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Lexmark C734dn Service Manual

Lexmark C734dn Service Manual

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Download this manual See also: Administrator's Manual, Information Manual

Revised: June 11, 2012

™

Lexmark

C734n, C734dn,

C734dnw, C736n, C736dn, CS736dn

5026-2xx, 4xx

• 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 C734dnw, C736n, C736dn, CS736dn 5026-2xx, 4xx • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and or other countries.
Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PrintCryption is a trademark of Lexmark International, Inc.
Page 3: Table Of Contents
5026 Table of contents Previous Notices and safety information ......... . . ix Laser notice .
Page 4 5026 147.xx, 920.01—POST (power-on self test) aligner error service check ....2-50 Previous 155.xx—Cam motor error service check ..........2-51 156.xx—COD (Color On Demand) motor service check .
Page 5 5026 920.18—POST (power-on self test)—Cartridge motor 3 not connected error service check . 2-110 Previous 920.19—POST (power-on self test)—Transfer module stepper motor not connected error service check ............... . 2-111 920.21—POST (power-on self test)—24 V power supply failure error service check .
Page 6 5026 Motor Calibration ............. . . 3-29 Previous Paper Prompts .
Page 7 5026 Cooling fan filter removal ............4-75 Previous Display detent spring .
Page 8 5026 System board diagram ............5-2 Previous Preventive maintenance .
Page 9: Notices And Safety Information
5026 Notices and safety information Previous The following laser notice labels may be affixed to this printer. Next Laser notice Go Back This product 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 10: Aviso Sobre O Laser
5026 Previous Avvertenze sui prodotti laser Questo prodotto è certificato negli Stati Uniti come prodotto conforme ai requisiti DHHS 21 CFR Sottocapitolo J per i prodotti laser di Classe I (1), mentre in altri paesi è certificato come prodotto laser di Classe I conforme ai requisiti IEC 60825-1.
Page 11 5026 Previous Laserinformatie Dit product is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR paragraaf J voor laserproducten van klasse I (1). Elders is het product gecertificeerd als een laserproduct van klasse I dat voldoet aan de vereisten van IEC 60825-1. Next Laserproducten van klasse I worden geacht geen gevaar op te leveren.
Page 12 5026 Previous Laser-notis Denna produkt är certifierad i USA i enlighet med kraven i DHHS 21 CFR underkapitel J för klass I (1)- laserprodukter, och på andra platser certifierad som en klass I-laserprodukt i enlighet med kraven i IEC 60825-1. Next Klass I-laserprodukter betraktas inte som skadliga.
Page 13 5026 Previous Next Go Back Notices and safety information xiii...
Page 14 5026 Previous Next Go Back Service Manual...
Page 15: Lithium Warning
5026 Previous Lithium warning CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY Next IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Go Back Safety information The safety of this product is based on testing and approvals of the original design and specific •...
Page 16 5026 Previous Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Next Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen •...
Page 17 5026 Previous Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 18: Preface
5026 Preface Previous This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
Page 19: Navigation Buttons
5026 Previous CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Next Go Back CAUTION...
Page 20 5026 Previous Next Go Back Service Manual...
Page 21: General Information
5026 1. General information Previous The Lexmark™ C73x family of color laser printers. Next Models Go Back Machine type Printer name Description and model Lexmark C734n 5026-210 Network Lexmark C734dn 5026-230 Duplex and network Lexmark C734dnw 5026-280 Duplex, network, and wireless...
Page 22: Media Options
3750 sheets and the C736 supports up to 4300 sheets. Go Back The Lexmark C73x options are compatible with the Lexmark X73x MFP, but not with any other Lexmark printers. No other options are supported by the C73x.
Page 23: Printer Specifications
The following table contains the dimensions and weight for each of the respective printer models. This does not Next include packaging. Go Back Height Width Depth Weight Lexmark C734/C736 Basic printer (cartridges only) 450mm 435mm 400mm 25.7kg (17.7 in) (17.1 in) (15.7 in)
Page 24: Clearances
5026 Clearances Previous Next Go Back Number Description Clearance Rear 100 mm (3.9 in.) Right side 100 mm (3.9 in.) Front 400 mm (15.7 in.) Left side 150 mm (5.9. in.) Above 150 mm (5.9 in.) Memory All models Memory Standard memory—The standard RAM is soldered onto the system board.
Page 25: Expansion Opportunities
Expansion opportunities Previous Lexmark Lexmark Lexmark Lexmark C734n, C734dw C736n C736dn C734dn Next Interface card expansion slots Code Enhancement Socket Go Back (application solution firmware) Hard disk Interface (for optional hard disk) Resolution The following resolutions are available: 4800CQ (default resolution) •...
Page 26: Electrical And Power Specifications
The following table specifies nominal average power requirements for the basic printer configurations. All power levels are shown in Watts (W). Maximum current is given in Amperes (A). Lexmark Lexmark Lexmark Lexmark Printing states C734n C734dn/dw C736n C736dn Typical Electricity Consumption (TEC) Normal settings 4.61 kwh/week 4.69 kwh/week Eco Mode settings 3.83 kwh/week...
Page 27: Acoustic Specifications
1988-04-15—Accoustics Declared noise emission values of computer and business equipment. 1-Meter average Declared sound power Operating mode bystander sound level at 4800 CQ pressure at 4800 CQ Lexmark C734/C736 Mono printing (full speed) 54 dBA Color printing (full speed) 54 dBA Duplex printing (full speed) 54 dBA...
Page 28: Media Specifications
Under high humidity conditions (over 60%), envelopes may seal during printing. • Transparencies Use letter or A4-size transparencies for color laser printers only. • See Ordering Information for the recommended transparencies for the Lexmark C734/C736 laser printers. • Do not use inkjet transparencies. • Labels Labels should be selected using guidelines found in the User's Guide or the Card Stock and Label Guide, and tested for acceptability.
Page 29 5026 Using recycled paper and other office papers Previous Recycled office paper produced specifically for use in laser (electrophotographic) printers may be used in your printer. However, no blanket statement can be made that all recycled paper will feed well. Generally, the following property guidelines apply to recycled paper.
Page 30: Input And Output Capacities
4,300 options input sources (sheets) Standard output bin capacity (sheets) Maximum output bin capacity (sheets) Duplex capability Standard for C734dn and Standard for C74dw models C734dn model Each 550-sheet Specialty Media Drawer replaces one 550-sheet option. The output bin capacity may be reduced by 50 sheets when the duplex feature is in use.
