Lexmark C93x Service Manual
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Lexmark C93x Service Manual

Color laser printer
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Table of Contents

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Edition: May 13, 2009
™
Lexmark
C93x Printer
5057-XXX
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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

  • Page 3: Table Of Contents

    5057-XXX Notices and safety information ......... xvii Laser notice .
  • Page 4 5057-XXX Fuser ............... . .1-17 Heat roll .
  • Page 5 5057-XXX Media tray assembly ............1-35 Rear media guide .
  • Page 6 5057-XXX Sensor (media out) ............1-53 Sensor (media level) .

  • Page 7: Black Toner Rfid Communication

    5057-XXX 901.xx RIP card assembly software error ......... . . 2-59 902.00 General upper engine error fuse #1 .

  • Page 8: Rip Card Assembly Cooling

    5057-XXX 943.00 Switch (media size) size sensing error (tray 3) ....... . .2-95 943.01 Sensor (media level) late error (tray 3) .
  • Page 9 5057-XXX Spots ..............2-142 After image .

  • Page 10: Printer Service Manual

    5057-XXX Exiting Diagnostics ............. .3-23 Entering Configuration Menu .
  • Page 11 5057-XXX 2nd transfer roll retract cam assembly removal ........4-31 Sensor (2nd transfer roll retract HP) removal .
  • Page 12 5057-XXX K developer / transport drive motor assembly removal ....... .4-97 K developer clutch removal .
  • Page 13 5057-XXX 2000-sheet dual input (TTM)–tray lift coupling assembly removal ..... 4-155 2000-sheet dual input (TTM)–tray module drive motor assembly removal ....4-155 2000-sheet dual input (TTM)–TTM tray 4 transport motor removal .
  • Page 14 5057-XXX Sensor (ATC) setup ............4-204 .
  • Page 15 5057-XXX Assembly 38: 3TM covers ............7-47 Assembly 39: 3TM feed unit assembly .
  • Page 16 5057-XXX Printer Service Manual...

  • Page 17: Notices And Safety Information

    5057-XXX Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 18 5057-XXX Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 19 5057-XXX Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) - lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
  • Page 20 5057-XXX Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
  • Page 21 5057-XXX Notices and safety information...
  • Page 22 5057-XXX xxii Printer Service Manual...

  • Page 23: Safety Information

    5057-XXX Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 24 5057-XXX Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 25 5057-XXX Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 26 5057-XXX Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

  • Page 27: General Information

    5057-XXX 1. General information The Lexmark™ C935 is color laser printer. All information in this service manual pertains to both models unless explicitly noted. Printer technology • Color laser Processor • 1.25 GHz Memory • Standard: 512 MB • Maximum: 1024 MB •...

  • Page 28: Printer Overview

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

  • Page 29: Configured Model

    5057-XXX Configured model The following illustration shows a fully configured printer. Items denoted with an asterisk (*) are options. Operator panel Duplex unit Bridge unit* (Used in conjunction with finisher) Multipurpose feeder (MPF) Finisher* Tray 3 and tray 4 850+1150 sheet dual input tray (TTM) Tray 1 and tray 2 (500 sheet trays)

  • Page 30: Printer Theory

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

  • Page 31: Sfp Paper Path Rolls

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

  • Page 32: Sfp Sensors

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

  • Page 33: Rear Media Guide

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

  • Page 34: Media Feed/Lift Motor

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

  • Page 35: Mpf Feed Roll

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

  • Page 36: Registration Clutch

    5057-XXX Media Width Length Folio 8.5 inches 13 inches Statement 5.5 inches 8.5 inches Universal 140 to 297 mm 98.4 to 432 mm 5.5 to 11.7 inches 3.9 to 17 inches MPF only 105 to 305 mm 148 to 482 mm 4.1 to 12 inches 5.8 to 19 inches 7 3/4 Envelope...

  • Page 37: Transfer Belt Drive Motor Assembly

    5057-XXX The registration roll assembly feeds the media at the precise moment to ensure that printed images are precisely placed. The registration roll assembly feeds media from all trays to the transfer belt. Registration clutch Sensor (transparency detect) Sensor (registration) Media transport roll assembly Transfer 1st transfer rolls (C,M,Y,K)

  • Page 38: Transfer Belt Unit Assembly

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

  • Page 39: Printhead Assembly

    5057-XXX Sensor (2nd transfer roll HP) The sensor (2nd transfer roll HP) is used to detect the home position of the 2nd transfer roll assembly. Transfer belt Sensor (2nd transfer roll retract HP) 2nd transfer roll assembly 2nd transfer roll retract motor Printhead assembly The printhead scans the four drum surface with four laser beams.
  • Page 40 5057-XXX Conceptual diagram of an image created by scanning Printhead 1-14 Printer Service Manual...
  • Page 41 5057-XXX Y Laser Path Y drum Sensor (Y start of scan) Polygon Mirror M Laser Path M drum Polygon Mirror Sensor (M start of scan) 1-15 General information...

  • Page 42: Printhead Shutter

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

  • Page 43: Heat Roll

    5057-XXX Fuser Fuser cooling fan Heat roll Sensor (fuser exit) Pressure belt Thumb screws Heat roll The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media. 1-17 General information...

  • Page 44: Heater Lamp

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

  • Page 45: Standard Media Exit Roll Assembly

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

  • Page 46: Cmyk Pc Cartridge Drive Motor Assembly

    5057-XXX The MPF/transport drive motor is a stepper motor that drives the MPF unit assembly and media transport roll. K developer/transport drive motor assembly MPF/transport drive motor CMYK PC cartridge drive motor assembly The CMYK PC cartridge drive motor assembly uses dual DC brushless motors that drive the four drums in the four PC cartridges.
  • Page 47 5057-XXX CMY developer drive motor assembly The CMY developer drive motor assembly uses a DC brushless motor to drive the three color developer unit assemblies. K developer clutch This clutch is used to engage the K developer unit assembly and is driven by the K-developer/transfer drive motor assembly.

  • Page 48: Waste Toner Agitator Motor Assembly

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

  • Page 49: Fuser Cooling Fan

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

  • Page 50: Upper Printer Engine Card Assembly

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

  • Page 51: Printhead Control

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

  • Page 52: Determination Of Printhead Ready

    5057-XXX Determination of printhead ready The printhead goes into ready state after the specified period passes since the reception of the printhead MPA start signal and the SOS cycle exceeds the reference value. Printhead reference value Printhead reference value Description Ready reference value SOS signal interval (equivalent to 98% or more of the rated RPM of the printhead motor)

  • Page 53: Xerographic Process During A Print Cycle

    5057-XXX Xerographic process during a print cycle K toner C toner M toner Y toner Fuser Transfer belt Transfer belt Cleaning roll K transfer roll C transfer roll M transfer roll cleaning Y transfer roll assembly 2nd transfer roll assembly Registration roll Printhead Erase Lamp...
  • Page 54 5057-XXX Charge The Charge Roll places a uniform negative electrostatic charge on the surface of the drum. The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness. Light striking the drum discharges the surface charge. HVPS Charge roll (-VDC)
  • Page 55 5057-XXX Exposure The Printhead generates a beam of laser light. Image data received from the RIP card assembly modulates this beam, turning it on and off according to image information that is received from the host computer and software. Through the use of a series of rotating and stationary mirrors within the Printhead, the beam scans the negative charged drum surface.
  • Page 56 5057-XXX The toner adhering to the Magnet Roll is always in contact with the drum surface. When a less negative point on the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet Roll, toner transfers from the Magnet Roll to that point on the drum.
  • Page 57 5057-XXX is now stuck to the transfer belt due to the relative electrical differences between the negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper. HVPS -VDC DRUM -VDC Transfer roll Sheet of paper Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process.

  • Page 58: Auto Density Sensing

    5057-XXX At the beginning of each individual printer cycle, the Printhead scans the surface of the drum, further discharging any residual DC charge that may be left on the drum. Erase lamp LED array DRUM Ground Auto density sensing Image density sensor assembly The image density sensor assembly uses a reflection type sensor that detects a pre-placed toner patch and image on the transfer belt and outputs pulses when the central line of the patch image aligns with the central line...

  • Page 59: Ttm Theory

    5057-XXX TTM theory 1-33 General information...

  • Page 60: Media Transport

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

  • Page 61: Functions Of Main Components

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

  • Page 62: Tray 2 Media Tray Assembly

    5057-XXX Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to come in contact with the pick roll.
  • Page 63 5057-XXX Tray 3 or 4 media tray assembly Rear lift cables Rear media guide Bottom plate F/R lift cable F/L lift cable 1-37 General information...

  • Page 64: Ttm Media Feed Units

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

  • Page 65: Main Components

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

  • Page 66: Ttm Tray 4 Media Transport Motor

    5057-XXX Tray module drive motor This motor is used to drive the media transport mechanism in the tray module. TTM tray 4 media transport motor This motor is used in the TTM to transport media from the tray 4 towards the tray module left door assembly. TTM controller card assembly The TTM controller card assembly, which contains a CPU, controls media feed in the tandem tray module upon receiving a command from the upper printer engine card assembly and sensor/switch information.
  • Page 67 5057-XXX Switch (TTM media size) The following table gives on/off states of the switches on the switch (TTM media size), corresponding to the media sizes of the media tray assembly. Note: The switches (TTM media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Analog switch Media Size S/W1...
  • Page 68 5057-XXX 3TM theory 1-42 Printer Service Manual...
  • Page 69 5057-XXX Media transport Media transport path Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown below. Tray 2 Tray 3 Tray 4 Pick roll Pick roll Pick roll Separation roll Separation roll Separation roll...
  • Page 70 5057-XXX Media transport path The following is a cross section of the printer and the tandem tray module, showing the main components directly associated with the media path and transport. Upper media transport roll assembly Finisher media entrance roll assembly Bridge unit assembly Upper media exit (included with finisher)

  • Page 71: Tray 2, 3, 4 Media Tray Assembly

    5057-XXX Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to come in contact with the pick roll.
  • Page 72 5057-XXX This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of the actuator leaves the sensor (media level) sensing area, the sensor detects that the media has been lifted. Main components Switch (tray module left door interlock) The switch (tray module left door interlock) detects open/close of the tray module left door assembly.

  • Page 73: Tray Module Media Transport Roll Assembly

    5057-XXX Tray module media transport roll assembly The tray module transport roll assembly feeds media from the tray 3 or tray 4 to the printer. Tray module drive motor This motor is used to drive the media transport mechanism in the tray module. 3TM controller card assembly The 3TM controller card assembly, which contains a CPU, controls media feed in the tandem tray module upon receiving a command from the upper printer engine card assembly and sensor/switch information.
  • Page 74 5057-XXX Switch (media size) The following table gives on/off states of the switches on the switch (media size), corresponding to the media sizes of the media tray assembly. Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Analog switch Media Size S/W1...
  • Page 75 5057-XXX 1TM theory 1-49 General information...
  • Page 76 5057-XXX Media transport Media transport path Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown below. Tray 2 Tray 3 Tray 4 Pick roll Pick roll Pick roll Separation roll Separation roll Separation roll...
  • Page 77 5057-XXX Media transport path The following is a cross section of the printer and the 1TM, showing the main components directly associated with the media path and transport. Upper media transport roll assembly Finisher media entrance roll assembly Bridge unit assembly Upper media exit (included with finisher) roll assembly...

  • Page 78: Tm Media Feed Units

    5057-XXX Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to come in contact with the pick roll.
  • Page 79 5057-XXX Switch (media size) The switch (media size) switches the setting of the size of media supplied from each media tray assembly. A signal indicating the set size is transmitted as a voltage to the printer engine card assembly. Sensor (media out) If there is no media in the media tray assembly, the media out actuator lowers and the flag of the media out actuator that has stayed in the sensor (media out) sensing area leaves there.
  • Page 80 5057-XXX Sensor (tray 2 feed-out) The sensor (tray 2 feed-out) detects media fed from the tray 2. Tray module media transport roll assembly The tray module transport roll assembly feeds media from the tray 2. Tray module drive motor This motor is used to drive the media transport mechanism in the tray module. 1TM controller card assembly The 1TM controller card assembly, which contains a CPU, controls media feed in the 1TM upon receiving a command from the upper printer engine card assembly and sensor/switch information.
  • Page 81 5057-XXX Switch (media size) The following table gives on/off states of the switches on the switch (media size), corresponding to the media sizes of the media tray assembly. Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Analog switch Media Size S/W1...
  • Page 82 5057-XXX Duplex 1-56 Printer Service Manual...

  • Page 83: Transfer Belt

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

  • Page 84: Duplex Controller Card Assembly

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

  • Page 85: Tools Required For Service

    5057-XXX Tools required for service Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle nose pliers Diagonal side cutters Spring hook Analog or digital multi meter Parallel wrap plug 1319128 Twinax/serial debug cable (#1381963) Coax/serial debug cable (#1381964) 5.5 mm hexdriver (magnetic) Color toner vacuum...
  • Page 86 5057-XXX Acronyms 1 Tray Module 3 Tray Module Alternating Current Automatic Document Feeder Automatic Paper Size ASIC Application Specific Integrated Circuit Automatic Toner Control Customer Replaceable Unit Customer Setup Counterclockwise Clockwise Direct Current DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM...
  • Page 87 5057-XXX SRAM Static Random Access Memory Tandem Tray Module TVOC Total Volatile Organic Compound Used Parts Return Volts V ac Volts alternating current V dc Volts direct current 1-61 General information...
  • Page 88 5057-XXX 1-62 Printer Service Manual...
  • Page 89 5057-XXX 1-63 General information...
  • Page 90 5057-XXX 1-64 Printer Service Manual...

