X6262 Belt motor cable 40X6161 Drive unit motor 40X7052 Base 1 screw parts pack 7-13...

  • Page 322: Assembly 7: Base 2

    5041-030 Assembly 7: Base 2 Previous Next Go Back 7-14 Service Manual...
  • Page 323 5041-030 Assembly 7: Base 2 Previous Asm- Part Units/ Units/ Description index number mach 40X6163 Sub unit drive 40X6171 Fuser fan Next 40X6170 Fuser duct 40X6355 Exit solenoid bracket Go Back 40X6165 Exit drive unit solenoid 40X6368 Engine power supply (Door interlock) cable 40X6166 Door open switch 40X1104...

  • Page 324: Assembly 8: Base 3

    5041-030 Assembly 8: Base 3 Previous Next Go Back 7-16 Service Manual...
  • Page 325 5041-030 Assembly 8: Previous Asm- Part Units/ Units/ Description index number mach 40X6174 Handle cover 40X6175 Bottom foot Next 40X6421 Rubber grip pad Go Back 7-17 Parts catalog...

  • Page 326: Assembly 9: Paperfeed

    5041-030 Assembly 9: Paperfeed Previous Next Go Back 7-18 Service Manual...
  • Page 327 5041-030 Assembly 9: Paper feed Previous Asm- Part Units/ Units/ Description index number mach 40X6176 Paperfeed unit 40X6193 Registration sensor cable Next 40X1104 Photo interuptor 40X6189 Registration sensor actuator spring Go Back 40X6188 Registration sensor actuator 40X6195 Static discharge brush 40X6581 Standard registration roller 40X6580...

  • Page 328: Assembly 10: Electrical 1

    5041-030 Assembly 10: Electrical 1 Previous Next Go Back 7-20 Service Manual...
  • Page 329 5041-030 Assembly 10: Electrical 1 Previous Asm- Part Units/ Units/ Description index number mach 40X6211 110V Fuser power cable 40X6440 220V Fuser power cable Next 40X6197 Theta sensor 40X6198 Theta sensor cable Go Back 40X6264 B/S sensor cleaner 40X6371 Main power button 40X6213 Insulation 40X6204...

  • Page 330: Assembly 11: Electrical 2

    5041-030 Assembly 11: Electrical 2 Previous Next Go Back 7-22 Service Manual...
  • Page 331 5041-030 Previous Assembly 11: Electrical 2 Asm- Part Units/ Units/ Description index number mach 40X6196 Engine board Next 40X6368 Engine power supply cable 40X6210 Power supply fan cable 40X6262 Belt motor cable Go Back 40X6206 Main fan cable (fan included) 40X6203 Humidity sensor cable 40X6120...

  • Page 332: Assembly 12: Upper Assembly

    5041-030 Assembly 12: Upper assembly Previous Next Go Back 7-24 Service Manual...
  • Page 333 5041-030 Assembly 12: Upper Assembly Previous Asm- Part Units/ Units/ Description index number mach 40X6429 LED printhead assembly 40X6216 LED FFC ribbon cable Next 40X6218 LED printhead 40X6217 Printhead controller board Go Back 40X6215 Contact spring 40X6214 Toner sensor 40X6369 PRCONT option cable 40X7449 Upper assembly screw parts pack...

  • Page 334: Assembly 13: Printhead Controller Board Cables

    5041-030 Assembly 13: Printhead controller board cables Previous Next Go Back 7-26 Service Manual...
  • Page 335 5041-030 Assembly 13: Printer controller board cables Previous Asm- Part Units/ Units/ Description index number mach 40X6193 Registration sensor cable 40X6211 Fuser power cable (110V) Next 40X6440 Fuser power cable (220V) 40X6168 Paper exit sensor cable Go Back 40X6278 Fuser exit sensor cable 40X6217 Printhead controller board 40X6201...

  • Page 336: Assembly 14: Paper Trays

    5041-030 Assembly 14: Paper trays Previous Next Go Back 7-28 Service Manual...
  • Page 337 5041-030 Assembly 14: Paper trays Previous Asm- Part Units/ Units/ Description index number mach 40X6223 Multipurpose tray 40X6219 Main paper tray Next 40X6220 Tray rack gear 40X6221 Tray pinion gear Go Back 40X7451 Cassette screw parts pack 7-29 Parts catalog...

  • Page 338: Assembly 15: Fuser

    5041-030 Assembly 15: Fuser Previous Next Go Back 7-30 Service Manual...
  • Page 339 5041-030 Assembly 15: Fuser Previous Asm- Part Units/ Units/ Description index number mach 40X6013 110V Fuser 40X6093 220V Fuser Next Go Back 7-31 Parts catalog...

  • Page 340: Assembly 16: 550 Sheet Option Feeder Covers

    5041-030 Assembly 16: 550 sheet option feeder covers Previous Next Go Back 7-32 Service Manual...
  • Page 341 5041-030 Assembly 16: 550 sheet option feeder covers Previous Asm- Part Units/ Units/ Description index number mach 40X6357 Right option tray cover 40X6227 Drive roller Next 40X6251 Right front option cover 40X6252 Right rear option cover Go Back 40X6254 Right switch cover 40X6224 Stand base foot 40X6250...