Page 31: Input And Output Sizes And Types
These sizes are accessible using Universal Size setting. Lower feed reliability may be encountered when feeding non-standard size media. The maximum length supported by the Lexmark C734 is 914.4mm (36 in). These sizes are accessible using Other Envelope setting. General information...
Page 32 These sizes are accessible using Universal Size setting. Lower feed reliability may be encountered when feeding non-standard size media. The maximum length supported by the Lexmark C734 is 914.4mm (36 in). These sizes are accessible using Other Envelope setting. Service Manual...
Page 33: Paper Guidelines
5026 Previous Media weight, primary tray and option tray Size Type Weight Letter, Legal, A4 Xerographic and bond Long grain 60 g/m –162.7 g/m (16 lb–43 lb) Next Short grain 162.7 g/m –198.9 g/m (43 lb–53.2 lb) Recycled Long grain 75 g/m –177 g/m (20 lb–47 lb)
Page 34 5026 Grain direction—Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain long, Previous running the length of the paper, or grain short, running the width of the paper. For 60 to 135 g/m (16 to 36 lb bond) paper, grain long paper is recommended.
Page 35: Tools Required For Service
5026 Storing paper Previous Use these paper storage guidelines to help avoid jams and uneven print quality: For best results, store paper where the temperature is 21°C (70°F) and the relative humidity is 40%. Most • label manufacturers recommend printing in a temperature range of 18 to 24°C (65 to 75°F) with relative Next humidity between 40 and 60%.
Page 36 5026 Multipurpose Feeder Previous NVRAM Nonvolatile Random Access Memory Photoconductor Picture element (pixel) Power-On Reset POST Power-On Self Test Next Raster Imaging Processor SDRAM Synchronous Dual Random Access Memory V ac Volts alternating current Go Back V dc Volts direct current Yellow Service Manual 1-16...
Page 37: Diagnostic Information
5026 2. Diagnostic information Previous Start Next CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable Go Back or electronic card or assembly for personal safety and to prevent damage to the printer. CAUTION Use the handholds on the side of the printer.
Page 38: Operator Panel And Menus
5026 Previous Operator panel and menus Operator panel Display Select Navigation arrow Next button buttons USB direct Go Back Numeric port keypad Menu button Indicator light Back button Cancel/ Stop Buttons and light description Button or light Function Display The display shows messages and pictures that communicate the status of the printer.
Page 39: Administrative Menus
5026 Previous Button or light Function Back Press to return to the previous screen. Note: This button is only active if appears on the top left of the screen. USB direct port Insert a USB flash drive to send data to the printer. Next Numeric keypad Consists of the numbers 0–9, a backspace button, and a pound (#) button.
Page 40: Power-On Self Test (Post) Sequence
5026 Previous Power-on self test (POST) sequence When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: Next The LED turns on. The main fan turns on. The operator panel turns on.
Page 41: Symptom Tables
5026 Previous Symptom tables Printer symptom table Next Symptom Action Dead printer Go to “Dead printer service check” on page 2-126. Operator panel—one or more buttons do Go to “One or more operator panel buttons fail” on Go Back not work. page 2-131.
Page 42: User Status And Attendance Messages
5026 Previous User status and attendance messages Error code Action Next Close Front Door Close the front door securely. If you continuously get this error, then either the 24 V interlock switch or the 5 V interlock switch is bad. See “24 V interlock switch service check”...
Page 43 5026 Previous Error code Action Load Manual <type> If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, <size> pressing Select indicates to the printer it should search for a source with the proper type and size.
Page 44 5026 Previous Error code Action 3x through 8x attendance messages 31 Defective or Missing • Reseat the specified toner cartridge. <color> Cartridge Next • Inspect the smart chip card contacts (A) for damage, contamination or positioning error. If damaged, contact your next level of service. Go Back •...
Page 45 5026 Previous Error code Action 37 Insufficient memory • Select Continue to print the portion of the job already stored and begin collating the rest to collate job of the job. • Cancel the current job. • If this does not fix the problem, replace the system board. See Next “System board removal”...
Page 46 5026 Previous Error code Action 53 Unformatted Flash • Select Continue to clear the message and continue printing. • Format the flash memory before storing any resources on it. If the error message remains, replace the flash memory. • If this does not fix the problem, replace the system board. See Next “System board removal”...
Page 47 5026 Previous Error code Action 58 Too Many Flash Too many flash options are installed. To continue: Options 1. Turn off and unplug the printer. 2. Remove the excess flash memory. Next 3. Plug in the printer, and turn it on. If this does not fix the problem, replace the system board.
Page 48 5026 Previous Error code Action 80 Fuser Life Warning • Select Continue to clear the message and continue printing. • Show Me, View Supplies, and Tell Me More displays additional information. • Order a replacement fuser. When print quality is reduced, install the new fuser using the instruction sheet that comes with the replacement fuser.
Page 49 5026 Previous Error code Action 82 Replace Waste • Replace the waste toner box using the instruction sheet that comes with the replacement Toner waste toner box. • Ensure that there is no interference between the waste toner box and the printer. •...
Page 50 5026 Previous Error code Action 84 <color> PC Unit • Scroll down the operator panel to see if the printer is showing that all four of the PC units Missing are missing. If so, check the HVPS cable between the system board and the HVPS. Ensure that the cable is not plugged in backwards on the HVPS.
Page 51 5026 Previous Error code Action • Show Me, View Supplies, and Tell Me More displays additional information. 88.xx <color> Cartridge • Replace the specified toner cartridge. • Select Continue to clear the message and continue printing. • If the problem persists, replace the system board. See “System board removal”...
Page 52: Error Codes And Messages
5026 Previous Error codes and messages Error code Description Action Next 1xx service error codes 110.01–110.07Mirror A mirror motor error has occurred. • POR the printer. Motor Error • If the error message persists, go to Go Back “110.xx— Mirror motor service check” on page 2-37.
Page 53 5026 Previous Error code Description Action 146.01–146.08 Duplex motor has failed. • POR the printer. Motor Error • If the error message persists, go to “146.xx, 148.xx—Motor (MPF/duplex) error service check” on page 2-48. Next 147.09–147.25 Aligner motor has failed. •...
Page 54 5026 Previous Error code Description Action 168.xx HCIT elevator motor error. • POR the printer. Motor Error • If the error message persists, go to “168.xx— Motor (HCIT elevator) error service check” on page 2-58. Next 199.xx Unrecoverable RIP software error. •...
Page 55 5026 Previous Error code Description Action 200.25 Input sensor is made when tray 1 is • Fan media, and stack flat in the tray or installed. multipurpose feeder. • Properly set media restraints in the paper tray. Possible causes: • If clearing a paper jam does not fix the problem, Next •...