  • Page 91: Diagnostic Information

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

  • Page 92: Confirm The Installation Status

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

  • Page 93: Error Code Table

    5057-XXX Error code table Error code or Error contents Description/Action message 200.00 Sensor (registration) late jam The media is late reaching the sensor (registration) within the specified time after being fed from any Paper jam given media tray. Go to “200.00 Sensor (registration) late jam”...
  • Page 94 5057-XXX Error code or Error contents Description/Action message 242.00 Sensor (tray 2 feed-out) late The media is late reaching the sensor (tray 2 feed- jam. out) within the specified time after the tray 2 media Paper jam feed lift motor is turned on. Go to “242.00 Sensor (tray 2 feed-out) late jam”...
  • Page 95 5057-XXX Error code or Error contents Description/Action message 281.00 Sensor (bridge unit media The media is late reaching the sensor (bridge unit exit) late jam media exit) within the specified time after reaching Paper jam the sensor (bridge unit media entrance). Refer to the Finisher Service Manual.
  • Page 96 5057-XXX Error code or Error contents Description/Action message 287.00 Sensor (upper media exit) The media is late reaching the sensor (upper media late jam exit) within the specified time after reaching the Paper jam sensor (finisher media entrance). Refer to the Finisher Service Manual. 287.01 Sensor (upper media exit) lag The media reached the sensor (upper media exit)
  • Page 97 5057-XXX Error code or Error contents Description/Action message <Color> toner cartridge The <Color> toner cartridge is defective or not detection error installed. Missing or “<Color> toner cartridge detection error” defective Go to <color> on page 2-51. cartridge Incorrect black toner cartridge A black toner cartridge of an incorrect specification error.
  • Page 98 5057-XXX Error code or Error contents Description/Action message 100K maintenance required Service is required to maintain printer performance. Scheduled Go to “100K maintenance required” on page 2-116. maintenance 100K kit 600K maintenance required Service is required to maintain printer performance. Scheduled Go to “600K maintenance required”...
  • Page 99 5057-XXX Error code or Error contents Description/Action message (Color) toner cartridge nearly The (color) toner cartridge is nearing the empty replacement interval. (Color) toner “(Color) toner cartridge nearly empty” on Go to page 2-123. (Color) toner cartridge empty The (color) toner cartridge requires replacing. Replace (color) Go to “(Color) toner cartridge empty”...
  • Page 100 5057-XXX Error code or Error contents Description/Action message 903.00 K developer/transport drive K developer/transport drive motor error does not motor error rotate at the specified speed. Service motor “903.00 K developer/transport drive error Go to assembly motor error” on page 2-67.
  • Page 101 5057-XXX Error code or Error contents Description/Action message 904.05 Sensor (CMY transfer roll The sensing area of the sensor (CMY transfer roll retract HP) late error retract HP) is not interrupted within the specified Service time when the CMY transfer rolls is moving to the transfer belt home position.
  • Page 102 5057-XXX Error code or Error contents Description/Action message 907.03 C laser SOS internal error The interval of the printhead start of scan C signals exceed the specified value. Printhead error “907.03 M laser SOS internal error” on Go to page 2-79.
  • Page 103 5057-XXX Error code or Error contents Description/Action message 920.02 Fuser sub lamp overheat The rear thermistor detected an abnormal high error temperature. Service fuser error This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur. “920.02 Fuser sub lamp overheat error”...
  • Page 104 5057-XXX Error code or Error contents Description/Action message 925.00 Sensor (Y ATC) Outputs of the sensor (Y ATC) are not in the specified range. Service PC cartridge This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur.
  • Page 105 5057-XXX Error code or Error contents Description/Action message 943.01 Sensor (media level) late The sensing area of the sensor (media level) in the error (tray 3) media tray 3 is not interrupted within the specified Service tray 3 time after the lift tray has risen to operating level. failure Go to “943.01 Sensor (media level) late error...
  • Page 106 5057-XXX Error code or Error contents Description/Action message 950.30 through EPROM mismatch failure This error code indicates a mismatch between the 950.60 RIP card assembly and the interconnect card assembly. Service NVRAM Warning: In the event of replacement of any one of mismatch the following components: •...
  • Page 107 5057-XXX Error code or Error contents Description/Action message 956.02 RIP card assembly cooling The RIP card assembly cooling fan is not fan failure functioning properly. Service system “956.02 RIP card assembly cooling board Go to Go to fan failure” on page 2-104.
  • Page 108 5057-XXX Error code or Error contents Description/Action message 983.01 Sensor (rear tamper HP) lag The sensing area of the sensor (rear tamper HP) error remains interrupted within the specified time after Service finisher the rear tamper starts moving from the home error position.
  • Page 109 5057-XXX Error code or Error contents Description/Action message 989.00 Stapler unit error The sensing area of the sensor (stapler unit motor HP) inside the stapler unit assembly is not Service finisher interrupted within the specified timer after the error stapler unit motor starts moving to the home position.
  • Page 110 5057-XXX Error code or Error contents Description/Action message 991.07 Sensor (booklet compiler no The sensing area of the sensor (booklet compiler no media) no media detected media) did not detect any media when the booklet Service finisher stapler motor was activated. error Refer to the Finisher Service Manual.
  • Page 111 5057-XXX Error code or Error contents Description/Action message Close door D 1TM, 3TM or TTM left door The 1TM, 3TM or TTM tray left door assembly is assembly open open. “1TM, 3TM or TTM left door assembly Go to open” on page 2-107.

  • Page 112: Service Checks

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

  • Page 113: Diagnostic Information

    5057-XXX Step Check Check the Replace the K developer/transport drive motor Go to step 9. Go to step 8. assembly for proper operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 114 5057-XXX Step Check Check the sensor (registration) for proper operation. Go to step 6. Go to step 5. 1. Enter the Diagnostics Menu. 2. Select BASE SENSOR TEST. 3. Select Media Path. 4. Select Registration. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection.

  • Page 115: Sensor Static Jam

    5057-XXX Step Check Check the Replace the K developer/transport drive motor Go to step 12. Go to step 11. assembly for proper operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.

  • Page 116: Sensor (Media On Belt) Late Jam

    5057-XXX Step Check POR the machine. Replace the lower Problem solved. printer engine card Does the error continue? assembly. Go to “Lower printer engine card assembly removal” on page 4-82. 200.03 Sensor (media on belt) late jam Step Check Check the media condition. Replace the Go to step 2.

  • Page 117: Sensor (Fuser Exit) Late Jam

    5057-XXX 201.00 Sensor (fuser exit) late jam Step Check Check the media position. Remove the Go to step 2. media. Does the media touch the sensor (fuser exit)? Check the fuser exit actuator. Replace the Go to step 3. sensor (fuser exit) Does the fuser exit actuator attached to the sensor (fuser exit) appear to be binding or sticking in its normal resting Go to...
  • Page 118 5057-XXX Step Check Check the duplex diverter gate solenoid for proper Replace the Replace the connection. duplex media connection. inverter assembly. Is the above component properly connected? Go to “Duplex media inverter assembly removal” on page 4-9. Check the registration clutch for proper operation. Go to step 10.

  • Page 119: Sensor (Fuser Exit) Lag Jam

    5057-XXX Step Check Perform a print test. Replace the lower Problem solved. printer engine card Does the error continue? assembly. Go to “Lower printer engine card assembly removal” on page 4-82. 202.00 Sensor (fuser exit) lag jam Step Check Check the media position. Remove the Go to step 2.

  • Page 120: Sensor (Duplex Wait) Late Jam (Duplex Media Feed)

    5057-XXX Step Check Check the Replace the K developer/transport drive motor Go to step 8. Go to step 7. assembly for proper operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 121 5057-XXX Step Check Check the sensor (duplex wait) for proper connection. Replace the sensor Replace the (duplex wait). connection. Is the above component properly connected? “Sensor Go to (duplex wait) removal” on page 4-11. Check the duplex diverter gate solenoid for proper Go to step 7.

  • Page 122: Sensor (Registration) Late Jam (Duplex Feed)

    5057-XXX Step Check Check the duplex media inverter clutch for proper Go to step 11. Go to step 10. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 123 5057-XXX Step Check Check the sensor (registration) for proper operation. Go to step 5. Go to step 4. 1. Enter the Diagnostics Menu. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection.

  • Page 124: Sensor (Registration) Late Jam (Duplex Media Feed)

    5057-XXX Step Check Check the duplex media inverter clutch for proper Go to step 11. Go to step 10. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 125 5057-XXX Step Check Check the sensor (registration) for proper operation. Go to step 5. Go to step 4. 1. Enter the Diagnostics Menu. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection.

  • Page 126: Sensor (Tray 1 Feed-Out) Late Jam

    5057-XXX Step Check Check the duplex media inverter clutch for proper Go to step 11. Go to step 10. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 127 5057-XXX Step Check Check the feed roll, separation roll, and pick roll for media Go to step 4. Clean or replace tray 1. the feed roll, separating roll, or Are the above components free of excess wear and pick roll. contamination? “Feed roll Go to...

  • Page 128: Sensor (Tray 2 Feed-Out) Late Jam

    5057-XXX Step Check Perform a print test. Replace the lower Problem solved. printer engine card Does the error continue? assembly. Go to “Lower printer engine card assembly removal” on page 4-82. 242.00 Sensor (tray 2 feed-out) late jam Step Check Check the media condition.

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

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

  • Page 130: Sensor (Tray 3 Feed-Out) Late Jam

    5057-XXX Step Check Check the sensor (tray 2 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 2. 5. Select Feed-out. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 131 5057-XXX Step Check Check the feed roll, separation roll, and pick roll for Go to step 4. Clean or replace the media tray 3. feed roll, separating roll, or pick roll. Are the above components free of excess wear and Go to “Feed roll contamination?

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

    5057-XXX Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM controller card assembly or the TTM controller card assembly. Go to “1X 500- sheet drawer (1TM)–1TM controller card assembly removal”...
  • Page 133 5057-XXX Step Check Check the sensor (tray 3 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 3. 5. Select Feed-out. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 134: Sensor (Tray 4 Feed-Out) Late Jam

    5057-XXX Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM controller card assembly or the TTM controller card assembly. Go to “1X 500- sheet drawer (1TM)–1TM controller card assembly removal”...
  • Page 135 5057-XXX Step Check Check the sensor (tray 4 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 4. 5. Select Feed-out. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 136: Sensor (Tray 3 Feed-Out) On Jam (Feeding From Tray)

    5057-XXX Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM controller card assembly or the TTM controller card assembly. Go to “1X 500- sheet drawer (1TM)–1TM controller card assembly removal”...
  • Page 137 5057-XXX Step Check Check the sensor (tray 4 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 4. 5. Select Feed-out. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 138: Sensor (Registration) Late Jam (Feeding From The Mpf)

    5057-XXX Step Check Perform a print test. Replace the 1TM Problem solved. controller card Does the error continue? assembly or the 3TM controller card assembly or the TTM controller card assembly. Go to “1X 500- sheet drawer (1TM)–1TM controller card assembly removal”...
  • Page 139 5057-XXX Step Check Check the sensor (registration) for proper operation. Go to step 7. Go to step 6. 1. Enter the Diagnostics Menu. 2. Select BASE SENSOR TEST. 3. Select Media Path. 4. Select Registration. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (registration) for proper connection...

  • Page 140: Black Toner Cartridge Detection Error

    5057-XXX Step Check Check the MPF/transport drive motor for proper connection. Replace the MPF/ Replace the transport drive connection. Is the above component properly connected? motor . Go to “MPF / transport drive motor assembly removal” on page 4-106. Perform a print test. Replace the lower Problem solved.

  • Page 141: Color> Toner Cartridge Detection Error

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

  • Page 142: Tray 1 Media Size Mismatch Error

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

  • Page 143: Tray 3 Media Size Mismatch Error

    5057-XXX Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error remain when the power is turned off/on? assembly. Go to “Upper printer engine card assembly removal” on page 4-79. Perform a POR. Replace the RIP Problem solved.

  • Page 144: Tray 4 Media Size Mismatch Error

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

  • Page 145: Tray 2 Media Type Mismatch Error

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

  • Page 146: Tray 3 Media Type Mismatch Error

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

  • Page 147: Tray 4 Media Type Mismatch Error

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

  • Page 148: Image Pipeline Asic Error

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

  • Page 149: Hard Drive/Configuration Id Mismatch

    5057-XXX 849.00 Hard drive/configuration ID mismatch Step Check Check the hard drive data and power connections. Replace the Replace the hard drive. connections. Are the above connections connected properly? Go to “Hard drive removal” on page 4-76. Perform a POR. Replace the RIP Problem solved.
  • Page 150 5057-XXX Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Upper printer engine card assembly removal” on page 4-79. 902.00 General upper engine error fuse #1 Step Check Perform a POR.
  • Page 151 5057-XXX Step Check Check the 24V LVPS cooling fan cables and any associated Go to step 7. Repair or replace cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? or replace the 24V LVPS cooling fan.
  • Page 152 5057-XXX Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Upper printer engine card assembly removal” on page 4-79. 902.02 General upper engine error fuse #3 Step Check Perform a POR.
  • Page 153 5057-XXX Step Check Check the duplex drive motor assembly cables and any Go to step 3. Repair or replace associated cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? or replace the duplex unit assembly.
  • Page 154 5057-XXX 902.05 General lower engine error fuse #3 Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Check the MPF/transport drive motor assembly cables and Go to step 3.
  • Page 155 5057-XXX Step Check Check the printhead shutter motor assembly cables and Go to step 4. Repair or replace any associated cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? or replace the printhead shutter motor assembly.
  • Page 156 5057-XXX Step Check Check the registration clutch cables and any associated Go to step 3. Repair or replace cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? or replace the registration clutch. Go to “Registration clutch removal”...

  • Page 157: K Developer/Transport Drive Assembly Motor Error

    5057-XXX Step Check Check the inverter reverse clutch cables and any Go to step 9. Repair or replace associated cables for damage. the appropriate cable assemblies Are the above components free from crimps and damage? or replace the duplex media inverter assembly.

  • Page 158: K Pc Drive Motor Error

    5057-XXX Step Check Perform a POR. Replace the lower Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Lower printer engine card assembly removal” on page 4-82. 903.01 K PC drive motor error Step Check Perform a POR.

  • Page 159: Cmy Pc Drive Motor Error

    5057-XXX 903.02 CMY PC drive motor error Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Check the CMYK PC cartridge drive motor assembly for Go to step 4.

  • Page 160: Sensor (Transfer Belt Hp) Late Error

    5057-XXX Step Check Check the CMY developer drive motor assembly for proper Go to step 4. Go to step 3. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.

  • Page 161: Transfer Belt Position Failure

    5057-XXX Step Check “Transfer Replace the transfer belt unit assembly. To to Replace the lower Problem solved. belt unit assembly removal” on page 4-16. printer engine card assembly. Does the error remain? Go to “Lower printer engine card assembly removal” on page 4-82.

  • Page 162: Sensor (Transfer Belt Edge) Failure

    5057-XXX 904.02 Sensor (transfer belt edge) failure Step Check Check the transfer belt unit assembly for proper installation. Go to step 2. Re-install the transfer belt unit Is the above component properly installed? assembly. Check the transfer belt unit assembly for damage. Go to step 3.
  • Page 163 5057-XXX Step Check Check the sensor (2nd transfer roll HP) for proper Go to step 4. Go to step 3. operation. 1. Enter the Diagnostics Menu. 2. Select Base Sensor Tests. 3. Select Media Path. 4. Select 2nd transfer roll retract HP. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 164: Sensor (2Nd Transfer Roll Retract Hp) Lag Error

    5057-XXX 904.04 Sensor (2nd transfer roll retract HP) lag error Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Check the sensor (2nd transfer roll HP) for proper Go to step 4.

  • Page 165: Sensor (Cmy Transfer Roll Retract Hp) Late Error

    5057-XXX Step Check Perform a POR. Replace the lower Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Lower printer engine card assembly removal” on page 4-82. 904.05 Sensor (CMY transfer roll retract HP) late error Step Check Perform a POR.

  • Page 166: Nvm Read/Write Cannot Be Executed Error

    5057-XXX 904.07 CMY transfer roll retract motor time out Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. “Transfer Replace the transfer belt unit assembly.

  • Page 167: Marking Device Xerographics Error

    5057-XXX 905.02 Marking device Xerographics error Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Upper printer engine card assembly removal” on page 4-79.

  • Page 168: Printhead Polygon Mirror Motor Error

    5057-XXX 907.00 Printhead polygon mirror motor error Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Go to step 3.

  • Page 169: M Laser Sos Internal Error

    5057-XXX Step Check Perform a POR. Replace the Problem solved. printhead Does the error occur when the power is turned off/on? assembly. Go to “Printhead assembly removal” on page 4-95. 907.03 M laser SOS internal error Step Check Perform a POR. Go to step 2.

  • Page 170: Printhead Control Error

    5057-XXX 907.05 Printhead control error Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Go to step 3.

  • Page 171: V Lvps Cooling Fan Error

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

  • Page 172: Fuser Cooling Fan Lock Error

    5057-XXX 911.02 Fuser cooling fan lock error Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Check the fuser cooling fan for proper operation. Go to step 4.

  • Page 173: Fuser Main Lamp Overheat Error

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

  • Page 174: Fuser Sub Lamp Overheat Error

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

  • Page 175: Main Lamp Warm Up Error

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

  • Page 176: Main Lamp On-Time Error

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

  • Page 177: Sub Lamp On-Time Error

    5057-XXX Step Check Perform a POR. Replace the AC Problem solved. drive card bracket Does the error occur when the power is turned off/on? assembly. Go to “AC drive card bracket assembly removal” on page 4-100. 920.07 Sub lamp on-time error Step Check Check the fuser unit assembly for a media jam.