  • Page 342: Assembly 17: 550 Sheet Option Feeder Base

    5041-030 Assembly 17: 550 sheet option feeder base Previous Next Go Back 7-34 Service Manual...
  • Page 343 5041-030 Assembly 17: 550 sheet option feeder base Previous Asm- Part Units/ Units/ Description index number mach 40X6361 UL1 Interface cable 40X6362 UL2 Interface cable Next 40X6430 Option switch sensor 40X6358 Rising unit hub Go Back 40X6359 Rising unit spring 40X6360 Timing belt 40X6231...

  • Page 344: Assembly 18: 550 Sheet Option Feeder Paperfeed

    5041-030 Assembly 18: 550 sheet option feeder paperfeed Previous Next Go Back 7-36 Service Manual...
  • Page 345 5041-030 Assembly 18: 550 sheet option feeder paperfeed Previous Asm- Part Units/ Units/ Description index number mach 40X6365 Option paperfeed cable 40X1107 Vertical paperfeed sensor Next 40X1111 Type2 feed roll 40X1173 Horizontal sensor (paperfeed) Go Back 40X1106 Retainer clip 40X1078 Option tray feed roll 40X1077 Option tray pick roll...

  • Page 346: Assembly 19: 550 Sheet Option Feeder Tray

    5041-030 Assembly 19: 550 sheet option feeder tray Previous Next Go Back 7-38 Service Manual...
  • Page 347 5041-030 Assembly 19: 550 sheet option feeder tray Previous Asm- Part Units/ Units/ Description index number mach 40X6246 Option paper tray Next Go Back 7-39 Parts catalog...

  • Page 348: Assembly 20: Maintenance Kits, Power Cords, And Options

    5041-030 Assembly 20: Maintenance kits, power cords, and options Previous Asm- Part Units/ Description index number 40X6372 300K paperfeed maintenance kit Next 40X6457 MFP maintenance kit 40X5301 256 M DDR DRAM DIMM Go Back 40X5302 512 M DDR DRAM DIMM 40X5303 1 GB DDR DRAM DIMM 40X4823...
  • Page 349 5041-030 Index Numerics 3-13 Exit Config Menu 3-10 Factory Defaults 2-52 2-57 3x–8x attendance messages – 3-12 Font Sharpening 2-13 200 paper jam 3-12 Jobs On Disk 2-14 201 paper jam Panel Menu 2-14 203 paper jam 3-11 Paper Prompts 2-16 231-39 paper jam 3-10...
  • Page 350 5041-030 4-63 Drive unit motor C/M/Y/K removal 4-60 Drive Unit removal 3-12 Jobs On Disk 4-89 Duplex clutch removal 4-53 Duplex removal 4-69 Duplex solenoid removal 4-19 LED assembly removal 2-19 Duplex unit service check 4-21 LED print head removal 4-13 left cover removal 4-39...
  • Page 351 Lexmark confidential until announce 5041-030 2-14 recommended types 203 paper jam 1-10 3-10 unacceptable PPDS Emulation paper and media print quality 3-16 paper checks print quality test pages 4-121 Paper empty sensor removal Print quality issues 4-24 paper exit guide removal...
  • Page 352 5041-030 4-70 4-74 Fuser entry sensor removal Toner sensor removal 4-72 4-102 Fuser exit drive unit motor removal Torque limiter removal 4-71 4-10 Fuser Fan removal touchscreen removal 4-51 4-31 fuser removal transfer belt CRU removal 4-52 4-77 handle cover removal Transfer belt motor removal 4-87 4-32...
  • Page 353 Lexmark confidential until announce 5041-030 2-65 2-34 hard disk options 132.xx abnormal theta sensor 2-64 2-35 imaging unit missing 136.xx - temperature humidity sensor error 2-63 2-35 insert tray 140.01 - main motor error 2-24 2-36 146.01 - tray 1 error...
  • Page 354 5041-030 UICC card removal 2-68 Unable to print from USB thumb drive service check uneven print unprinted spots 4-102 Upper and lower registration springs removal 3-19 USB HS Test Mode 2-61 USB port service check 2-52 User attendance messages (0–99) 4-47 Video board removal 2-68...

  • Page 355: Part Number Index

    5041-030 Part number index Description Page 1 GB DDR DRAM DIMM (40X5303) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40 110V fuser pwoer cable (40X6211) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21...
  • Page 356 5041-030 C/S carrying roller (40X6154) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carry cover (40X6257) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Cassette screw parts pack (40X7451) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29...
  • Page 357 5041-030 Humidity sensor (40X6202) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 humidity sensor (40X6203) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23...
  • Page 358 5041-030 Op panel bezel cover (40X6284) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Op panel bottom cover (40X6285) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Op panel paper exit guide (40X6004) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Opt tray door closed sensor (40X6234) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 359 5041-030 Release link (40X6227) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Release spring (40X6271) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Remote off switch cable (40X7454) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23...
  • Page 360 5041-030 Transfer roll (40X6012) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Transfer roll bushing (40X6143) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - tray lift motor cable (40X6209) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23...

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