Page 56 5026 Previous Error code Description Action 201.08 Exit sensor is never made. • Check for anything in the paper path that might cause the paper to jam. Possible causes: • The fuser exit sensor may not be functioning • Improper loading properly.
Page 57 5026 Previous Error code Description Action 202.02 Exit sensor is made when printer tries • Check for anything in the paper path that might to print from an idle state. cause the paper to jam. • The fuser exit sensor may not be functioning Possible causes: properly.
Page 58 5026 Previous Error code Description Action 203.09 During duplex printing retract, the exit • Check for anything in the paper path that might sensor is never made. cause the paper to jam. • The fuser exit sensor may not be functioning Possible causes: properly.
Page 59 5026 Previous Error code Description Action 230.21 Duplex motor stalled. • Check for anything in the duplex paper path that might cause the paper to jam. This includes the Possible causes: paper guides in tray 1. • Obstructed duplex path •...
Page 60 5026 Previous Error code Description Action 242.05 Tray 2 picked, but page failed to reach 1. Ensure proper media is set for the type of paper the option sensor in time. used in tray 2. 2. Fan media, and stack flat in tray 2. Possible causes: 3.
Page 61 5026 Previous Error code Description Action 242.29 Tray 2 is not ready or missing while • Make sure that tray 2 is correctly inserted. printing. • Go to “242.29—Paper Jam service check” on page 2-74. Possible cause is paper tray 2 assembly failure Next 243.02...
Page 62 5026 Previous Error code Description Action 243.17 Tray 3 detected a jam from idle. • Clear away anything in the paper path that might cause the media to jam. Possible causes: • If the problem persists, go to “243.17—Paper • Paper jam leaving page over Jam service check”...
Page 63 5026 Previous Error code Description Action 244.05 Tray 4 picked, but page failed to reach 1. Ensure proper media is set for the type of paper the option sensor in time. used in tray 4. 2. Fan media, and stack flat in tray 4. Possible causes: 3.
Page 64 5026 Previous Error code Description Action 244.29 Tray 4 is not ready, or missing while • Make sure that tray 4 is correctly inserted. printing. • If the problem persists, go to “244.29—Paper Jam service check” on page 2-85. Possible cause is paper tray 4 assembly failure.
Page 65 5026 Previous Error code Description Action 245.17 Tray 5 detected a jam from idle. • Clear away anything in the paper path that might cause the paper to jam. Possible causes: • If the problem persists, go to “245.17—Paper • Paper jam leaves a page over the Jam service check.
Page 66 5026 Previous Error code Description Action 9xx service error messages 900.00–900.99 Unrecoverable RIP software error. Go to “900.00–900.99 (except 900.05)—System Software Error software error service check” on page 2-90. Next (except 900.05) 900.05 Transfer module has failed • POR the printer. Software Error.
Page 67 5026 Previous Error code Description Action 920.05 Printhead motor not connected. • POR the printer. POST Error • If the error message persists, go to “920.05— POST (power-on self test) printhead motor not connected error service check” on Next page 2-98.
Page 68 5026 Previous Error code Description Action 920.17 Output bin cable not connected. • POR the printer. POST Error • If the error message persists, go to “920.17— POST (power-on self test)—Output bin cable not connected error service check” on Next page 2-109.
Page 69 5026 Previous Error code Description Action 920.30 Option sensor disconnected. Use the following list to determine which service POST Error check to use: • Tray 2—Go to “242.02—Paper Jam service check” on page 2-68. Next • Tray 3—Go to “243.02—Paper Jam service check”...
Page 70 5026 Previous Error code Description Action 947.01 Yellow transfer roll has failed. • POR the printer. Transfer Roll • If the error message persists, go to “945.xx, 947.xx—Transfer roll error service check” on page 2-118. Next 947.02 Cyan transfer roll has failed. •...
Page 71 5026 Previous Error code Description Action 959.00–959.05 Invalid engine code • POR the printer. Engine Code Error • If the error message persists, download the engine code again. • POR the printer again. Next • If the error message persists, replace the system board.
Page 72 5026 Previous Error code Description Action 983.00–983.99 Invalid command parameter by • POR the printer. <device> specified device. • If the error message persists, replace the Communications Error system board. See “System board removal” on page 4-153. Next 984.00–984.99 Invalid command parameter by •...
Page 73: Service Checks
5026 Previous Service checks 110.xx—Mirror motor service check Next Step Questions / actions View the Event Log: Replace the printhead. See Go to step 2. “Printhead removal, Go Back 1. Turn off the printer, press and hold installation, and and turn on the printer. adjustment”...
Page 74: Xx, 112.Xx, 113.Xx, And 114.Xx-Printhead Error Service Check
5026 111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check Previous Step Questions / actions View the Event Log: Replace the printhead. See Go to step 2. “Printhead removal, Next 1. Turn off the printer, press and hold installation, and . and turn on the printer adjustment”...
Page 75: Xx-Fuser Error Service Check
5026 120.xx—Fuser error service check Previous Step Questions / actions Check the input voltage switch on the back of Go to step 2. Set the switch for the the low-voltage power supply (LVPS). proper country voltage. Next Note: Some LVPS FRU do not have switches and switch automatically.
Page 76 5026 Previous Step Questions / actions Remove the rear frame cover. See“Rear Replace the fuser DC Go to step 5. 4-33. Check cable.See frame cover removal” on page “Fuser DC the cable in connector JFUSER1 (A) (fuser cable removal” on DC cable) for proper connection to the system page 4-106.
Page 77 5026 Previous Step Questions / actions Check for the following continuity between the Go to step 8. Replace the fuser DC DC autoconnect JFUSER1 on the system cable. See “Fuser DC board. cable removal” on page 4-106. Next DC auto- JFUSER1 connect Pin 9...
Page 78: Xx, 920.02-Autocomp (Tray 1) Motor Error Service Check
5026 140.xx, 920.02—Autocomp (tray 1) motor error service check Previous Step Questions / actions Turn the printer off, and then remove the rear Replace the paper pick Go to step 2. frame cover. See mechanism. See “Rear frame cover “Paper Next 4-33.
Page 79: Xx, 906.01-906.04-Motor (Fuser) Error Service Check
5026 142.xx, 906.01–906.04—Motor (fuser) error service check Previous Step Questions / actions 1. Turn the printer off. Replace the cartridge Go to step 2. motor1/fuser motor cable. 2. Remove the rear frame cover. See Next “Rear “Cartridge motor 1/ frame cover removal” on page 4-33.