  • Page 178: Magenta Toner Rfid Communication Error

    5057-XXX Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Upper printer engine card assembly removal” on page 4-79. 924.01 Magenta toner RFID communication error Step Check Check the M toner cartridge.

  • Page 179: Black Toner Rfid Communication Error

    5057-XXX Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error occur when the power is turned off/on? assembly. Go to “Upper printer engine card assembly removal” on page 4-79. 924.03 Black toner RFID communication error Step Check Check the K toner cartridge.

  • Page 180: Sensor (C Atc)

    5057-XXX Step Check Perform a very large print test. Replace the upper Problem solved. printer engine card Does the error continue? assembly. Go to “Upper printer engine card assembly removal” on page 4-79. 925.01 Sensor (M ATC) Step Check Reset the M ATC failure lock out condition. Go to step 2.

  • Page 181: Mpf Tray 5 Size Sensing Error

    5057-XXX Step Check Check the sensor (C ATC) for proper connection. Replace the C Replace the Developer unit connection. Is the above component properly connected? assembly. Go to “Developer unit assembly removal” on page 4-53. Perform a very large print test. Replace the upper Problem solved.
  • Page 182 5057-XXX Step Check Check the MPF feed unit assembly. Replace the MPF Replace the feed unit connection. Is the above component properly connected? assembly . Go to “MPF feed unit assembly removal” on page 4-8. Perform a POR. Replace the upper Problem solved.
  • Page 183 5057-XXX 941.01 Sensor (media level) late error (tray 1) Step Check Check the media. Go to step 2. Load media properly. Is media loaded in tray 1 properly? Check the sensor (media level) (tray 1) for proper operation. Go to step 4. Go to step 3.
  • Page 184 5057-XXX 942.00 Switch (media size) size sensing error (tray 2) Step Check Check the media. Go to step 2. Load media properly. Is media loaded in tray 2 properly? Check the media tray. Replace the media Go to step 3. tray assembly.
  • Page 185 5057-XXX Step Check Check the sensor (media level) (tray 2) for proper Replace the Replace the connection. sensor (media connection. level). Is the above component properly connected? Go to “Sensor (media level) removal” on page 4-24. Check the media feed/lift motor (tray 2) for proper Go to step 6.
  • Page 186 5057-XXX Step Check Check the tray 3 switch (media size) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor Test. 4. Select Tray 3. 5. Select Tray 3 present. Does the display on the operator panel, change every time the media tray is opened and closed? 3TM equipped machines check the tray 3 switch (media...
  • Page 187 5057-XXX Step Check Check the sensor (media level) (tray 3) for proper Replace the Replace the connection. sensor (media connection. level). Is the above component properly connected? Go to “Sensor (media level) removal” on page 4-24. Check the media feed/lift motor (tray 3) for proper Go to step 6.
  • Page 188 5057-XXX Step Check Check the tray 4 switch (media size) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor Test. 4. Select Tray 4. 5. Select Tray 4 present. Does the display on the operator panel, change every time the media tray is opened and closed? 3TM equipped machines check the tray 4 switch (media...

  • Page 189: Through 950.29 Eprom Mismatch Failure

    5057-XXX Step Check Check the sensor (media level) (tray 4) for proper Replace the Replace the connection. sensor (media connection. level). Is the above component properly connected? Go to “Sensor (media level) removal” on page 4-24. Check the media feed/lift motor (tray 4) for proper Go to step 6.

  • Page 190: Through 950.60 Eprom Mismatch Failure

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

  • Page 191: Xx Rip Card Assembly Nvram Failure

    5057-XXX If problem remains, replace the original panel assembly with Contact the next Problem solved. a new and not previously installed interconnect card level of support. assembly. Go to “Interconnect card assembly removal” on page 4-75. Does the error remain? 951.XX RIP card assembly NVRAM failure Step Check...

  • Page 192: Xx Operator Panel Assembly Nvram Failure

    5057-XXX 953.XX Operator panel assembly NVRAM failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the Problem solved.

  • Page 193: Xx Rip Card Assembly Nand Crc Failure

    5057-XXX 955.XX RIP card assembly NAND CRC failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the RIP Problem solved.

  • Page 194: Rip Card Assembly Cooling Fan Failure

    5057-XXX 956.02 RIP card assembly cooling fan failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Go to step 3.

  • Page 195: Hvps Controller Communication Error

    5057-XXX Step Check Perform a POR. Replace the 1TM, Problem solved. 3TM or the TTM Does the error continue when the power is turned off/ TTM controller card assembly. “1X 500- Go to sheet drawer (1TM)–1TM controller card assembly removal” on page 4-203, “3X...

  • Page 196: Communication Error Between Printer And Rip Card Assembly

    5057-XXX 980.02 Communication error between printer and RIP card assembly Step Check Check the RIP card assembly and the printer engine card Go to step 2. Replace the assembly for proper connection. connection. Is the above component properly connected? Perform a POR. Replace the RIP Problem solved.

  • Page 197: Tm, 3Tm Or Ttm Left Door Assembly Open

    5057-XXX 1TM, 3TM or TTM left door assembly open Step Check Check the 1TM, 3TM or TTM left door for proper Go to step 2. Replace the 1TM, operation. 3TM or TTM left door assembly. Is the above component open and close properly? Go to “1X 500- sheet drawer...

  • Page 198: Duplex Left Door Assembly Open

    5057-XXX Step Check Perform a POR. Replace the upper Problem solved. printer engine card Does the error continue when the power is turned off/ assembly. Go to “Upper printer engine card assembly removal” on page 4-79. Duplex left door assembly open Step Check Check the duplex left door for proper operation.

  • Page 199: Media Size Mismatch In Width

    5057-XXX Media size mismatch in width Step Check Check the media. Go to step 2. Load media properly. Is media properly loaded in the tray? Check the media. Go to step 3. Set the guides properly. Is the rear media tray guide, and media tray end guide of tray 1 or tray 2 set correctly? Check the switch (media size) for proper installation.

  • Page 200: No Media In The Selected Media Tray

    5057-XXX Step Check Check the switch (TTM media size) for proper Replace the Replace the connection. appropriate switch connection. (TTM media size). Check tray 3 and tray 4. Go to “2000-sheet Are the above sensors connected properly? dual input (TTM)–switch (TTM media size) removal”...
  • Page 201 5057-XXX Step Check Check the sensor (media out) for operation. Go to step 4. Go to step 3. 1. Enter the Diagnostics Menu. 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 1. 5. Select Media out. 1.

  • Page 202: Pc Cartridge End Of Life

    5057-XXX Paper is installed (short edge) in the media paper tray Step Check Is the media installed (short edge) orientation in the media Turn media 90 Go to step 2. tray assembly as opposed to long edge? degrees or enable short edge feeding which is found in the config menu...

  • Page 203: Printer Front Door Assembly Open

    5057-XXX Printer front door assembly open Step Check Check the printer front door for proper operation. Go to step 2. Replace the printer front door Does the above component open and close properly? assembly. Go to “Printer front door assembly removal”...

  • Page 204: Printer Left Door Open

    5057-XXX Printer left door open Step Check Check the printer left door closed actuator located on the Go to step 2. Replace the rear of the printer left door assembly for damage. printer left door closed actuator Is the above component, as shown in the graphic below, (40X4098).

  • Page 205: Transfer Belt Access Door Open

    5057-XXX Transfer belt access door open Step Check Check the transfer belt access door for proper operation. Go to step 2. Replace the printer right cover Does the above component open and close properly? assembly. Go to “Printer left door damper removal”...

  • Page 206: K Maintenance Required

    5057-XXX Step Check Check the switch (printer left lower door interlock) for Go to step 4. Go to step 3. operation. 1. Enter the Diagnostics Menu. 2. Select BASE SENSOR TEST. 3. Select Cover and Door. 4. Select Door B left/lower. Does the display on the operator panel change every time the actuator on the above switch is operated? Check the switch (printer left lower door interlock)

  • Page 207: Adf Maintenance Required

    5057-XXX ADF maintenance required Step Check Install the ADF maintenance kit. Reset the ADF Problem solved. maintenance Does the message still occur? counter. Go to “Scheduled maintenance” on page 6-2. Standard media bin full Step Check Check the actuator for movement. Go to step 2.

  • Page 208: Toner Cartridge Set Error

    5057-XXX Step Check Checking the sensor (RFID toner cartridge) connection. Replace the Replace the sensor (RFID connection. Is the sensor (RFID toner cartridge) properly connected? toner cartridge). Go to Go to “Sensor (RFID toner cartridge) removal” on page 4-110. • Perform a print test. Replace the Problem solved.

  • Page 209: Waste Toner Cartridge Not Detected

    5057-XXX Step Check Check the sensor (waste toner cartridge full) for proper Go to step 5. Go to step 3. operation. 1. Enter the Diagnostics Menu. 2. Select BASE SENSOR TEST. 3. Select Exit level. 4. Select Standard bin full 1. Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?

  • Page 210: Waste Toner Cartridge Nearly Full

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

  • Page 211: Color) Pc Cartridge Invalid

    5057-XXX (Color) PC cartridge invalid Step Check Check the appropriate PC cartridge. Go to step 2. Reinstall the appropriate PC Is the above component the correct part number and cartridge. installed properly? Go to “PC cartridge unit removal” on page 4-43.

  • Page 212: Cmy Pc Cartridges Exhausted

    5057-XXX CMY PC cartridges exhausted Step Check Check the CMY PC cartridges. Go to step 2. Reinstall the CMY PC cartridges. Is the above component properly installed? Go to “PC cartridge unit removal” on page 4-43. Replace the CMY PC cartridges. Go to step 3.

  • Page 213: Color) Toner Cartridge Nearly Empty

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

  • Page 214: Color) Toner Cartridge Empty

    5057-XXX Step Check Check the CMYK toner add motor assembly connection. Replace the Replace the CMYK toner add connection. Is the above component properly connected? motor assembly. Go to “CMYK toner add motor assembly removal” on page 4-94. Perform a POR. Replace the upper Problem solved.
  • Page 215 5057-XXX Step Check Check the CMYK toner add motor assembly connection. Replace the Replace the CMYK toner add connection. Is the above component properly connected? motor assembly. Go to “CMYK toner add motor assembly removal” on page 4-94. Perform a POR. Replace the upper Problem solved.

  • Page 216: Image Quality Trouble

    5057-XXX Image quality trouble Printer Related Troubleshooting Note: First, get a printout as a base, and follow the symptom table to identify the possible failing FRU’s. Image quality symptoms • “Faint print (Low contrast)” on page 2-127. Faint print (low contrast)– •...

  • Page 217: Image Quality

    5057-XXX Image Quality Faint print (Low contrast) Leading edge Trailing edge Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path. Step Check Check the media condition. Problem solved. Go to step 2. Load new, dry, recommended media, and perform a print test.
  • Page 218 5057-XXX Step Check Check the toner add motor assembly. Go to step 7. Problem solved. Replace the toner add motor assembly. “CMYK toner add motor assembly removal” on Go to page 4-94. Does the error continue. Check the developer/transfer roll HVPS card assembly. Go to step 8.

  • Page 219: Blank Print (No Print)

    5057-XXX Blank print (no print) Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the four toner cartridges. Problem solved. Replace any empty toner Re-print the defective image. cartridges. Is the image density normal? Check the 2nd transfer roll assembly for contamination Go to step 3.
  • Page 220 5057-XXX Step Check Check the printhead assembly installation. Go to step 8. Problem solved. Install the printhead assembly properly, and perform a print test. Does the problem remain? Check the printhead assembly for connection. Go to step 9. Replace the connection.

  • Page 221: Solid Black

    5057-XXX Solid black Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the four PC cartridges for proper installation. Go to step 2. Correct and clean Check the PC cartridge connections. contaminated pins, or replace Are the PC cartridge connections free of excess wear the appropriate...

  • Page 222: Vertical Lines And Bands (Process Direction)

    5057-XXX Vertical lines and bands (process direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Is the media transfer route and the media path clear of Go to step 3.
  • Page 223 5057-XXX Step Check Check the upper printer engine card assembly. Go to step 9. Problem solved. Replace the upper printer engine card assembly. “Upper printer engine card assembly removal” Go to on page 4-79. Perform a print test. Does the problem remain? Check the printhead assembly for connection.

  • Page 224: Horizontal White Stripes Or Bands (Side To Side Direction)

    5057-XXX Horizontal white stripes or bands (side to side direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, and recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
  • Page 225 5057-XXX Step Check Check the printhead assembly. Go to step 9. Problem solved. Replace the printhead assembly. “Printhead assembly removal” on page 4-95. Go to Does the error continue? Check the upper printer engine card assembly. Replace the RIP problem solved. card assembly.

  • Page 226: Vertical Stripes (Process Direction)

    5057-XXX Vertical stripes (process direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
  • Page 227 5057-XXX Step Check Check the upper printer engine card assembly. Problem solved. Replace the RIP card assembly. Replace the upper printer engine card assembly. Go to “RIP card “Upper printer engine card assembly removal” Go to assembly on page 4-79. removal”...

  • Page 228: Horizontal Stripes (Side To Side Direction)

    5057-XXX Horizontal stripes (side to side direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3.
  • Page 229 5057-XXX Step Check Check the developer/transfer roll HVPS card assembly. Go to step 8. Problem solved. Replace the developer/transfer roll HVPS card assembly. Go to “Developer / transfer roll HVPS card assembly removal” on page 4-104. Perform a print test. Does the problem remain? Check the upper printer engine card assembly.

  • Page 230: Partial Lack

    5057-XXX Partial lack Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? Check the four toner cartridges. Problem solved. Replace any empty toner Re-print the defective image.
  • Page 231 5057-XXX Step Check Check the printhead assembly. Go to step 9. Problem solved. Replace the printhead assembly. “Printhead assembly removal” on page 4-95. Go to Does the error continue? Check the upper printer engine card assembly. Problem solved. Replace the RIP card assembly.
  • Page 232 5057-XXX Spots Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media route free of contamination or debris? contamination.

  • Page 233: After Image

    5057-XXX Step Check Check the printhead assembly. Go to step 8. Problem solved. Replace the printhead assembly. “Printhead assembly removal” on page 4-95. Go to Does the error continue? Check the upper printer engine card assembly. Replace the RIP Problem solved. card assembly.
  • Page 234 5057-XXX Step Check Check the upper printer engine card assembly. Replace the RIP Problem solved. card assembly. Replace the upper printer engine card assembly. Go to “RIP card “Upper printer engine card assembly removal” Go to assembly on page 4-79. removal”...

  • Page 235: Background (Fog)

    5057-XXX Background (fog) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media path free of contamination or debris.
  • Page 236 5057-XXX Step Check Check the printhead assembly. Go to step 8. Problem solved. Replace the printhead assembly. “Printhead assembly removal” on page 4-95. Go to Does the error continue? Check the upper printer engine card assembly. Replace the RIP Problem solved. card assembly.
  • Page 237 5057-XXX Skew Leading edge Trailing edge The printed image is not paralleled with both sides of the media. Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for damaged printer caster. Is the setup surface normal? Properly load media into the media tray assembly and Go to step 3.
  • Page 238 5057-XXX Step Check Check the registration/transport roll assembly. Go to step 7. Replace registration/ Are all drive rolls on the registration/transport roll transport roll assembly free of contamination, wear and damage? assembly. Go to “Registration / transport roll assembly removal” on page 4-36.

  • Page 239: Media Damage

    5057-XXX Media damage Leading edge Trailing edge Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for missing printer foot. Is the setup surface normal? Check the media feed. Go to step 3.
  • Page 240 5057-XXX Step Check Check the heat roll and pressure roll. Replace the Inspect the fuser unit machine for Remove the fuser unit assembly. assembly. obstructions in the media path. CAUTION: Allow the fuser unit assembly to Go to “Fuser unit assembly cool down.