Page 80: Xx-Motor (Ep Drive Assembly Top Cartridge 1 Motor) Error Service Check
5026 Previous Step Questions / actions Measure the resistance across fuse F6 (A) on Replace the system board. Replace the EP drive the system board. assembly. See “System board removal” on page 4-153. “Electrophotographic (EP) drive assembly Next removal” on page 4-82.
Page 81 5026 Previous Step Questions / actions Remove the right cover. See Replace the cartridge Go to step 3. “Right cover 4-37. Check the cartridge motor 1/fuser motor cable. removal” on page motor 1/fuser motor cable (A0 for proper “Cartridge motor 1/ connection to the EP drive assembly, for fuser cable removal”...
Page 82: Xx-Motor (Ep Drive Assembly Middle Cartridge) Error Service Check
5026 144.xx—Motor (EP drive assembly middle cartridge) error service check Previous Step Questions / actions 1. Turn the printer off. Replace cartridge motor 2/ Go to step 2. 3 cable. See “Cartridge 2. Remove the rear frame cover. See Next “Rear motor 2/3 cable removal”...
Page 83: Xx-Motor (Ep Drive Assembly Bottom Cartridge) Error Service Check
5026 Previous Step Questions / actions Measure the resistance across fuse F9 on the Replace the system board. Replace the EP drive system board. assembly. See “System board removal” on page 4-153. “Electrophotographic (EP) drive assembly Next removal” on page 4-82.
Page 84: Xx, 148.Xx-Motor (Mpf/Duplex) Error Service Check
5026 Previous Step Questions / actions Remove the right cover. Check the cartridge Replace the cartridge Go to step 3. motor 2/3 cable for proper connection to the motor 2/3 cable. See EP drive assembly, pinch points for the cable, “Cartridge motor 2/3 and damage to the cable or connector (A).
Page 85 5026 Previous Step Questions / actions Is the multipurpose feeder damaged? Replace input tray. Go to step 3. Next Go Back 1. Turn the printer off. Replace the MPF/duplex Go to step 4. motor cable. See 2. Remove the rear frame cover. See “Rear “Multipurpose feeder frame cover removal”...
Page 86: Xx, 920.01-Post (Power-On Self Test) Aligner Error Service Check
5026 Previous Step Questions / actions Check the MPF/duplex gear assembly for Go to step 6. Replace the MPF/duplex damage. gear assembly. See “Multipurpose feeder (MPF)/duplex gear and Next housing removal” on page 4-116. Go Back Do the gears turn freely, and are they free of damage? Measure the resistance across fuse F5 (A) on Replace the system board.
Page 87: Xx-Cam Motor Error Service Check
5026 Previous Step Questions / actions Check the cable in the connector JFDPCK1 Replace paper pick Go to step 3. for pinch points and for any other damage to mechanism. See “Paper the cable or connector. pick mechanism assembly removal” on Is the cable damaged? Next page...
Page 88 5026 Previous Step Questions / actions Check the transport motor cable from the cam Replace the transport Go to step 4. motor to the motor driver card for poor motor cable. See connections or damage. “Transport cable removal” on page 4-170.
Page 89: Xx-Cod (Color On Demand) Motor Service Check
5026 156.xx—COD (Color On Demand) motor service check Previous Step Questions / actions 1. Turn the printer off. Replace the COD Go to step 2. assembly. See “Color on 2. Remove the rear frame cover. See Next “Rear demand assembly frame cover removal”...
Page 90: Xx, 161.Xx-Motor Error (Option Tray 2) Service Check
5026 160.xx, 161.xx—Motor Error (option tray 2) service check Previous Step Questions / actions 1. Turn the printer off. Problem resolved. Go to step 2. 2. Reseat option tray 2. Next 3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold .
Page 91: Xx, 163.Xx-Motor Error (Option Tray 3) Service Check
5026 162.xx, 163.xx—Motor Error (option tray 3) service check Previous Step Questions / actions 1. Turn the printer off. Problem resolved. Go to step 2. 2. Reseat option tray 3. Next 3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold .
Page 92: Xx, 165.Xx-Motor Error (Option Tray 4) Service Check
5026 164.xx, 165.xx—Motor Error (option tray 4) service check Previous Step Questions / actions 1. Turn the printer off. Problem resolved. Go to step 2. 2. Reseat option tray 4. Next 3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold .
Page 93: Xx, 167.Xx-Motor Error (Option Tray 5) Service Check
5026 166.xx, 167.xx—Motor Error (option tray 5) service check Previous Step Questions / actions 1. Turn the printer off. Problem resolved. Go to step 2. 2. Reseat option tray 5. Next 3. Bring the printer up in Diagnostics Menu (turn off the printer, press and hold .
Page 94: Xx-Motor (Hcit Elevator) Error Service Check
5026 168.xx—Motor (HCIT elevator) error service check Previous Step Questions / actions Is the paper properly loaded in the high- Go to step 2. Fan the media, and then capacity input tray (HCIT)? stack flat in the HCIT Next drawer. 1.
Page 95: 250.03-Paper Jam Error Service Check
5026 200.11, 250.03—Paper Jam error service check Previous Step Questions / actions Open the front access door. Turn the Go to step 2. Replace the transport belt. transport belt gear clockwise. “Transfer module Next removal” on page 4-168. Go Back Did the transport belt move? 1.
Page 96: 201.31-Paper Jam Error Service Check
5026 201.06, 201.31—Paper Jam error service check Previous Step Questions / actions Open the front access door. Turn the Go to step 2. Replace the transport transport belt gear clockwise. module. See “Transfer Next module removal” on page 4-168. Go Back Did the transport belt move? Bring the printer up in Diagnostics Menu (turn Go to step 3.
Page 97 5026 Previous Step Questions / actions Remove the rear frame cover. See Replace the fuser DC Go to step 7 “Rear cable. See frame cover removal” on page 4-33. “Fuser DC cable removal” on Check the fuser DC cable in the connector page 4-106.
Page 98 5026 Previous Step Questions / actions 1. Replace the fuser. See Problem resolved Replace the system board. “Fuser removal” on page 4-104. “System board 2. Bring the printer up in Diagnostics Menu removal” on page 4-153. (turn off the printer, press and hold Next .
Page 99: Paper Jam Error Service Check
5026 203.09—Paper Jam error service check Previous Step Questions / actions Open the front access door. Turn the Go to step 2. Replace the transport belt. transport belt gear clockwise. “Transfer module Next removal” on page 4-168. Go Back Did the transport belt move? Turn the printer off, and then remove the Replace the fuser.
Page 100 5026 Previous Step Questions / actions Remove the rear frame cover. See Replace the fuser DC Go to step 6. “Rear cable. See frame cover removal” on page 4-33. “Fuser DC cable removal” on Check the fuser DC cable in the connector page 4-106.
Page 101 5026 Previous Step Questions / actions 1. Replace the fuser. See Problem resolved. Replace the system board. “Fuser removal” on page 4-104. “Fuser removal” on 2. Bring the printer up in Diagnostics Menu page 4-104. (turn off the printer, press and hold Next .
Page 102: 230.05-Paper Jam Error Service Check
5026 230.03, 230.05—Paper Jam error service check Previous Step Questions / actions Is the paper fan-folded? Replace the front door Go to step 2. assembly. See “Front Next door assembly removal” on page 4-93. 1. Turn the printer off Replace the fuser DC Go to step 3.
Page 103 5026 Previous Step Questions / actions Check the MPF/duplex gear assembly for Replace the MPF/duplex Go to step 6. damage. gear assembly. See “Multipurpose feeder (MPF)/duplex gear and Next housing removal” on page 4-116. Go Back Are the gears damaged? Replace the MPF/duplex motor assembly.
Page 104: Paper Jam Service Check
5026 242.02—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 4. Go to step 2. before? Next 1. Turn the printer off. Replace the option cable. Go to step 3. 2.
Page 105: 242.11-Paper Jam Service Check
5026 242.03, 242.11—Paper Jam service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics Menu Problem resolved. Go to step 2. (turn off the printer, press and hold Next . and turn on the printer). 2. Select PRINT TESTS, and press Select ( Go Back 3.
Page 106: Paper Jam Service Check
5026 242.05—Paper Jam service check Previous Step Questions / actions Has the paper been fed from an input option Go to step 5. Go to step 2. before? Next 1. Bring the printer up in Diagnostics Menu Problem resolved. Go to step 3. (turn off the printer, press and hold .
Page 107: Paper Jam Service Check
5026 Previous Step Questions / actions Carefully lift the printer off the option, and lay Replace the option cable. Go to step 5. the printer on its back. “Option cable removal” on page 4-125. Check the option connector for damage. Next Go Back Is the connector damaged?
Page 108: Paper Jam Service Check
5026 242.17—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 4. Go to step 2. before? Next 1. Turn the printer off Replace the option cable. Go to step 3. 2.
Page 109: Paper Jam Service Check
5026 242.26—Paper Jam service check Previous Step Questions / actions Determine the input tray. Problem resolved. Go to step 2. Next 1. Bring the printer up in Diagnostics Menu ((turn off the printer, press and hold . and turn on the printer). 2.
Page 110: Paper Jam Service Check
5026 242.29—Paper Jam service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics Menu Problem resolved. Go to step 2. (turn off the printer, press and hold Next . and turn on the printer). 2. Select PRINT TESTS, and press Select ( Go Back 3.
Page 111: 243.11-Paper Jam Service Check
5026 Previous Step Questions / actions Carefully lift the printer off the option, and lay Replace the option cable. Go to step 4. the printer on its back. “Option cable removal” on page 4-125. Check the option connector for damage. Next Go Back Is the connector damaged?
Page 112: Paper Jam Service Check
5026 243.05—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 5. Go to step 2. before? Next 1. Bring the printer up in Diagnostics Menu Problem resolved. Go to step 3. (turn off the printer, press and hold .
Page 113: Paper Jam Service Check
5026 Previous Step Questions / actions Carefully lift the printer off the option, and lay Replace the option cable. Go to step 5. the printer on its back. “Option cable removal” on page 4-125. Check the option connector for damage. Next Go Back Is the connector damaged?
Page 114: Paper Jam Service Check
5026 243.17—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 4. Go to step 2. before? Next 1. Turn the printer off. Replace the option cable. Go to step 3. 2.
Page 115: Paper Jam Service Check
5026 243.26—Paper Jam service check Previous Step Questions / actions 1. Determine the input tray. Problem resolved Go to step 2. 2. Bring the printer up in Diagnostics Menu Next (turn off the printer, press and hold . and turn on the printer). 3.
Page 116: Paper Jam Service Check
5026 244.02—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 4. Go to step 2. before? Next 1. Turn the printer off. Replace the option cable. Go to step 3. 2.
Page 117: 244.11-Paper Jam Service Check
5026 244.03, 244.11—Paper Jam service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics Menu Problem resolved. Go to step 2. (turn off the printer, press and hold Next . and turn on the printer). 2. Select PRINT TESTS, and press Select ( Go Back 3.
Page 118 5026 Previous Step Questions / actions 1. Turn the printer off. Replace the option cable. Go to step 4. 2. Remove the rear frame cover. See “Rear frame cover removal” on page 4-33. 3. Remove the right cover. See “Right Next cover removal”...
Page 119: Paper Jam Service Check
5026 244.10—Paper Jam service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics Menu Problem resolved Replace the complete (turn off the printer, press and hold tray 4 option. Next . and turn on the printer). 2.
Page 120: Paper Jam Service Check
5026 Previous Step Questions / actions Carefully lift the printer off the option, and lay Replace the option cable. Go to step 4. the printer on its back. “Option cable removal” on page 4-125. Check the option connector for damage Next Go Back Did the page feed correctly?
Page 121: Paper Jam Service Check
5026 244.29—Paper Jam service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics Menu Problem resolved. Go to step 2. (turn off the printer, press and hold Next . and turn on the printer). 2. Select PRINT TESTS, and press Select ( Go Back 3.
Page 122: 245.11-Paper Jam Service Check
5026 Previous Step Questions / actions Carefully lift the printer off the options, and lay Replace the option cable. Go to step 4. the printer on its back. “Option cable removal” on page 4-125. Check the option connector for damage. Next Go Back Is the connector damaged?
Page 123: Paper Jam Service Check
5026 245.05—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 5. Go to step 2. before? Next 1. Bring the printer up in Diagnostics Menu Replace the option cable. Go to step 3.
Page 124: Paper Jam Service Check
5026 Previous Step Questions / actions Carefully lift the printer off the option, and lay Replace the option cable. Go to step 5. the printer on its back. “Option cable removal” on page 4-125. Check the option connector for damage. Next Go Back Is the connector damaged?
Page 125: Paper Jam Service Check
5026 245.17—Paper Jam service check Previous Step Questions / actions Has paper been fed from an input option Go to step 4. Go to step 2. before? Next 1. Turn the printer off. Replace the option cable. Go to step 3. 2.
Page 126: Paper Jam Service Check
Note: Before troubleshooting, determine the operating system used when the error occured. If possible determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device. Step Action and questions POR the device.
Page 127 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.