  • Page 241: No Fuse

    5057-XXX No fuse Leading edge Trailing edge Step Check Check the fuser unit assembly installation. Go to step 2. Problem solved. Check that the levers, on both sides of the fuser unit assembly, are pushed down. Re-print the defective image. Does the error continue? Check the media condition.

  • Page 242: Color Misregistration

    5057-XXX Color misregistration Step Check Replace the transfer belt unit assembly. Go to Go to step 2. Problem solved. “Transfer belt unit assembly removal” on page 4-16. Does the error remain? Replace the transfer belt steering motor. Go to Go to step 3. Problem solved.
  • Page 243 5057-XXX Deletions Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? Replace the transfer belt unit assembly. Go to Go to step 3. Problem solved. “Transfer belt unit assembly removal”...

  • Page 244: High Frequency Bands

    5057-XXX High frequency bands Step Check Check the four PC cartridges for proper installation. Go to step 2. Correct and clean Check the PC cartridge connections. contaminated pins, or replace Are the PC cartridge connections free of excess wear the appropriate and contamination? PC cartridge or connector.
  • Page 245 5057-XXX Select a menu or menu item for more details. Supplies Menu Job Menu Serial Menu PCL Emul Menu Color Menu <color> Toner Cancel Job PCL SmartSwitch Font Source Color Adjust Oiler Reset Printer PS SmartSwitch Font Name Color Balance Waste Bottle Print Buffer NPA Mode...
  • Page 246 5057-XXX 2-156 Printer Service Manual...

  • Page 247: Diagnostic Aids

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

  • Page 248: Entering Diagnostics Menus

    5057-XXX Diagnostics Menus Entering Diagnostics Menus 1. Turn off the printer. 2. Press and hold the buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available tests Tests appear on the LCD in the order shown: MOTOR TESTS “MOTOR TESTS”...
  • Page 249 5057-XXX Booklet stapler motor Bridge unit bin media exit solenoid Printer Motor Tests Transfer belt steering motor CMY PC cartridge drive motor K PC cartridge drive motor Printhead polygon mirror motor Tray 1 media feed/lift motor Registration clutch 2nd transfer roll retract motor K developer/transport motor MPF pick solenoid MFP/transport drive motor...
  • Page 250 5057-XXX “Panel Test” on page 3-7. Panel Test “Button Test” on page 3-7. Button Test “DRAM Test” on page 3-8. DRAM Test CACHE Test “CACHE Test” on page 3-8. DUPLEX TESTS Quick Test “Quick Test” on page 3-8. Sensor Test “Sensor Test (duplex)”...

  • Page 251: Motor Tests

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

  • Page 252: Print Tests

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

  • Page 253: Input Source Print Test

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

  • Page 254: Dram Test

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

  • Page 255: Sensor Test

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

  • Page 256: Sensor Test

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

  • Page 257: Feed To All Bins

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

  • Page 258: Hole Punch Test

    5057-XXX To run the Staple Test 1. Select FINISHER TESTS from the Diagnostics Menu. 2. Select Staple Test. The printer feeds eight pieces of media from the default input source to the output bin that supports stapling. After all eight pieces of media are deposited, the device staples the packet. While this test runs, Staple Test Running...
  • Page 259 5057-XXX Available Cover and Door Sensors Sensor Name Door G finisher front Surface H eject cover Cover F bridge unit top Available Bin Level Sensors Sensor Name Finisher upper media bin full Stacker bin level1 Stacker bin level2 Stacker bin upper limit Stacker bin no media Stacker bin level encod Available Media Path 1 Sensors...

  • Page 260: Base Sensor Test

    5057-XXX Booklet front tamper HP Booklet rear tamper HP Booklet unit media entrance Booklet unit media exit Booklet bin media present Booklet compiler media present Booklet unit interlock Booklet front low staple Booklet rear low staple Available Punch and Staple Sensors Sensor Name Punch side reg1 Punch side reg2...
  • Page 261 5057-XXX Door A printer left Door C printer left lower Door D tray module left Door E printer front Door J transfer belt access Devices Sensors Sensor Name C PC cartridge present M PC cartridge present Y PC cartridge present K PC cartridge present Waste toner full Exit Level Sensor...

  • Page 262: Printer Setup

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

  • Page 263: Event Log

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

  • Page 264: Print The Event Log

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

  • Page 265: Dev Unit Reset

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

  • Page 266: Engine Adjust

    5057-XXX ENGINE ADJUST To begin PH Adjust (media tray registration), the test page must be printed. To print the test page the printer must be in standard mode. 1. Select Menus. 2. Select Reports. 3. Select Network Setup Page The following report prints. Using a fine incremental ruler, measure from the black line border to the edge of the media.
  • Page 267 5057-XXX Adj Lead Reg ALL (appears on LCD) Registration values appear on the LCD. If required, reset the values (Adj lead reg all trays) and Select to submit the changes. Adj Lead Reg Tr165 (appears on LCD) Registration values appear on the LCD.
  • Page 268 5057-XXX PRO-CON (ATC sensor setup and adjust) This procedure is used to adjust the following: Sensor (C ATC) Sensor (M ATC) Sensor (Y ATC) Sensor (K ATC) Select PRO-CON and select: Then Select: Appears on the LCD ATC Sensor Adjust values Sen Grad SNR-Y Registration values appear on the LCD.

  • Page 269: Booklet Fold Adjust

    5057-XXX Color registration (RegCon) The purpose of the color registration is to establish correct horizontal and vertical positioning of the four primary color images. The procedure consists of the following steps, which must be performed in the listed sequence: 1. Belt Edge Learn - Used to align the transfer belt positioning system. 2.

  • Page 270: Entering Configuration Menu

    5057-XXX Entering Configuration Menu 1. Turn off the printer. 2. Press and hold the Select and Right Arrow buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available menus Maintenance Counter Value “Maintenance Counter Value” on page 3-24.

  • Page 271: Reset Maintenance Counter

    5057-XXX After installing the required maintenance kit, reset this count to zero. Reset Maintenance Counter After scheduled maintenance, reset the Maintenance Counter. To reset the maintenance page counter to zero: 1. Select Reset Maintenance Counter from the Configuration Menu. 2. Reset Maintenance Counter appears in the header. 3.

  • Page 272: Panel Menus

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

  • Page 273: Factory Defaults

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

  • Page 274: Envelope Prompts

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

  • Page 275: Tray Low Message

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

  • Page 276: Repeating Defects

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

  • Page 277: Repair Information

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

  • Page 278: Removal Procedures

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

  • Page 279: Printer Front Door Assembly Removal

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

  • Page 280: Right Cover Assembly Removal

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

  • Page 281: Rear Cover Assembly Removal

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

  • Page 282: Rear Left Middle Cover Removal

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

  • Page 283: Rear Left Upper Cover Removal

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

  • Page 284: Printer Left Lower Door Assembly Removal

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

  • Page 285: Front Left Cover Removal

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

  • Page 286: Duplex Unit Assembly Removal

    5057-XXX Duplex unit assembly removal 1. Remove the two screws securing the duplex unit assembly (A) to the printer left door assembly (B). 2. Gently pull the duplex unit assembly (A) from the printer left door assembly (B). Note: When removing the duplex unit assembly (A), the plastic panel (C) may become detached. 3.

  • Page 287: Switch (Duplex Left Door Interlock) Removal

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

  • Page 288: Duplex Media Exit Turn Guide Removal

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

  • Page 289: Duplex Drive Motor Removal

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

  • Page 290: Duplex Controller Card Assembly Removal

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

  • Page 291: Fuser Unit Assembly Removal

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

  • Page 292: Transfer Belt Unit Assembly Removal

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

  • Page 293: Transfer Belt Cleaning Assembly Removal

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

  • Page 294: Standard Media Exit Bin Full Actuator Removal

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

  • Page 295: Switch (Printer Left Door Interlock) Removal

    5057-XXX Switch (printer left door interlock) removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. Warning: Ensure that the rear left middle cover is removed before removing the rear left upper cover, or damage will occur.
  • Page 296 5057-XXX 5. Remove the screw securing the bracket (A) to the standard media exit bin shift assembly. 6. Remove the bracket (A). 7. Release the hooks securing the switch (printer left door interlock) (B) to the bracket (A). 8. Remove the switch (printer left door interlock). Hooks Hooks Hooks...

  • Page 297: Media Feed Unit Assembly 1 Removal

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

  • Page 298: Media Out Actuator Removal

    5057-XXX Sensor (media out) removal “Printer left lower door assembly removal” on page 4-8. 1. Remove the printer left lower door assembly. See 2. Remove the media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-21. 3.
  • Page 299 5057-XXX 4. Remove the media out actuator (A). Front Bosses Lower view 4-23 Repair information...

  • Page 300: Sensor (Media Level) Removal

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

  • Page 301: Sensor (Fuser Exit) Removal

    5057-XXX Sensor (fuser exit) removal 1. Open the printer left door assembly. 2. Remove the E-clip securing the fuser exit roll assembly (A) to the machine. 3. Remove the bushing (B). 4. Remove the fuser exit roll assembly (A). 5. Remove the two screws securing the sensor (fuser exit) (C) to the machine. 6.

  • Page 302: Printer Left Door Assembly Removal

    5057-XXX Printer left door assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...
  • Page 303 5057-XXX C-clip Safety screw Approximately 75° Replacement warning: When replacing the printer left door assembly (B), ensure that the black lines are aligned on the damper assembly (E), or the door will not properly operate. Black line 4-27 Repair information...
  • Page 304 5057-XXX ‘ Replacement warning: When replacing the printer left door assembly (B), ensure that the duplex media exit turn guide (F) is held in its upper-most position, or the printer left door assembly (B) will not close properly. 4-28 Printer Service Manual...

  • Page 305: Printer Left Door Damper Removal

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

  • Page 306: Sensor (Media On Belt) Removal

    5057-XXX Replacement warning: When replacing the printer left door assembly (D), ensure that the duplex media exit turn guide (E) is held in its upper-most position, or the printer left door assembly (D) will not close properly. Sensor (media on belt) removal 1.

  • Page 307: Nd Transfer Roll Retract Cam Assembly Removal

    5057-XXX 2nd transfer roll retract cam assembly removal “2nd transfer roll assembly removal” on page 4-35. 1. Remove the 2nd transfer roll assembly. See 2. Remove the two screws securing the registration pinch guide assembly (A) to the machine. 3. Remove the registration pinch guide assembly (A). 4.
  • Page 308 5057-XXX Connector Replacement note: When reinstalling the transfer roll retract cam assembly (D), ensure that the bushing (E), pin (F), and washer are replaced. E-clip Actuator Connector 4-32 Printer Service Manual...
  • Page 309 5057-XXX 4-33 Repair information...

  • Page 310: Sensor (2Nd Transfer Roll Retract Hp) Removal

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

  • Page 311: Nd Transfer Roll Retract Motor Assembly Removal

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

  • Page 312: Registration / Transport Roll Assembly Removal

    5057-XXX Warning: When removing the main transfer roll assembly (B), do not touch the roll surface. Replacement warning: When reinstalling the transfer roll assembly (B), do not touch the roll surface. Registration / transport roll assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal”...

  • Page 313: Registration Clutch Removal

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

  • Page 314: Sensor (Transparency Detect) Removal

    5057-XXX 9. Disconnect the connector from the sensor (registration) (C). Sensor (transparency detect) removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. “Rear left middle cover removal” on page 4-6. 2. Remove the rear left middle cover. See 3.

  • Page 315: Waste Toner Cartridge Cover Removal

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

  • Page 316: Sensor (Waste Toner Cartridge Full) Removal

    5057-XXX Connectors Sensor (waste toner cartridge full) removal 1. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3. “Front left cover removal” on page 4-9. 2. Remove the front left cover. See “Waste toner cartridge cover removal” on page 4-39.

  • Page 317: Switch (Waste Toner Cartridge Interlock) Removal

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

  • Page 318: Remove The Front Left Cover. See

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

  • Page 319: Remove The Waste Toner Cartridge Sensor Assembly

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

  • Page 320: Front Left Cover Removal" On Page

    5057-XXX Replacement warning: Ensure that all PC cartridge units are properly seated and aligned before raising the transfer belt lift handle to its upper-most position, or damage will occur. Never force the transfer belt lift handle into its home position, or damage will occur. Button Image density sensor assembly removal “Printer front door assembly removal”...
  • Page 321 5057-XXX Warning: Note the orientation of the harnesses to ensure they are not pinched when replacing the harness access cover (A), or damage will occur. 8. Remove the harness access cover (A) from the machine. Connectors 9. Disconnect the three connectors from the image density sensor assembly (B). 10.

  • Page 322: Cmy Toner Add Assembly Removal

    5057-XXX 12. Remove the image density sensor assembly (A). Replacement note: Requires color calibration adjustments. Replacement warning: When replacing the harness access cover, ensure that the harnesses are not pinched, or damage will occur. CMY toner add assembly removal 1. Remove the printer front door assembly. See “Printer front door assembly removal”...
  • Page 323 5057-XXX 8. Remove the appropriate CMY toner add assemblies (A). Shutter 4-47 Repair information...

  • Page 324: K Toner Add Assembly Removal

    5057-XXX K toner add assembly removal Warning: Ensure the three CMY toner add assemblies are removed before removing the K toner add assembly, or damage will occur. “Printer front door assembly removal” on page 4-3. 1. Remove the printer front door assembly. See 2.
  • Page 325 5057-XXX Warning: When removing the CMY toner add assemblies, the toner cartridges should be left installed in order to reduce toner spillage. “CMY toner add assembly removal” on page 4-46. 7. Remove the three CMY toner add assemblies. See Warning: When removing the K toner add assembly, the toner cartridge should be left installed in order to reduce toner spillage.
  • Page 326 5057-XXX Warning: Note the orientation of the four developer unit harnesses and the three erase lamp harnesses to ensure proper reinstallation or damage may occur. 14. While holding the four developer unit assemblies firmly inside the machine, gently remove the developer interlock plate assembly (A).
  • Page 327 5057-XXX Replacement note: When replacing the developer interlock plate assembly (A), install the bottom edge first and ensure that all four developer unit assemblies are properly aligned when replacing the developer interlock plate assembly (A). 4-51 Repair information...
  • Page 328 5057-XXX Replacement warning: Ensure that the erase lamp harnesses and developer unit assembly harnesses are correctly installed in the clamps, or they may become detached. Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle up and down several times before reinstalling the inner cover. Erase lamp &...

  • Page 329: Developer Unit Assembly Removal

    5057-XXX Developer unit assembly removal Note: The following procedure can be applied to the C, M, Y, and K developer unit assemblies. Warning: When removing developer unit assemblies, ensure that the area on the floor in front of the machine is protected from toner spillage.
  • Page 330 5057-XXX Warning: Ensure that the harness coupler (B) is removed from the old developer unit assembly (A) and installed on the new one. Replacement warning: Ensure that the rear area new developer unit assembly (A) is properly engaged into the machine or the magnetic rolls will not turn properly.
  • Page 331 5057-XXX detached. Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle up and down several times before reinstalling the inner cover. Erase lamp & developer unit assembly harnesses Clamps Clamp 11. Remove the printhead cleaning tool from the printer front door assembly. 4-55 Repair information...
  • Page 332 5057-XXX 12. Clean the four printhead glass windows using the printhead cleaning tool. 4-56 Printer Service Manual...