Page 128 5026 Previous Step Action and questions Replace the modem. Restart the device. Go to step 31. Problem resolved. Does the 900.xx error reoccur? Run a fax job. Go to step 31. Go to step 21. Next Does the 900.xx error reoccur? Are there any ISP (internal solutions port) options Go to step 22.
Page 129: Transfer Module Error Service Check
5026 900.05—Transfer module error service check Previous Step Questions / actions 1. Turn the printer off. Replace the transport Go to step 2. cable. See “Transport 2. Remove the rear frame cover. See Next “Rear cable removal” on frame cover removal” on page 4-33.
Page 130: Engine Software Error, Nvram Mgr Problem Service Check
5026 902.59—Engine software error, NVRAM MGR problem service check Previous Step Questions / actions Has the printhead been recently replaced? Replace with a new system Go to step 2. board that has never been Next used before. See “System board removal” on page 4-153 Go Back Has the transfer module been recently...
Page 131 5026 Previous Step Questions / actions Turn the printer off, and then remove the rear Problem resolved. Go to step 3. frame cover. See “Rear frame cover removal” on page 4-33. Reseat the transport cable in connector Next JTPS1 (A). Go Back JFUSER1 JHVPS1...
Page 132: Post (Power-On Self Test) Error Service Check
5026 920.04—POST (power-on self test) error service check Previous Step Questions / actions Turn the printer off, and then remove the rear Problem resolved. Go to step 2. frame cover. See “Rear frame cover Next removal” on page 4-33. Reseat the cables in connectors JCARTP1 (A) and JCARTS1 (B).
Page 133 5026 Previous Step Questions / actions Check the continuity of JCARTP1, pins 4, 5, Go to step 5. Replace the cartridge and 6 and JCARTS1, pins 7 through 12. motor 1/fuser motor cable. “Cartridge motor 1/ fuser cable removal” on Next page 4-62.
Page 134: Post (Power-On Self Test) Printhead Motor Not Connected Error Service Check
5026 920.05—POST (power-on self test) printhead motor not connected error service check Previous Step Questions / actions 1. Turn the printer off. Problem resolved. Go to step 2. 2. Remove the rear frame cover. See Next “Rear frame cover removal” on page 4-33.
Page 135: Post (Power-On Self Test) Error Service Check
5026 920.07—POST (power-on self test) error service check Previous Step Questions / actions Turn the printer off, and then remove the rear Problem resolved. Go to step 2. frame cover. See “Rear frame cover Next removal” on page 4-33. Reseat the cable in connector JTRAY1. Go Back JBIN1 JFUSER1...
Page 136 5026 Previous Step Questions / actions 1. Disconnect the cable in JTRAY1. Remove the paper pick Replace the system board. mechanism. See 2. Connect the cable from the new paper “Paper “System board pick mechanism. pick mechanism removal” on page 4-153.
Page 137: Post (Power-On Self Test)-Four Toner Sensors Not Connected Error Service Check
5026 920.09—POST (power-on self test)—Four toner sensors not connected error service Previous check Step Questions / actions Next Turn the printer off, and then remove the rear Problem resolved. Go to step 2. frame cover. See “Rear frame cover removal” on page 4-33.
Page 138: Post-Three Toner Sensors Not Connected Error Service Check
5026 920.10—POST—Three toner sensors not connected error service check Previous Step Questions / actions Remove the left cover. See If only one or two of the Go to step 2. “Left cover 4-21. Check all the toner toner level sensor are removal”...
Page 139 5026 Previous Step Questions / actions Reconnect the HVPS cable. Disconnect one • If the error recurrs, then Repeat this step for the of the toner level sensors and POR the this sensor is one of the other toner level sensors printer.
Page 140: Post (Power-On Self Test)-One Sensor Not Connected Error Service Check
5026 920.12—POST (power-on self test)—One sensor not connected error service check Previous Step Questions / actions Remove the left cover. See Replace the damaged Go to step 2. “Left cover 4-21. Check all the toner sensor. See removal” on page “Toner level Next level sensor cables connected to the rear of...
Page 141: Post (Power-On Self Test) Cartridge Motor 1 Not Connected Error Service Check
5026 920.13—POST (power-on self test) cartridge motor 1 not connected error service Previous check Step Questions / actions Next Turn the printer off, and then remove the rear Problem resolved. Go to step 2. frame cover. See “Rear frame cover removal”...
Page 142: Post (Power-On Self Test)-Cartridge Motor 2 Not Connected Error Service Check
5026 920.14—POST (power-on self test)—Cartridge motor 2 not connected error service Previous check Step Questions / actions Next 1. Turn the printer off. Problem resolved. Go to step 2. 2. Remove the rear frame cover. See “Rear frame cover removal” on page 4-33.
Page 143 5026 Previous Step Questions / actions Measure the resistance across the fuse F7 Replace system board. Replace the EP drive (A) on the system board. assembly. See “System board removal” on page 4-153. “Electrophotographic (EP) drive assembly Next removal” on page 4-82.
Page 144: Post (Power-On Self Test)-Bad Printhead Nvram Data Error Service Check
5026 Previous Step Questions / actions Lower the front access cover. Check the Replace the transport Go to step 4. transport cable for pinch points and any other cable. See “Transport cable damage. cable removal” on page 4-170. Next Go Back Is the cable damaged? Replace the transfer module.
Page 145: Post (Power-On Self Test)-Output Bin Cable Not Connected Error Service Check
5026 920.17—POST (power-on self test)—Output bin cable not connected error service Previous check Step Questions / actions Next Turn the printer off, and then remove the rear Problem resolved. Go to step 2. frame cover. See “Rear frame cover removal” on page 4-33.
Page 146: Post (Power-On Self Test)-Cartridge Motor 3 Not Connected Error Service Check
5026 920.18—POST (power-on self test)—Cartridge motor 3 not connected error service Previous check Step Questions / actions Next Turn the printer off and remove the rear frame Problem resolved. Go to step 2. cover. See “Rear frame cover removal” on page 4-33.
Page 147: Post (Power-On Self Test)-Transfer Module Stepper Motor Not Connected Error Service Check
5026 Previous Step Questions / actions Measure the resistance across the fuse F10 Replace the system board. Replace the EP drive on the system board. assembly. See “System board removal” on page 4-153. “Electrophotographic (EP) drive assembly Next removal” on page 4-82.
Page 148 5026 Previous Step Questions / actions Measure the resistance across fuses F12 (A) Replace the system board. Go to step 4. and F13 (B)on the system board. “System board removal” on page 4-153. Next Go Back Is either fuse blown? Check the transport motor cable for pinch Replace the transport Go to step 5.