  • Page 333: Developer Carrier Removal And Replacement

    5057-XXX Developer carrier removal and replacement Note: The following procedure can be applied to the C, M, Y, and K developer carriers. Warning: Always perform the sensor (ATC sensor) setup and adjustment if required or print quality problems “Sensor (ATC) setup” on page 4-204.
  • Page 334 5057-XXX 11. Remove the top cover (A). 12. Completely remove the carrier (B) from the assembly by dumping it and using a toner vacuum or if installing a new developer unit assembly, go to next step. 4-58 Printer Service Manual...
  • Page 335 5057-XXX Replacement warning: If reusing an existing developer unit assembly, ensure that all traces of old carrier (B) are removed from the developer unit assembly, or print quality issues may occur. 4-59 Repair information...
  • Page 336 5057-XXX To install the new carrier (B): Warning: Ensure that the carrier is installed evenly and uniformly in the assembly, or spillage may occur. 1. Open the appropriate bag, and dump the appropriate carrier into the appropriate assembly. Hook Tabs Seal Hook Seal...

  • Page 337: Photoconductor (Pc) Unit Assembly Removal

    5057-XXX Photoconductor (PC) unit assembly removal Warning: Ensure that all four PC cartridges are concealed from all sources of light, or damage will occur. Note: This procedure can be applied to either the C, M, Y, or K PC unit assemblies. 1.
  • Page 338 5057-XXX 5. Pull the appropriate PC unit assembly (C) from the machine. Note: When the PC unit assembly (C) is removed, ensure that it is stored in the position as shown in the graphic below. 4-62 Printer Service Manual...

  • Page 339: Transfer Belt Lift Latch Assembly Removal

    5057-XXX Replacement warning: When replacing the PC unit assembly (C), ensure that the rail on the PC unit assembly (C) is properly inserted into the metal track or physical binding and damage will occur. In the event that the PC unit assembly (C) becomes bound, it can be removed by twisting it in a clockwise direction while pulling it from the machine.
  • Page 340 5057-XXX 9. Remove the transfer belt lift latch assembly (A). 4-64 Printer Service Manual...

  • Page 341: Transfer Belt Steering Motor Removal

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

  • Page 342: K Erase Lamp Assembly Removal

    5057-XXX 12. Gently raise the rear of the appropriate CMY erase lamp assembly (B) to detach the mounting hook from the machine. 13. Remove the appropriate CMY erase lamp assembly (B). Connector Mounting hook K erase lamp assembly removal Warning: Ensure the transfer belt assembly unit is removed, or damage will occur. 1.
  • Page 343 5057-XXX 13. Gently raise the rear of the K erase lamp assembly (B) to detach the mounting hook from the machine. 14. Remove the K erase lamp assembly (B). Connector 4-67 Repair information...

  • Page 344: Printhead Shutter Motor Assembly Removal

    5057-XXX Mounting hook Printhead shutter motor assembly removal 1. Remove the rear cover assembly. See “Rear cover assembly removal” on page 4-5. “Rear left middle cover removal” on page 4-6. 2. Remove the rear left middle cover. See 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...
  • Page 345 5057-XXX Replacement warning: When reinstalling the printhead shutter motor assembly (A), ensure that the plastic arm is inserted into the printhead shutter (B). Connectors 4-69 Repair information...

  • Page 346: Switch (Printer Front Door Interlock) Removal

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

  • Page 347: Sensor (Printer Left Lower Door Interlock) Removal

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

  • Page 348: Controller Box Assembly Removal

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

  • Page 349: Switch (Main Power) Removal

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

  • Page 350: Bridge Card Assembly Removal

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

  • Page 351: Rip Card Assembly Removal

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

  • Page 352: Hard Drive Removal

    5057-XXX 3. Remove the RIP card assembly (A) from the machine. 4. Remove the riser card assembly. See “Interconnect card assembly removal” on page 4-77. Replacement warning: When replacing the RIP card assembly, ensure the interconnect card assembly is removed from the defective RIP card assembly and installed on the replacement rip card assembly or the machine will not function.

  • Page 353: Interconnect Card Assembly Removal

    5057-XXX Interconnect card assembly removal Warning: In the event of replacement of any one of the following components: • RIP card assembly • Interconnect card assembly Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
  • Page 354 5057-XXX 12. Remove the upper printer engine card bracket assembly (A). Connector Replacement warning: Ensure that the upper printer engine card (B) assembly and the lower printer engine card assembly (C) are connected. 4-78 Printer Service Manual...

  • Page 355: Upper Printer Engine Card Assembly Removal

    5057-XXX Upper printer engine card assembly removal Warning: When reinstalling the upper printer engine card assembly, ensure that the NVM board from the defective upper printer engine card assembly is installed on the replacement upper printer engine card assembly, or the machine will not function. “Rear cover assembly removal”...
  • Page 356 5057-XXX Bottom view Replacement warning: When reinstalling the upper printer engine card assembly (B), ensure that the NVM board (D) is installed on the new upper printer engine card assembly (B), or the machine may not function properly. Replacement warning: Ensure that the bridge card assembly (C) and the lower printer engine card (D) are connected.

  • Page 357: Lower Printer Engine Card Bracket Assembly Removal

    5057-XXX Lower printer engine card bracket assembly removal “Rear upper cooling fan bracket assembly 1. Remove the rear upper cooling fan bracket assembly. See removal” on page 4-102. 2. Remove the developer / transfer roll HVPS card assembly. See “Developer / transfer roll HVPS card assembly removal”...

  • Page 358: Lower Printer Engine Card Assembly Removal

    5057-XXX Lower printer engine card assembly removal “Rear upper cooling fan bracket assembly removal” 1. Remove the rear upper cooling fan bracket assembly. See on page 4-102. 2. Remove the developer / transfer roll HVPS card assembly. See “Developer / transfer roll HVPS card assembly removal”...

  • Page 359: Transfer Belt Drive Motor Cooling Fan Removal

    5057-XXX Transfer belt drive motor cooling fan removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.

  • Page 360: Transfer Belt Drive Motor Assembly Removal

    5057-XXX Transfer belt drive motor assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.
  • Page 361 5057-XXX 7. Remove the switch (transfer belt access door interlock) (A). Connector 4-85 Repair information...

  • Page 362: Laser Diode Power Card Assembly Removal

    5057-XXX Laser diode power card assembly removal “Rear upper cooling fan bracket assembly removal” 1. Remove the rear upper cooling fan bracket assembly. See on page 4-102. 2. Remove the developer / transfer roll HVPS card assembly. See “Developer / transfer roll HVPS card assembly removal”...

  • Page 363: V Lvps Card Bracket Assembly Removal

    5057-XXX 24V LVPS card bracket assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.

  • Page 364: V Lvps Card Assembly Removal

    5057-XXX 24V LVPS card assembly removal 1. Disconnect the three connectors from the 24V LVPS card assembly (A). 2. Remove the three screws securing the 24V LVPS card assembly (A). 3. Remove the 24V LVPS card assembly (A). 5V LVPS card bracket assembly removal “Rear upper cooling fan bracket assembly removal”...

  • Page 365: V Lvps Cooling Fan Removal

    5057-XXX 5V LVPS card assembly removal “Rear upper cooling fan bracket assembly 1. Remove the rear upper cooling fan bracket assembly. See removal” on page 4-102. 2. Remove the developer / transfer roll HVPS card assembly. See “Developer / transfer roll HVPS card assembly removal”...

  • Page 366: Rear Lower Cooling Fan Assembly

    5057-XXX 7. Remove the 24V LVPS cooling fan (A). Connector Replacement warning: When replacing the 24V LVPS cooling fan (A), ensure that the label is facing up. Rear lower cooling fan assembly 1. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal”...

  • Page 367: Cmyk Pc Cartridge Drive Motor Assembly Removal

    5057-XXX CMY developer drive motor assembly “Rear upper cooling fan bracket assembly 1. Remove the rear upper cooling fan bracket assembly. See removal” on page 4-102. 2. Remove the developer / transfer roll HVPS card assembly. See “Developer / transfer roll HVPS card assembly removal”...

  • Page 368: Fuser Cooling Fan Removal

    5057-XXX “5V LVPS card bracket assembly removal” on page 4-88. 5. Remove the 5V LVPS card bracket assembly. See “Transfer belt drive motor cooling fan removal” on 6. Remove the transfer belt drive motor cooling fan. See page 4-83. 7. Remove the transfer belt drive motor assembly. See “Transfer belt drive motor assembly removal”...

  • Page 369: Main Power Switch Actuator Removal

    5057-XXX 5. Remove the fuser cooling fan. Connector Main power switch actuator removal 1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-4. 2. Remove the screw securing the main power switch actuator (A) to the machine. 3.

  • Page 370: Cmyk Toner Add Motor Assembly Removal

    5057-XXX CMYK toner add motor assembly removal “Top cover assembly removal” on page 4-4. 1. Remove the top cover assembly. See 2. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-3. 3. Remove the front left cover. See “Front left cover removal”...

  • Page 371: Printhead Assembly Removal

    5057-XXX CMYK transfer HVPS card assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.
  • Page 372 5057-XXX 9. Gently pull the printhead assembly (A) from the machine. Replacement warning: When replacing the printhead assembly, perform the color registration (RegCon) setup “Color registration (RegCon)” on page 4-208. and adjustment. See 4-96 Printer Service Manual...

  • Page 373: Transfer Belt Waste Toner Auger Assembly Removal

    5057-XXX Transfer belt waste toner auger assembly removal “Transfer belt unit assembly removal” on page 4-16. 1. Remove the transfer belt unit assembly. See 2. Remove the two screws securing the transfer belt waste toner auger assembly (A). 3. Detach the bushing (B) from the transfer belt waste toner auger assembly (A). 4.
  • Page 374 5057-XXX 16. Gently remove the K developer transport drive motor assembly (A). Connector Frame clamp Connector Clamp Clamps Connectors Clamps 4-98 Printer Service Manual...
  • Page 375 5057-XXX Connector 4-99 Repair information...

  • Page 376: K Developer Clutch Removal

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

  • Page 377: Noise Filter Assembly Removal

    5057-XXX 8. Disconnect the six connectors from the AC drive card bracket assembly (A). 9. Remove the five large connectors from the AC drive card bracket assembly (A). 10. Remove the three screws securing the AC drive card bracket assembly (A) to the machine. 11.

  • Page 378: Rear Upper Cooling Fan Bracket Assembly Removal

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

  • Page 379: Rear Upper Cooling Fan Removal

    5057-XXX Rear upper cooling fan removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102. 3.

  • Page 380: Developer / Transfer Roll Hvps Card Assembly Removal

    5057-XXX Developer / transfer roll HVPS card assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.

  • Page 381: Charge Roll Hvps Card Assembly Removal

    5057-XXX Charge roll HVPS card assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.

  • Page 382: Mpf / Transport Drive Motor Assembly Removal

    5057-XXX MPF / transport drive motor assembly removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear upper cooling fan bracket assembly. See “Rear upper cooling fan bracket assembly removal” on page 4-102.

  • Page 383: Feed Roll Removal

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

  • Page 384: Pick Roll Removal

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

  • Page 385: Separation Roll Removal

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

  • Page 386: Sensor (Rfid Toner Cartridge) Removal

    5057-XXX Sensor (RFID toner cartridge) removal Note: This removal applies to the sensor (RFID K toner cartridge), (RFID C toner cartridge), (RFID M toner cartridge) and (RFID Y toner cartridge). “Top cover assembly removal” on page 4-4. 1. Remove the top cover assembly. See 2.

  • Page 387: Mpf Media Out Actuator Removal

    5057-XXX Fuser exit roll assembly removal 1. Open the printer left door assembly. 2. Remove the E-clip securing the fuser exit roll assembly (A) to the machine. 3. Remove the bushings (B). 4. Remove the fuser exit roll assembly (A). E-clip MPF media out actuator removal 1.

  • Page 388: Mpf Pick Roll Assembly Removal

    5057-XXX Sensor (MPF media out) removal “Rear cover assembly removal” on page 4-5. 1. Remove the rear cover assembly. See 2. Remove the rear left middle cover. See “Rear left middle cover removal” on page 4-6. 3. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal”...
  • Page 389 5057-XXX Replacement note: When replacing the MPF feed roll assemblies (C), do not touch the rubber surface. Replacement note: When replacing the MPF feed roll assemblies (C), ensure that the directional arrow is properly aligned. 4-113 Repair information...

  • Page 390: Media Feed Lift Motor Removal

    5057-XXX Media feed lift motor removal “Printer left lower door assembly removal” on page 4-8. 8. Remove the printer left lower door assembly. See 1. Remove the media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-21.

  • Page 391: Switch (Media Size) Removal

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

  • Page 392: Sheet Dual Input (Ttm) Removals

    5057-XXX 2000-sheet dual input (TTM) removals 2000-sheet dual input (TTM)—top cover removal 1. Pull out tray 2 assembly. 2. Remove the two screws securing the top cover (A). 3. Remove the top cover (A). 2000-sheet dual input (TTM)—foot cover removal 1.
  • Page 393 5057-XXX 4. Remove the foot cover (A). Front 2000-sheet dual input (TTM)—right cover removal 1. Remove the four screws securing the right cover (A). 2. Remove the right cover (A) by lifting up and out. 2000-sheet dual input (TTM)— tray module left cover removal 1.
  • Page 394 5057-XXX 2. Remove the tray module left cover (A). 2000-sheet dual input (TTM)—rear cover removal 1. Remove the four screws securing the rear cover (A). 2. Remove the rear cover (A). 2000-sheet dual input (TTM)—caster removal 1. Remove the media tray 2. 2.
  • Page 395 5057-XXX 7. Remove the caster (A). 2000-sheet dual input (TTM)—tray support roll removal 1. Remove the tray module left cover. See “2000-sheet dual input (TTM)– tray module left cover removal” on page 4-117. “2000-sheet dual input (TTM)–TTM media tray 3 assembly removal” on 2.
  • Page 396 5057-XXX 8. Remove the shafts (D). 9. Remove the tray support rolls (B). 4-120 Printer Service Manual...
  • Page 397 5057-XXX 2000-sheet dual input (TTM)—TTM media tray 4 assembly removal 1. Pull out the TTM media tray 4 assembly. 2. Remove the two screws securing the TTM tray 4 media transport assembly (A) to the TTM media tray 4 assembly (B).
  • Page 398 5057-XXX 2000-sheet dual input (TTM)—TTM media tray 3 assembly removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Open the TTM left door assembly. 3. Loosen the screw securing the TTM tray 3 stopper (A). 4.
  • Page 399 5057-XXX 2000-sheet dual input (TTM)—tray 3 rear cable assembly removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Remove the tray module left cover. See “2000-sheet dual input (TTM)– tray module left cover removal” on page 4-117.
  • Page 400 5057-XXX 8. Move the rear lift cable pulley (D) toward the rear of the tray to release the two tray 3 rear cables (E) from the tray lift shaft assembly (B). Rear 9. Remove the two tray 3 rear cables (E) from the tray lift shaft assembly (B). 10.
  • Page 401 5057-XXX 2000-sheet dual input (TTM)—tray 3 front cable assembly removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Remove the tray module left cover. See “2000-sheet dual input (TTM)– tray module left cover removal” on page 4-117.
  • Page 402 5057-XXX 2000-sheet dual input (TTM)—media tray 4 front cover removal 1. Pull out the media tray 4 assembly. 2. Remove the four screws securing the tray 4 front cover (A). 3. Remove the tray 4 front cover (A). 4. Remove the six screws securing the bracket (B) to the tray. 5.
  • Page 403 5057-XXX 5. Gently move the tray lift shaft assembly (B) toward the rear of the tray and detach the rear bushing (C) from the frame. Note: Do not remove the front lift cable pulley (A), or the front lift cables will become detached. 6.
  • Page 404 5057-XXX 12. Remove the tray 4 rear cables (D) from the bottom plate (H). Replacement note: Before re-installing: — It is recommended that all four cables be replaced. — Ensure tray 4 rear cables (D) are not twisted or kinked. —...
  • Page 405 5057-XXX 2000-sheet dual input (TTM)—tray 4 front cables removal “2000-sheet dual input (TTM)–TTM media tray 4 assembly 1. Remove the media tray 4 assembly. See removal” on page 4-121. 2. Remove the tray 4 front cover. See “2000-sheet dual input (TTM)–media tray 4 front cover removal” on page 4-126.
  • Page 406 5057-XXX 10. Remove the tray 4 front cables (C) from the bottom plates (F). Replacement note: Before re-installing: — It is recommended that all four cables be replaced. — Ensure tray 4 front cables (C) are not twisted or kinked. —...
  • Page 407 5057-XXX 7. Remove the two screws securing the media feed unit assembly (A). Connectors Front 8. Remove one screw securing the front bracket (B) to the machine. 9. Remove the front bracket (B). 10. Move the media feed unit assembly (A) to the left and up in the direction of the arrow. 11.
  • Page 408 5057-XXX 2000-sheet dual input (TTM)—sensor (tray 4 feed-out) removal 1. Remove the media tray 2 assembly. 2. Remove the tray module left cover. See “2000-sheet dual input (TTM)– tray module left cover removal” on page 4-117. 3. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)–TTM media tray 3 assembly removal”...