Page 149: Post (Power-On Self Test)-24 V Power Supply Failure Error Service Check
5026 920.21—POST (power-on self test)—24 V power supply failure error service check Previous Step Questions / actions Check the input voltage switch on the back of Go to step 2. Set switch for the proper the low-voltage power supply (LVPS). country voltage.
Page 150: Post (Power-On Self Test)-Duplex Motor Not Connected Error Service Check
5026 Previous Step Questions / actions Measure the resistance across fuses F5, F6, Replace the system board. Replace the low-voltage F7, F9, F10, F12, and F13 on the system power supply. See “System board “Low- board. removal” on page 4-153. voltage power supply (LVPS) removal”...
Page 151 5026 Previous Step Questions / actions Measure the resistance across fuse F13 on Replace the system board. Go to step 4. the system board. “System board removal” on page 4-153. Next Go Back JBIN1 JFUSER1 JHVPS1 JBLW1 JSB1 JFAN1 JBOR1 JMIRR1 JOPP1 JCVR1...
Page 152: 920.28, 920.29-Post (Power On Self Test) Service Check
5026 920.27, 920.28, 920.29—POST (power on self test) service check Previous Step Questions / actions Is the specified option the 550-sheet tray? Replace the 550-sheet tray Go to step 2. with a new 550-sheet tray Next option. Is the specified option the special media tray? Replace the special media Go to step 3.
Page 153: 925.04, 925.06-Cartridge Cooling Fan Error Service Check
5026 925.02, 925.04, 925.06—Cartridge cooling fan error service check Previous Step Questions / actions Turn the printer off, and remove the rear Replace the blower. See Go to step 2. frame cover. See “Rear frame cover “Cartridge cooling fan Next removal”...
Page 154: Xx, 947.Xx-Transfer Roll Error Service Check
5026 945.xx, 947.xx—Transfer roll error service check Previous Step Questions / actions Replace the transfer module. POR the printer. Problem resolved. Replace the original transfer module. Go to step Next Did the error clear? Turn the printer off, and then remove the rear Replace the HVPS cable.
Page 155 5026 Previous Step Questions / actions Remove the HVPS. See Go to step 4. Replace the transfer “High-voltage contact assembly. power supply (HVPS) removal” on 4-108. Check for continuity between the page contacts (yellow1 and yellow2, cyan1 and Next cyan2, magenta1 and magenta2, or black1 and black2) on the transfer contact assembly.
Page 156: 950.29-Eprom Mismatch Failure
5026 950.00–950.29—EPROM mismatch failure Previous When replacing any one of the following components: Warning: • System board Operator assembly card or top access cover assembly • Next Replace only one component at a tie or the printer will be rendered inoperable. Replace the required component, bring the printer up in Diagnostic menu (see 3-2), and verify “Diagnostics menu”...
Page 157: Xx-System Board Failure Service Check
5026 956.xx—System board failure service check Previous Step Questions / actions Turn the printer off, and remove the rear Replace the system board. Reseat the cable. frame cover. See “Rear frame cover “System board Next removal” on page 4-33. removal” on page 4-153.
Page 158 5026 Previous Step Questions / actions Turn the printer off, and remove the rear Replace the 5 V interlock Go to step 3. frame cover. See switch. See “Rear frame cover “5 V interlock removal” on page 4-33. switch cable removal” on page 4-45.
Page 159: V Interlock Switch Service Check
5026 24 V interlock switch service check Previous Step Questions / actions Is the 24 V interlock switch damaged? Replace the 24 V interlock Go to step 2. switch. See “24 V Next interlock switch removal” on page 4-47. Go Back Turn the printer off, and remove the rear Replace the 24 V interlock Go to step 3.
Page 160: Bubble Sensor Service Check
5026 Bubble sensor service check Previous Step Questions / actions Is the bubble sensor flag damaged? Replace the fuser. See Go to step 2. “Fuser removal” on Next page 4-104. Go Back Remove the rear frame cover. See Replace the fuser DC Go to step 3.
Page 161 5026 Previous Step Questions / actions Place a voltmeter between FUSER1 pin 3 and Go to step 6. Go to step 5. ground (pin 6). Next Go Back Pin 3 Pin 6 (ground) Does the meter read +5 V dc? 1.
Page 162: Dead Printer Service Check
5026 Dead printer service check Previous A dead printer is a condition where the display is blank, the LED on the operator panel is off, no fans turn, no motors turn, and the fuser lamp does not come on. If a 550-sheet option assembly is installed, remove the option and check the base printer for correct operation. If Next the base printer operates correctly, replace the 550-sheet option assembly.
Page 163: Exit Sensor Service Check
5026 Exit sensor service check Previous Step Questions / actions Verify the paper is loaded properly in the Go to step 2. Load paper correctly. paper tray or manual feed slot. Next Is the paper properly loaded? Turn the printer off, and remove the fuser. Problem resolved.
Page 164: Input Sensor Service Check
5026 Previous Step Questions / actions 1. Replace the fuser. Problem resolved. Replace the system board. 2. Bring the printer up in Diagnostics Menu “System board (turn off the printer, press and hold removal” on page 4-153. . and turn on the printer). Next 3.
Page 165: Networking Service Check
Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Step...
Page 166 5026 Previous Step Questions / actions Reset the address on the printer to match the Problem fixed. Go to step 10. IP address on the driver. Did this resolve the issue? Next Have the network admin verify that the printer Go to step 12.
Page 167: Operator Panel Service Check
5026 Operator panel service check Previous One or more operator panel buttons fail Step Questions / actions Next Run the Button Test. See“Button Test” on Replace the operator panel Go to step 2. in Diagnostics mode. assembly. See page 3-12 “Operator panel assembly removal”...
Page 168: Print Quality Service Check
5026 Operator panel display all diamonds, no beeps Previous Step Questions / actions Check the operator panel assembly cable. Replace the top access Go to step 2. cover assembly. See “Top Next Is the cable damaged? access cover assembly removal” on page 4-40.
Page 169 Print quality—background Go Back Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.
Page 170 5026 Previous Step Questions / actions Reseat the JHVPS connector. Problem solved. Go to step 5. Does this fix the problem? Replace the HVPS. See Problem solved. Go to step 6. “High-voltage Next power supply (HVPS) removal” on page 4-108. Does this fix the problem? Go Back Clean the printhead.
Page 171 5026 Previous Step Questions / actions Check the high voltage contact from the Replace the transfer Go to step 6. HVPS to the photoconductor charge roll. contact assembly. Ensure the contact springs are properly mounted and that the charge roll contact Next spring is making good contact with the HVPS spring that runs through the left printer frame...