  • Page 409: Sheet Dual Input (Ttm) Switch (Media Size) Removal

    5057-XXX 2000-sheet dual input (TTM) switch (media size) removal Note: This procedure can be applied to tray 1 or tray 2 switch (media size). 1. Remove media Tray 1 and media Tray 2. 2. Remove one screw securing the switch (media size) (A) to the bracket inside the machine. 3.
  • Page 410 5057-XXX 2000-sheet dual input (TTM)—switch (TTM media size) removal Note: This removal procedure may be applied to media tray 3 and media tray 4. “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117.

  • Page 411: Sheet Dual Input (Ttm)–Media Feed Unit Assembly 2 Removal

    5057-XXX 2000-sheet dual input (TTM)–media feed unit assembly 2 removal 1. Remove the media tray 2. 2. Open the TTM left door assembly. 3. Disconnect the connector from the media feed unit assembly (A). 4. Release the harness from the clamp. 5.
  • Page 412 5057-XXX 4-136 Printer Service Manual...
  • Page 413 5057-XXX 2000-sheet dual input (TTM)—sensor (tray 3 feed-out) removal 1. Open the TTM left door assembly. 2. Remove the two screws securing the two support straps (A) to the machine. 3. Disconnect the connector to the bracket (B). 4. Remove the two screws securing the bracket (B) to the machine. 5.
  • Page 414 5057-XXX 2000-sheet dual input (TTM)—sensor (tray 2 feed-out) removal 1. Open the TTM left door assembly. 2. Remove the two screws securing bracket (A) to the machine. 3. Remove the bracket (A). 4. Disconnect the connector from the sensor (tray 2 feed-out) (B). 5.
  • Page 415 5057-XXX 8. Remove the media feed lift motor (B). Connector Rear 4-139 Repair information...
  • Page 416 5057-XXX 2000-sheet dual input (TTM)—one-way clutch / gear assembly removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)–TTM media tray 3 assembly removal” on page 4-122.
  • Page 417 5057-XXX 10. Remove the tray lift one-way gear 24 tooth (C). Harness Washer Rear Replacement note: Before re-installing, ensure all gears and washers are securely attached to the bracket (A). 4-141 Repair information...
  • Page 418 5057-XXX 2000-sheet dual input (TTM)—media out actuator removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)–TTM media tray 3 assembly removal” on page 4-122.
  • Page 419 5057-XXX 2000-sheet dual input (TTM)—sensor (media level) removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)–TTM media tray 3 assembly removal”...
  • Page 420 5057-XXX 2000-sheet dual input (TTM)—sensor (media out) removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Remove the media tray 3 assembly. See “2000-sheet dual input (TTM)–TTM media tray 3 assembly removal” on page 4-122.
  • Page 421 5057-XXX 2000-sheet dual input (TTM)—feed roll removal 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.
  • Page 422 5057-XXX 2000-sheet dual input (TTM)—feed roll one-way clutch removal 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)–feed roll removal” on page 4-145. 3. Remove the feed roll one-way clutch (A) from the shaft (B). 4-146 Printer Service Manual...
  • Page 423 5057-XXX 2000-sheet dual input (TTM)—one-way 22 tooth removal 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)–feed roll removal” on page 4-145. 3. Remove the feed roll one-way clutch. See “2000-sheet dual input (TTM)–feed roll one-way clutch removal” on page 4-146.
  • Page 424 5057-XXX 2000-sheet dual input (TTM)—separation roll one-way friction clutch removal 1. Remove the media tray assembly. 2. Remove the separation roll. See “2000-sheet dual input (TTM)–separation roll removal” on page 4-149. 3. Remove the separation roll spacer (A). 4. Remove the separation roll one-way friction clutch (B). 4-148 Printer Service Manual...
  • Page 425 5057-XXX 2000-sheet dual input (TTM)—separation roll removal 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). 4-149 Repair information...
  • Page 426 5057-XXX 4. Remove the separation roll (B). Note: Do not touch the rubber surface of the feed roll (B). Replacement note: Before re-installing, do not touch the rubber surface of the separation roll (B). 4-150 Printer Service Manual...
  • Page 427 5057-XXX 2000-sheet dual input (TTM)—pick roll removal 1. Remove the media tray assembly. 2. Move the front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4.
  • Page 428 5057-XXX 2000-sheet dual input (TTM)—left door assembly removal “2000-sheet dual input (TTM)– tray module left cover removal” on 1. Remove the tray module left cover. See page 4-117. 2. Open the TTM left door assembly. 3. Remove the two screws securing the two support straps (A) to the machine. 4.
  • Page 429 5057-XXX 2000-sheet dual input (TTM)—switch (TTM left door interlock) removal 1. Open the TTM left door assembly. 2. Remove the screw securing the support strap (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.
  • Page 430 5057-XXX 2000-sheet dual input (TTM)—tray 3 lift gear assembly removal “2000-sheet dual input (TTM)–rear cover removal” on page 4-118. 1. Remove the rear cover. See 2. Pull the tray 3 media assembly out of the machine. 3. Remove the two screws securing the tray 3 lift gear assembly (A) to the machine. Note: When removing the tray 3 lift gear assembly (A), the tray lift coupling assembly (B) my become detached.
  • Page 431 5057-XXX 2000-sheet dual input (TTM)—tray lift coupling assembly removal Note: This procedure can be applied to both the tray 3 and the tray 4 media assemblies. “2000-sheet dual input (TTM)–tray 3 lift gear 1. Remove the tray 3 lift gear or the tray 3 lift gear assembly. See assembly removal”...
  • Page 432 5057-XXX 4. Remove the tray module drive motor (A). Connector 4-156 Printer Service Manual...
  • Page 433 5057-XXX 2000-sheet dual input (TTM)—TTM tray 4 transport motor removal “2000-sheet dual input (TTM)–rear cover removal” on page 4-118. 1. Remove the rear cover. See 2. Disconnect the connector from the TTM tray 4 transport motor (A). 3. Release the harness from the clamp. 4.
  • Page 434 5057-XXX 3X 500-sheet drawer (3TM) removals 3X 500-sheet drawer (3TM) —top cover removal 1. Pull out tray 2 assembly (A). 2. Remove the two screws securing the top cover (B). 3. Remove the top cover (B). 4-158 Printer Service Manual...

  • Page 435: Right Cover Removal

    5057-XXX 3X 500-sheet drawer (3TM) —foot cover removal 1. Remove the media tray 4 assembly. 2. Remove the two screws securing the foot cover (A) to the machine. 3. Remove the foot cover (A). Front 3X 500-sheet drawer (3TM) —right cover removal 1.
  • Page 436 5057-XXX 3X 500-sheet drawer (3TM) —tray module left cover removal 1. Remove the four screws securing the tray module left cover (A). 2. Remove the tray module left cover (A). 3X 500-sheet drawer (3TM) —rear cover removal 1. Remove the four screws securing the rear cover (A). 2.
  • Page 437 5057-XXX 3X 500-sheet drawer (3TM) —caster removal 1. Remove the media tray 2 assembly. 2. Remove the media tray 3 assembly. 3. Remove the media tray 4 assembly. 4. Place the right side of the drawer down. 5. Remove the three screws securing the caster (A). 6.
  • Page 438 5057-XXX 3X 500-sheet drawer (3TM)—sensor (tray 4 feed-out) removal 1. Open the 3TM left door assembly. 2. Remove the two screws securing the two support straps (A) to the machine. 3. Disconnect the connector from the sensor (tray 4 feed-out) (B). 4.
  • Page 439 5057-XXX 3X 500-sheet drawer (3TM)—sensor (tray 2 feed-out) removal 1. Open the 3TM left door assembly. 2. Remove the two screws securing bracket (A) to the machine. 3. Remove the bracket (A). 4. Disconnect the connector from the sensor (tray 2 feed-out) (B). 5.
  • Page 440 5057-XXX 3X 500-sheet drawer (3TM)—switch (media size) removal Note: This removal procedure may be applied to media tray 2, 3 and media tray 4 assemblies. 1. Remove the media tray 2 assembly. 2. Remove the media tray 3 assembly. 3. Remove the media tray 4 assembly. 4.
  • Page 441 5057-XXX 3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 3) 1. Remove the media tray 4 assembly. 2. Open the 3TM left door assembly. 3. Remove the two screws securing the two support straps (A) to the machine. 4. Release the harness from the clamp. 5.
  • Page 442 5057-XXX 4-166 Printer Service Manual...
  • Page 443 5057-XXX 3X 500-sheet drawer (3TM)—media feed unit assembly removal (tray 2) 1. Remove the media tray 2 assembly. 2. Open the 3TM left door assembly. 3. Remove the two screws securing the two support straps (A) to the machine. 4. Release the harness from the clamp. 5.
  • Page 444 5057-XXX 3X 500-sheet drawer (3TM)—sensor (tray 3 feed-out) removal 1. Open the 3TM left door assembly. 2. Remove the two screws securing the two support straps (A) to the machine. 3. Disconnect the connector from the sensor (tray 3 feed-out) (B). 4.
  • Page 445 5057-XXX 7. Remove the sensor (tray 3 feed-out) (B). 3X 500-sheet drawer (3TM)—media feed lift motor removal 1. Remove the media feed unit assembly. See“3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 2)” on page 4-167, “3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 3)” on page 4-165, or “3X 500-sheet drawer (3TM)–media out actuator removal”...
  • Page 446 5057-XXX 3X 500-sheet drawer (3TM)—one-way clutch / gear assembly removal See“3X 500-sheet drawer (3TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. (tray 2)” on page 4-167 “3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 3)” on page 4-165.
  • Page 447 5057-XXX 3X 500-sheet drawer (3TM)—media out actuator removal See“3X 500-sheet drawer (3TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. (tray 2)” on page 4-167 “3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 3)” on page 4-165.
  • Page 448 5057-XXX 3X 500-sheet drawer (3TM)—sensor (media level) removal See“3X 500-sheet drawer (3TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. (tray 2)” on page 4-167 “3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 3)” on page 4-165.
  • Page 449 5057-XXX 3X 500-sheet drawer (3TM)—sensor (media out) removal See“3X 500-sheet drawer (3TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. (tray 2)” on page 4-167 “3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 3)” on page 4-165.
  • Page 450 5057-XXX 3X 500-sheet drawer (3TM)—feed roll removal 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.
  • Page 451 5057-XXX 3X 500-sheet drawer (3TM)—feed roll one-way clutch removal 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)–feed roll removal” on page 4-145. 3. Remove the feed roll one-way clutch (A) from the shaft (B). Front 4-175 Repair information...
  • Page 452 5057-XXX 3X 500-sheet drawer (3TM)—one-way 22 tooth removal 1. Remove the media tray assembly. 2. Remove the feed roll. See “2000-sheet dual input (TTM)–feed roll removal” on page 4-145. 3. Remove the feed roll one-way clutch. See “2000-sheet dual input (TTM)–feed roll one-way clutch removal” on page 4-146.
  • Page 453 5057-XXX 3X 500-sheet drawer (3TM)—separation roll one-way friction clutch removal 1. Remove the media tray assembly. 2. Remove the separation roll. See “2000-sheet dual input (TTM)–separation roll removal” on page 4-149. 3. Remove the separation roll spacer (A). 4. Remove the separation roll one-way friction clutch (B). Front 4-177 Repair information...
  • Page 454 5057-XXX 3X 500-sheet drawer (3TM)—separation roll removal 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). Front 4-178 Printer Service Manual...
  • Page 455 5057-XXX 4. Remove the separation roll (B). Note: Do not touch the rubber surface of the feed roll (B). Front Replacement note: Before re-installing, do not touch the rubber surface of the separation roll (B). 4-179 Repair information...
  • Page 456 5057-XXX 3X 500-sheet drawer (3TM)—pick roll removal 1. Remove the media tray assembly. 2. Move the front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4.
  • Page 457 5057-XXX 3X 500-sheet drawer (3TM)—3TM left door assembly removal 1. Open the 3TM left door assembly. 2. Remove the two screws securing the two supports straps (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.
  • Page 458 5057-XXX 7. Remove the switch (tray module left door interlock) (C). 3X 500-sheet drawer (3TM)—tray module drive motor assembly removal 1. Remove the rear cover. See “3X 500-sheet drawer (3TM)–rear cover removal” on page 4-160. 2. Disconnect the connector from the tray module drive motor (A). 3.
  • Page 459 5057-XXX 3X 500-sheet drawer (3TM)—3TM controller card assembly removal “3X 500-sheet drawer (3TM)–rear cover removal” on page 4-160. 1. Remove the rear cover. See 2. Disconnect the nine connectors from the 3TM controller card assembly (A). 3. Remove the four screws securing the 3TM controller card assembly (A) to the machine. 4.
  • Page 460 5057-XXX 1X 500-sheet drawer (1TM) removals 1X 500-sheet drawer (1TM) —top cover removal 1. Pull out tray 2 assembly (A). 2. Remove the two screws securing the top cover (B). 3. Remove the top cover (B). 4-184 Printer Service Manual...
  • Page 461 5057-XXX 1X 500-sheet drawer (1TM) —foot cover removal 1. Open the 1TM front door. 2. Remove the two screws securing the foot cover (A) to the machine. 3. Remove the foot cover (A). 1X 500-sheet drawer (1TM) —right cover removal 1.
  • Page 462 5057-XXX 1X 500-sheet drawer (1TM) —tray module left cover removal 1. Remove the four screws securing the tray module left cover (A). 2. Remove the tray module left cover (A). 1X 500-sheet drawer (1TM) —rear cover removal 1. Remove the four screws securing the rear cover (A). 2.
  • Page 463 5057-XXX 1X 500-sheet drawer (1TM) —caster removal 1. Remove the media tray 2 assembly. 2. Place the right side of the drawer down. 3. Remove the three screws securing the caster (A). 4. Remove the caster (A). 1X 500-sheet drawer (1TM)—media feed unit assembly removal (tray 2) 1.
  • Page 464 5057-XXX 1X 500-sheet drawer (1TM)—sensor (tray 2 feed-out) removal 1. Open the 1TM left door assembly. 2. Remove the two screws securing bracket (A) to the machine. 3. Remove the bracket (A). 4. Disconnect the connector from the sensor (tray 2 feed-out) (B). 5.
  • Page 465 5057-XXX 1X 500-sheet drawer (1TM)—switch (media size) removal 1. Remove the media tray 2 assembly. 2. Open the 1TM front door. 3. Disconnect the connector from the switch (media size) (A). 4. Remove the screw securing the switch (media size) (A). 5.
  • Page 466 5057-XXX 1X 500-sheet drawer (1TM)—media feed lift motor removal “1X 500-sheet drawer (1TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. See (tray 2)” on page 4-187. 2. Disconnect the harness from the media feed lift motor (A). 3.
  • Page 467 5057-XXX 6. Remove the tray lift one-way gear 24 tooth (C). Harness Washer Rear Replacement note: Before re-installing, ensure all gears and washers are securely attached to the bracket (A). 4-191 Repair information...
  • Page 468 5057-XXX 1X 500-sheet drawer (1TM)—media out actuator removal “1X 500-sheet drawer (1TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. See (tray 2)” on page 4-187. 2. Release the two bosses on the media out actuator (A) from the media feed unit assembly. 3.
  • Page 469 5057-XXX 1X 500-sheet drawer (1TM)—sensor (media level) removal “1X 500-sheet drawer (1TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. See (tray 2)” on page 4-187. 2. Disconnect the connector from the sensor (media level) (A). 3. Release the hooks securing the sensor (media level) (A) to the media feed unit assembly. 4.
  • Page 470 5057-XXX 1X 500-sheet drawer (1TM)—sensor (media out) removal “1X 500-sheet drawer (1TM)–media feed unit assembly removal 1. Remove the media feed unit assembly. See (tray 2)” on page 4-187. 2. Remove the media out actuator. See “1X 500-sheet drawer (1TM)–media out actuator removal” on page 4-192.
  • Page 471 5057-XXX 1X 500-sheet drawer (1TM)—feed roll removal 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the feed roll (B) to the shaft (C). 4.
  • Page 472 5057-XXX 1X 500-sheet drawer (1TM)—feed roll one-way clutch removal 1. Remove the media tray assembly. 2. Remove the feed roll. See “1X 500-sheet drawer (1TM)–feed roll removal” on page 4-195. 3. Remove the feed roll one-way clutch (A) from the shaft (B). 4-196 Printer Service Manual...
  • Page 473 5057-XXX 1X 500-sheet drawer (1TM)—one-way 22 tooth removal 1. Remove the media tray assembly. 2. Remove the feed roll. See “1X 500-sheet drawer (1TM)–feed roll removal” on page 4-195. 3. Remove the feed roll one-way clutch. See “1X 500-sheet drawer (1TM)–feed roll one-way clutch removal” on page 4-196.
  • Page 474 5057-XXX 1X 500-sheet drawer (1TM)—separation roll one-way friction clutch removal 1. Remove the media tray assembly. 2. Remove the separation roll. See “1X 500-sheet drawer (1TM)–separation roll removal” on page 4-199. 3. Remove the separation roll spacer (A). 4. Remove the separation roll one-way friction clutch (B). Seal 4-198 Printer Service Manual...
  • Page 475 5057-XXX 1X 500-sheet drawer (1TM)—separation roll removal 1. Remove the media tray assembly. 2. Move the feed unit front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the separation roll (B) to the shaft (C). 4.
  • Page 476 5057-XXX 1X 500-sheet drawer (1TM)—pick roll removal 1. Remove the media tray assembly. 2. Move the front guide (A) toward the front in the direction of the arrow. 3. Release the hook securing the pick roll (B) to the shaft (C). 4.
  • Page 477 5057-XXX 1X 500-sheet drawer (1TM)—tray module left door assembly removal 1. Open the 3TM/TMM left door assembly. 2. Remove the two screws securing the two supports straps (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.
  • Page 478 5057-XXX 1X 500-sheet drawer (1TM)—switch (tray module left door interlock) removal 1. Open the 1TM left door assembly. 2. Remove the screw securing the support strap (A) to the machine. 3. Remove the screw securing the bracket (B) to the machine. 4.
  • Page 479 5057-XXX 1X 500-sheet drawer (1TM)—tray module drive motor assembly removal “1X 500-sheet drawer (1TM)–rear cover removal” on page 4-186. 1. Remove the rear cover. See 2. Disconnect the connector from the tray module drive motor (A). 3. Remove the two screws securing the tray module drive motor (A) to the machine. 4.

  • Page 480: Setup And Adjustments

    5057-XXX Setup and adjustments Sensor (ATC) setup Step Check Warning: Before installing any new developer unit assembles in the machine, record the bar code number located on the sensor (ATC) for all new developer units being installed. Example: Sensor (C ATC) XXX Sensor (M) ATC XXX Sensor (Y) ATC XXX Sensor (K) ATC XXX...
  • Page 481 5057-XXX Step Check Update the following settings using the newly converted values from step 2 for all newly installed developer units: Sensitivity gradient Sensor output reference 1. Enter the Diagnostics Menu. 2. Touch ENGINE ADJUST. 3. Touch ATC Sensor Adjust Values 4.
  • Page 482 5057-XXX ATC VALUE CONVERSION CHART Bar code number Sensitivity gradient default value Standard TC output default value (last 2 digits) 4-206 Printer Service Manual...
  • Page 483 5057-XXX ATC VALUE CONVERSION CHART Bar code number Sensitivity gradient default value Standard TC output default value (last 2 digits) 4-207 Repair information...
  • Page 484 5057-XXX ATC VALUE CONVERSION CHART Bar code number Sensitivity gradient default value Standard TC output default value (last 2 digits) Color registration (RegCon) 4-208 Printer Service Manual...

  • Page 485: Measurement Cycle Test

    5057-XXX Measurement cycle test Step Check Perform the Measurement cycle test. Perform the Go to step 2. “Control sensor 1. Enter the Diagnostics Menu. check”. 2. Select ENGINE ADJUST. “Control 3. Select RegCon adjust sensor check” on 4. Select Measurement cycle page 4-210.

  • Page 486: Control Sensor Check

    5057-XXX Control sensor check Step Check Perform the Control sensor check test. Perform the Go to step 2. “Control sensor 1. Enter the Diagnostics Menu. cycle”. 2. Select ENGINE ADJUST. “Control 3. Select RegCon adjust sensor cycle” on 4. Select Control Sensor Check page 4-210.

  • Page 487: Skew Fine Setup

    5057-XXX Belt edge learn test Step Check Perform the Belt edge learn test. Perform “Skew Go to step 2. setup”. 1. Enter the Diagnostics Menu. “Skew fine 2. Select ENGINE ADJUST. setup” on 3. Select RegCon adjust page 4-211. 4. Select Belt edge learn Does the above test pass? Replace the transfer belt unit assembly.
  • Page 488 5057-XXX Step Check Perform the Skew fine setup printhead adjustment. Perform the In/Out Adjust the setup. printhead Select Cycle result values. adjustment screws “In/out then perform the setup” on In/Out setup. page 4-216. Locate the following new values for the following settings: “In/out Y- Skew adjustment setup”...
  • Page 489 5057-XXX Step Check Analyze the fine skew setup. Go to step 4. Go to step 6. 1. Enter the Diagnostics Menu. 2. Select ENGINE ADJUST. 3. Select RegCon adjust 4. Select Control setup cycles 5. Select Cycle result values Locate the following new values for the following settings: Patch-B in Patch-B out Is the value for both of the above settings a “4”?
  • Page 490 5057-XXX Step Check Perform the skew rough setup printhead adjustment. Re-perform step 1. Go to step 6. If the test fails then 1. Enter the Diagnostics Menu. replace the 2. Select ENGINE ADJUST. printhead. 3. Select RegCon adjust “Printhead 4. Select Control setup cycles assembly 5.
  • Page 491 5057-XXX Step Check Check the image density sensor assembly for toner Remove and clean Go to step 8. contamination. the image density sensor assembly. Is the above component dirty or contaminated? “Image density sensor assembly removal” on page 4-44. Re-Perform the Skew fine setup. Perform the In/Out Replace the image setup.

  • Page 492: In/Out Setup

    5057-XXX In/out setup Step Check Perform the In/out setup: Perform the Go to step 2. Center setup. 1. Enter the Diagnostics Menu. “Center 2. Select ENGINE ADJUST. setup” on 3. Select RegCon adjust page 4-220. 4. Select Control setup cycles 5.
  • Page 493 5057-XXX Step Check Perform the skew rough setup printhead adjustment. Re-perform step 1. Go to step 7. If the test fails then 1. Enter the Diagnostics Menu. replace the 2. Select ENGINE ADJUST. printhead. 3. Select RegCon adjust “Printhead 4. Select Control setup cycles assembly 5.
  • Page 494 5057-XXX Step Check Perform the In/out skew setup printhead adjustment. Go to the Center Adjust the setup. printhead 1. Enter the Diagnostics Menu. adjustment screw “Center 2. Select ENGINE ADJUST. then go to Center setup” on 3. Select RegCon adjust. setup.
  • Page 495 5057-XXX Step Check Check the image density sensor assembly for toner Remove and clean Go to step 8. contamination. the image density sensor assembly. Is the above component dirty or contaminated? “Image density sensor assembly removal” on page 4-44. Re-Perform the In/out setup. Perform the Replace the image Center setup.

  • Page 496: Center Setup

    5057-XXX Center setup Step Check Warning: Ensure that the image density sensor Go to step 2. Repeat step 1. assembly is moved to the center position or the test will not function. Move the image density sensor assembly to the center position.
  • Page 497 5057-XXX Step Check Perform the center setup: Move the image Go to step 3. density sensor 1. Enter the Diagnostics Menu. back to its original 2. Select ENGINE ADJUST. position. 3. Select RegCon adjust The color 4. Select Control setup cycles registration 5.
  • Page 498 5057-XXX 4-222 Printer Service Manual...

  • Page 499: Connector Locations

    5057-XXX 5. Connector locations Locations Waste toner agitator motor assembly Sensor (waste toner cartridge full) Switch (waste toner cartridge interlock) Connector locations...
  • Page 500 5057-XXX Image density sensor assembly Duplex unit assembly Printer left door assembly Printer Service Manual...
  • Page 501 5057-XXX Fuser unit assembly Thumb screws C toner add motor K toner add motor M toner add motor Y toner add motor Main power switch activator Switch (main power) Connector locations...
  • Page 502 5057-XXX Printhead Polygon mirror motor Printer Service Manual...
  • Page 503 5057-XXX Charge roll HVPS card assembly 24 V LVPS card assembly Developer/transfer roll HVPS card assembly Connector locations...
  • Page 504 5057-XXX AC drive card assembly Printer power Finisher power hookup connector hookup connector Upper printer engine card assembly NVM card assembly Printer Service Manual...
  • Page 505 5057-XXX Lower printer card assembly CMYK transfer roll HVPS card assembly 5V LVPS card assembly Connector locations...
  • Page 506 5057-XXX Feed/lift motor Sensor (media out) Sensor (media level) Media feed unit assembly Sensor (printer left lower door interlock) Sensor (tray 1 feed-out) Printer left lower door assembly Printer Service Manual...
  • Page 507 5057-XXX Connector locations...
  • Page 508 5057-XXX 5-10 Printer Service Manual...
  • Page 509 5057-XXX 3TM controller card assembly Tray module drive motor Feed/lift motor Sensor (media out) Sensor (media level) Switch (tray module Media feed left door interlock) unit assembly Sensor (tray 2 feed-out) Sensor (tray 3 feed-out) 3TM left door assembly Sensor (tray 4 feed-out) 5-11 Connector locations...
  • Page 510 5057-XXX TTM controller card assembly Tray module drive motor TTM tray 4 transport drive motor 5-12 Printer Service Manual...
  • Page 511 5057-XXX Switch (media size) Switch (TTM media size) 5-13 Connector locations...
  • Page 512 5057-XXX Media feed unit assembly Sensor (tray 4 feed-out) 5-14 Printer Service Manual...

  • Page 513: Preventive Maintenance

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

  • Page 514: Scheduled Maintenance

    5057-XXX EVERY EVERY EVERY LEXMARK C935 SERVICE NOTE: 100K 600K CALL DEVELOPER UNITS Transfer Developer unit (4) Replace C developer carrier Replace M developer carrier Replace Y developer carrier Replace K developer carrier Replace TRANSFER ROLL 2nd Transfer Roll assembly...
  • Page 515 5057-XXX After replacing the kit, the maintenance count must be reset to zero to clear the “80 scheduled maintenance” message. To reset the maintenance count Turn off the printer. Press and hold the 2 and 6 buttons simultaneously. Turn on the printer. Release the buttons after 10 seconds.
  • Page 516 5057-XXX Printer Service Manual...

  • Page 517: Parts Catalog

    NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. • PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. Model name Configuration Machine type Maximum speed Lexmark X940e Network 7510-030 35 PPM Lexmark X945e Network 7510-230 45 PPM...

  • Page 518: Assembly 1: Covers

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

  • Page 519: Assembly 2: Covers

    5057-XXX Assembly 2: Covers 2 Parts catalog...
  • Page 520 5057-XXX Assembly 2: Covers Asm- Part FRUs/ Units/ Description index number mach 40X3782 RIP card access cover 40X3781 Top cover assembly 40X3787 Switch (main power) 40X3786 Main power switch actuator 40X3783 Main switch cable assembly 40X3785 Inner cover 40X4111 Front left cover 40X4089 SFP operator panel assembly TBD??

  • Page 521: Assembly 3: Covers

    5057-XXX Assembly 3: Covers 3 Asm- Part FRUs/ Units/ Description index number mach 40X3796 Rear left upper cover 40X3793 Rear left middle cover 40X3795 Left front cover 40X3794 Rear left lower cover 40X3788 Rear blind cover 40X3791 Rear cover assembly 110 V 40X3792 Rear cover assembly 220 V Parts catalog...

  • Page 522: Assembly 4: Pc Cartridge And Developer Drive

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

  • Page 523: Assembly 5: Id Sensor And Transfer Belt Steering

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

  • Page 524: Assembly 6: Media Tray

    5057-XXX Assembly 6: Media tray Asm- Part FRUs/ Units/ Description index number mach 40X3677 Switch (media size) 40X3676 Media tray slide 40X3678 Media tray assembly kit • Media tray assembly • #1 label • #2 label • #3 label • #4 label •...

  • Page 525: Assembly 7: Printer Left Lower Door And Media Feed Unit

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

  • Page 526: Assembly 8: Media Feed Unit

    5057-XXX Assembly 8: Media feed unit 7-10 MFP Service Manual...
  • Page 527 5057-XXX Assembly 8: Media feed unit Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3687 Media out actuator 40X3688 Sensor (tray media out) 40X3688 Sensor (tray media level) 40X3684 Media feed lift motor 40X0888 Bushing 6 mm 40X0590 Pick roll assembly spring 40X3686...

  • Page 528: Assembly 9: Mpf Feed Unit Assembly

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

  • Page 529: Assembly 10: Mpf Feed Unit Assembly

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

  • Page 530: Assembly 11: Mpf Feed Unit Assembly

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

  • Page 531: Assembly 12: Registration / Transport Roll Assembly

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

  • Page 532: Assembly 13: Printer Left Door And Duplex

    5057-XXX Assembly 13: Printer left door and duplex Asm- Part FRUs/ Units/ Description index number mach 40X4078 Printer left door assembly (this comes assembled) 40X3697 Printer left door damper assembly 40X3696 Printer left door damper idler gear 40X3799 Duplex unit assembly (this comes assembled) 40X3798 Printer left door blind cover 7-16...

  • Page 533: Assembly 14: Printer Left Door Assembly

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

  • Page 534: Assembly 15: Printer Left Door Assembly

    5057-XXX Assembly 15: Printer left door assembly 2 Asm- Part FRUs/ Units/ Description index number mach 40X4078 Printer left door assembly (this comes assembled) 40X3704 Printer left door damper sector gear 40X3688 Sensor (2nd transfer roll retract HP) 40X3701 2nd transfer roll retract cam assembly 40X3702 2nd transfer retract motor assembly 40X3703...

  • Page 535: Assembly 16: Duplex Media Inverter Assembly

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

  • Page 536: Assembly 17: Duplex

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

  • Page 537: Assembly 18: Standard Media Exit Shift

    5057-XXX Assembly 18: Standard media exit shift Asm- Part FRUs/ Units/ Description index number mach 40X3705 Standard media exit shift assembly (this comes assembled) 40X3707 Standard bin full actuator 40X3688 Sensor (standard bin full) 40X0553 Switch (printer left door interlock) 40X3706 Standard exit top cover 40X4080...

  • Page 538: Assembly 19: Printhead Assembly

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

  • Page 539: Assembly 20: Xerographic And Waste Toner

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

  • Page 540: Assembly 21: Erase Lamps And Developer Interlock Plate

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

  • Page 541: Assembly 22: Transfer Belt Lift

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

  • Page 542: Assembly 23: Transfer Belt

    5057-XXX Assembly 23: Transfer belt Asm- Part FRUs/ Units/ Description index number mach 40X3732 Transfer belt unit assembly 40X3733 Transfer belt cleaner assembly 40X3729 Transfer belt auger front gear 14T 40X3731 Transfer belt auger assembly 40X0880 Bushing 6 mm 40X3730 Transfer belt auger rear gear 18T 7-26 MFP Service Manual...

  • Page 543: Assembly 24: Transfer Belt Lift

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

  • Page 544: Assembly 25: Toner Dispense

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

  • Page 545: Assembly 26: Developer Unit Assemblies

    5057-XXX Assembly 26: Developer unit assemblies Asm- Part FRUs/ Units/ Description index number mach 40X3742 Developer unit assembly 40X3744 Y developer carrier 40X3745 M developer carrier 40X3746 C developer carrier 40X3743 K developer carrier 7-29 Parts catalog...

  • Page 546: Assembly 27: Fuser Assembly

    5057-XXX Assembly 27: Fuser assembly Asm- Part FRUs/ Units/ Description index number mach 40X4153 Fuser assembly 100 V 40X3747 Fuser assembly 110 V 40X3748 Fuser assembly 220 V 7-30 MFP Service Manual...

  • Page 547: Assembly 28: Cooling Fans

    5057-XXX Assembly 28: Cooling fans Asm- Part FRUs/ Units/ Description index number mach 40X3750 Fuser cooling fan 40X3749 Printhead shutter motor assembly 40X3752 Rear lower cooling fan assembly (this comes assembled) 40X3751 Transfer belt drive motor cooling fan 7-31 Parts catalog...

  • Page 548: Assembly 29: Electrical

    5057-XXX Assembly 29: Electrical 1 7-32 MFP Service Manual...
  • Page 549 5057-XXX Assembly 29: Electrical 1 Asm- Part FRUs/ Units/ Description index number mach 40X3762 Laser diode power card assembly 40X3757 Lower printer engine card assembly 40X3758 24 V LVPS card assembly 40X3763 Rear upper cooling fan 40X3759 24 V LVPS cooling fan 40X3760 CMYK transfer roll HVPS card assembly 40X3755...

  • Page 550: Assembly 30: Electrical

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

  • Page 551: Assembly 31: Electrical

    5057-XXX Assembly 31: Electrical 3 7-35 Parts catalog...
  • Page 552 5057-XXX Assembly 31: Electrical 3 Asm- Part FRUs/ Units/ Description index number mach 40X3775 DC main cable assembly 40X3776 DC rear right cable assembly 40X3774 2nd transfer charge roll cable 40X3771 CK transfer roll cable assembly 40X3770 YM transfer roll cable assembly 40X3772 Transfer belt charge cable 40X3769...

  • Page 553: Assembly 32: Electrical

    5057-XXX Assembly 32: Electrical 4 7-37 Parts catalog...
  • Page 554 5057-XXX Assembly 32: Electrical 4 Asm- Part FRUs/ Units/ Description index number mach 40X3804 RIP card cooling fan cover assembly (this comes assembled) 40X3807 RIP bridge card assembly 40X2359 Interconnect card assembly 40X5864 SFP RIP card assembly (C935 model) 40X3808 Upper printer engine card chassis assembly 40X4081 Upper printer engine card cable assembly...

  • Page 555: Assembly 33: 1Tm Covers

    5057-XXX Assembly 33: 1TM covers Asm- Part FRUs/ Units/ Description index number mach 40X3825 Tray module right cover 40X3824 Tray module foot cover 40X4142 1TM front door assembly 40X3826 Tray module left cover 40X3827 Tray module rear cover 40X3823 Tray module top cover 7-39 Parts catalog...

  • Page 556: Assembly 34: 1Tm Feed Unit Assembly

    5057-XXX Assembly 34: 1TM feed unit assembly 7-40 MFP Service Manual...
  • Page 557 5057-XXX Assembly 34: 1TM feed unit assembly Asm- Part FRUs/ Units/ Description index number mach 40X3677 Switch (media size) 40X3676 Media tray slide 40X3675 Media tray catch 40X3678 Media tray assembly kit • Media tray assembly • #1 label • #2 label •...

  • Page 558: Assembly 35: 1Tm Media Feed Unit

    5057-XXX Assembly 35: 1TM media feed unit 7-42 MFP Service Manual...
  • Page 559 5057-XXX Assembly 35: 1TM media feed unit Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3687 Media out actuator 40X3688 Sensor (tray media out) 40X3688 Sensor (tray media level) 40X3684 Media feed lift motor 40X0888 Bushing 6 mm 40X0590 Pick roll assembly spring...

  • Page 560: Assembly 36: 1Tm Left Door

    5057-XXX Assembly 36: 1TM left door Asm- Part FRUs/ Units/ Description index number mach 40X3818 Tray 2 feed-out sensor cable assembly 40X3817 Sensor (tray 2 feed-out) 40X3821 Switch (tray module left door interlock) 40X4141 1TM left door assembly (this comes assembled) 40X4119 Tray module media transport roll assembly 7-44...
  • Page 561 5057-XXX Assembly 37: 1TM drive and electrical 7-45 Parts catalog...

  • Page 562: Assembly 37: 1Tm Drive And Electrical

    5057-XXX Assembly 37: 1TM drive and electrical Asm- Part FRUs/ Units/ Description index number mach 40X4152 1TM controller card assembly 40X3812 Tray module drive motor assembly 40X4068 Tray module left retaining bracket 40X4034 Tray module retainer screw 40X3815 Media transport gear 33T 40X3813 Media transport gear 23/46T 40X4117...

  • Page 563: Assembly 38: 3Tm Covers

    5057-XXX Assembly 38: 3TM covers 7-47 Parts catalog...
  • Page 564 5057-XXX Assembly 38: 3TM covers Asm- Part FRUs/ Units/ Description index number mach 40X3825 Tray module right cover 40X3824 Tray module foot cover 40X3826 Tray module left cover 40X3827 Tray module rear cover 40X3823 Tray module top cover 7-48 MFP Service Manual...

  • Page 565: Assembly 39: 3Tm Feed Unit Assembly

    5057-XXX Assembly 39: 3TM feed unit assembly 7-49 Parts catalog...
  • Page 566 5057-XXX Assembly 39: 3TM feed unit assembly Asm- Part FRUs/ Units/ Description index number mach 40X3677 Switch (media size) 40X3676 Media tray slide 40X3675 Media tray catch 40X3678 Media tray assembly kit • Media tray assembly • #1 label • #2 label •...

  • Page 567: Assembly 40: 3Tm Media Feed Unit

    5057-XXX Assembly 40: 3TM media feed unit 7-51 Parts catalog...
  • Page 568 5057-XXX Assembly 40: 3TM Media feed unit Asm- Part FRUs/ Units/ Description index number mach 40X3679 Media feed unit assembly 40X3687 Media out actuator 40X3688 Sensor (tray media out) 40X3688 Sensor (tray media level) 40X3684 Media feed lift motor 40X0888 Bushing 6 mm 40X0590 Pick roll assembly spring...

  • Page 569: Assembly 41: 3Tm Left Door

    5057-XXX Assembly 41: 3TM left door 7-53 Parts catalog...
  • Page 570 5057-XXX Assembly 41: 3TM left door Asm- Part FRUs/ Units/ Description index number mach 40X3818 Tray 2 feed-out sensor cable assembly 40X3817 Sensor (tray 2 feed-out) 40X3821 Switch (tray module left door interlock) 40X3819 Tray 3/4 feed-out sensor actuator 40X3820 Sensor (tray 3 feed-out) 40X3820 Sensor (tray 4 feed-out)
  • Page 571 5057-XXX Assembly 42: 3TM drive and electrical 7-55 Parts catalog...

  • Page 572: Assembly 42: 3Tm Drive And Electrical

    5057-XXX Assembly 42: 3TM drive and electrical Asm- Part FRUs/ Units/ Description index number mach 40X3811 3TM controller card assembly 40X3812 Tray module drive motor assembly 40X4068 Tray module left retaining bracket 40X4034 Tray module retainer screw 40X3815 Media transport gear 33T 40X3813 Media transport gear 23/46T 40X3814...

  • Page 573: Assembly 43: Ttm Covers

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

  • Page 574: Assembly 44: Ttm Media Trays

    5057-XXX Assembly 44: TTM media trays 7-58 MFP Service Manual...
  • Page 575 5057-XXX Assembly 44: TTM media trays Asm- Part FRUs/ Units/ Description index number mach 40X3678 Media tray assembly kit • Media tray assembly • #1 label • #2 label • #3 label • #4 label • Instruction label 40X3830 Switch (TTM media size) 40X3831 TTM tray support roll 40X3829...

  • Page 576: Assembly 45: Ttm Media Tray

    5057-XXX Assembly 45: TTM media tray 3 7-60 MFP Service Manual...
  • Page 577 5057-XXX Assembly 45: TTM tray 3 Asm- Part FRUs/ Units/ Description index number mach 40X0711 TTM tray separation pad 40X3832 TTM tray 3 front cover 40X4126 TTM tray lift idler pulley 40X4127 TTM tray lift idler pulley guide 40X4084 TTM tray 3 lift cable 40X0708 TTM large idler pulley kit •...

  • Page 578: Assembly 46: Ttm Media Tray

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

  • Page 579: Assembly 47: Ttm Media Tray 4 Transport

    5057-XXX Assembly 47: TTM media tray 4 transport Asm- Part FRUs/ Units/ Description index number mach 40X3838 TTM tray 4 media transport assembly 40X3679 Media feed unit assembly 40X3841 TTM tray 4 lower media guide 40X3840 TTM tray 4 upper media guide 40X3694 Sensor (tray 4 feed-out) 7-63...

  • Page 580: Assembly 48: Ttm Media Transport

    5057-XXX Assembly 48: TTM media transport Asm- Part FRUs/ Units/ Description index number mach 40X3817 Sensor (tray 2 feed-out) 40X3843 TTM vertical turn guide 40X3679 Media feed unit assembly 40X3842 Tray 3 feed-out sensor assembly (this comes assembled) 40X3818 Tray 2 feed-out sensor cable assembly 40X4119 Tray module media transport roll assembly 7-64...

  • Page 581: Assembly 49: Ttm Left Door

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

  • Page 582: Assembly 50: Ttm Tray Lift Drive

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

  • Page 583: Assembly 51: Ttm Drive And Electrical

    5057-XXX Assembly 51: TTM drive and electrical 7-67 Parts catalog...
  • Page 584 5057-XXX Assembly 51: TTM drive and electrical Asm- Part FRUs/ Units/ Description index number mach 40X3850 TTM controller card assembly 40X3849 TTM tray 4 transport drive motor assembly 40X3812 Tray module drive motor assembly 40X4068 Tray module left retaining bracket 40X3815 Media transport gear 33T 40X3813...

  • Page 585: Assembly 52: Miscellaneous

    40X4102 SFP relocation kit 40X4112 SFP relocation kit with options 56P2129 Lexmark MarkNet N7020e (4 USB ports) 1-0/100/1000 w/out power cord 56P2744 N4050e 802.11g Wireless Print Server (Americas, Argentina, & Brazil) w/out power cord 56P2745 N4050e 802.11g Wireless Print Server (European, UK/Ireland, & Australia)
  • Page 586 40X1378 Marknet N8050 802.11g wireless, US 40X1562 Marknet N8050 802.11g wireless, International 40X1593 Lexmark marknet N7000e (1 USB port) 10/100 ethernet 40X1594 Lexmark marknet N7002e (1 parallel port) 10/100 ethernet 40X1592 Lexmark marknet N7020e (4 USB ports) 10/100/1000 ethernet 40X2610 Hard drive assembly includes: •...
  • Page 587 5057-XXX Index 3-17 Numerics Display the Event Log 3-18 Print the Event Log 1-53 1TM main components FINISHER TESTS 1-49 1TM theory 3-12 Feed Tests 1-52 1TM media feed units 3-12 Hole Punch Test 1-50 media transport 3-12 Sensor Test 1-51 media tray assembly 3-11...
  • Page 588 5057-XXX 2-48 2-131 MPF) solid black 2-58 2-126 841.00 image pipeline ASIC failure troubleshooting 2-59 849.00 hard drive failure vertical blank lines (white stripes in media transport 2-59 2-132 900.XX RIP card assembly software failure direction) 2-60 2-61 901.XX RIP card assembly software error image quality troubles 2-62 2-64...
  • Page 589 5057-XXX 4-118 media transport caster 4-155 4-157 4-182 4-183 media transport path drive motor assembly 4-203 SFP sensors 4-145 4-174 4-195 media tray assembly feed roll 4-146 4-175 4-196 detection of media size feed roll one-way clutch 4-116 media feed unit assembly foot cover 4-125 media feed/lift motor...
  • Page 590 5057-XXX 1-33 TTM theory 1-39 main components 1-34 media transport 1-35 media tray assembly 1-38 TTM media feed units Printer Service Manual...
  • Page 591 Lexmark marknet N7002e (1 parallel port) 10/100 ethernet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 592 5057-XXX 7-70 40X2610 Hard drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-70 40X2767 Bar code card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 593 5057-XXX 7-23 40X3717 Sensor (waste toner cartridge full) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24 40X3718 Developer interlock plate assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 594 5057-XXX 40X3781 Top cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X3782 RIP card access cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X3783...
  • Page 595 7-38 7-69 56P2129 Lexmark MarkNet N7020e (4 USB ports) 1-0/100/1000 w/out power cord - - - - - - - - - - - - - - - - - - - - - - 7-69 56P2744 N4050e 802.11g Wireless Print Server (Americas, Argentina, & Brazil) w/out power cord - - - - - - - - - -...
  • Page 596 5057-XXX I-10 Printer Service Manual...
  • Page 598 5057 AND 7510 Tray Modules SENSOR (tray2 feed out) +5VDC 5V RTN SENSOR (tray4 feed out) 1TM ONLY +5VRTN +5VDC +5VDC 5V RTN SWITCH (TTM media 5V RTN size) #4 +5VDC P546 P546 P548 +5VDC5V RTN SWITCH (media size #2) 5V RTN SENSOR (tray3 5V RTN (SHORTING WIRE)

This manual is also suitable for:

C93 seriesC935

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