Page 172 5026 Print quality—blurred or fuzzy print Previous Blurred or fuzzy print is usually caused by a problem in the EP drive assembly or in the transfer module. Check the EP drive assembly and transfer module for correct operation. Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, or duplex Next paper path.
Page 173 5026 Print quality—random marks Previous Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit, developer roll, or transfer module. Next Step Questions / actions Is there any loose or foreign material on the Replace the Go to step 2.
Page 174 5026 Print quality—solid color page Previous Service tip: A solid color page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum. Next Step Questions / actions...
Page 175 5026 Previous Step Questions / actions Replace the HVPS. See Problem solved. Replace the system board. “High-voltage power supply (HVPS) removal” on “System board page 4-108. removal” on page 4-153. Did this solve the problem? Next Print quality—vertical banding Go Back Replace the developer cartridge.
Page 176: Tray Linking Service Check
5026 Previous Step Questions / actions 1. Reseat the HVPS card. Problem resolved. Replace the HVPS. See 2. Make sure the contacts is properly aligned “High-voltage power with the HVPS. supply (HVPS) removal” on page 4-108. Does this fix the problem? Next Tray linking service check Go Back...
Page 177: Diagnostic Aids
5026 3. Diagnostic aids Previous This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Next There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics menu 1.
Page 178: Diagnostics Menu Structure
5026 Previous Diagnostics menu Note: Tray 2 refers to the 550-sheet tray located in the 550-sheet option assembly. Diagnostics menu structure Next When the Diagnostics mode is entered, each Diagnostics main menu item displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays and each individual test displays in the Go Back order shown.
Page 179 5026 Previous PRINT TESTS Tray 1 “Input source tests” on page 3-10. Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Next Tray 5 (if installed) Multi-Purpose Feeder Go Back Prt Quality Pgs “Print quality test pages (Prt Quality Pgs)” on page 3-11.
Page 180 5026 Previous DEVICE TESTS (if hard disk or flash is installed) Quick Disk Test “Quick Disk Test” on page 3-18. Disk Test/Clean “Disk Test/Clean” on page 3-19. Flash Test “Flash Test” on page 3-19. Next PRINTER SETUP Defaults “Defaults” on page 3-20.
Page 181: Registration
5026 Registration Previous Note: If you need to perform alignment or registration, see “Printhead alignment” on page 4-8. The following information is meant to explain the uses for the menu items. Next Print registration makes sure the black printing is properly aligned on the page. This is one of the steps in aligning a new printhead.
Page 182 5026 Print registration Previous To set print registration: Select REGISTRATION from the DIAGNOSTICS menu. Select Quick Test, and press Select ( Next The message Quick Test Printing… appears on the display. Note: Retain this page to determine the changes you need to make to the margin settings. to select the margin setting you need to change, and press Select ( Go Back to decrease or...
Page 183 5026 Quick Test Previous The Quick Test contains the following information: Print registration settings • Alignment diamonds at the left, right, top and bottom • Next Horizontal lines to check for skew • • General printer information, including current page count, installed memory, serial number, and code level. Go Back To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper.
Page 184: Alignment
5026 Alignment Previous Note: If you need to perform alignment or registration, see “Printhead alignment” on page 4-8. The following information is meant to explain the uses for the menu items. Next Alignment is part of the process of adjusting the printhead and the color planes to the black plane and to each other.
Page 185: Motor Tests
5026 Motor tests Previous The motor tests are run primarily to locate noises in the printer. General motor tests procedures Next In some instances, when you enter a particular test, you will be given the choice to run the motor in forward or reverse.
Page 186: Print Tests
5026 Previous Setup requirements Values in Motor test Notes Top cover Lower door menu position position Closed Forward, If the cam or COD are at the farthest Reverse extent forward or backward, selecting Next this value does not show a result. If this Closed Forward, happens, select the other value.
Page 187 5026 Tray 4 (if installed) Previous Tray 5 (if installed) Multi-Purpose Feeder (if installed) Select Single or Continuous, and press Select ( If Single is selected, a single page is printed. • If Continuous is selected, printing continues until Stop ( ) is pressed to cancel the test.
Page 188: Hardware Tests
5026 Hardware Tests Previous Panel Test This test verifies the operator panel LCD function. Next To run the Panel Test: Select HARDWARE TESTS from DIAGNOSTICS, and press Select ( Go Back Select Panel Test, and press Select ( The Panel Test continually executes. Each pixel is activated at the darkest level to the lightest level, and then the backlight illuminates and turns off.
Page 189 5026 Serial 1 Wrap Previous The Serial 1 Wrap Test is used to check the operation of the serial port hardware using a wrap plug. Each serial signal is tested. To perform the Serial 1 Wrap Test: Next Disconnect the serial interface cable, and install the serial wrap plug. Select HARDWARE TESTS from the Diagnostics Menu, and press Select ( Select Serial 1 Wrap, and press Select ( Go Back...
Page 190: Duplex Tests
5026 USB HS Test Mode Previous Select HARDWARE TESTS from DIAGNOSTICS, and press Select ( Select USB HS Test Mode, and press Select ( Select the port (Port 0, Port 1, Port 2, or Port 3), and press Select ( Select the test for that port from the following list: Next Test J...
Page 191: Print Test (Duplex)
5026 To run the Quick Test (duplex): Previous Select Quick Test from DUPLEX TESTS, and press Select ( Select Single or Continuous, and press Select ( The single Duplex Quick test cannot be canceled. • The printer attempts to print the Quick Test Page from the default paper source. •...
Page 192: Top Margin (Duplex)
5026 Skew (duplex) Previous This setting adjusts the duplex motor speed when it feeds through the aligning roll. It controls the skew between the first scan line and the top of the page. Adjustments are made to the image that is facedown in the output tray.
Page 193: Sensor Test
5026 to select the margin setting you need to change. Previous • Each increment shifts the duplex left margin by 4 pixels at 600 dpi (0.00666 inches or 0.1693 mm). The Left Margin range is -50 to +50, and the default value is 0. •...
Page 194: Printhead Tests
5026 Printhead Tests Previous Mirror Motor Test Select PRINTHEAD TESTS in DIAGNOSTICS, and press Select ( Select Mirror Motor Test, and press Select ( Next The panel displays Mirror Motor Test—Motor Running…. After the test completes, the panel displays either Pass or Fail. Go Back To stop the test, press Back ( ) or Stop (...
Page 195 5026 Disk Test/Clean Previous Warning:This test destroys all data on the disk and should not be attempted on a good disk. This test may run approximately 1½ hours depending on the disk size. To run the Disk Test/Clean Test: Next Select DEVICE TESTS in the Diagnostics Menu, and press Select ( Select Disk Test/Clean, and press Select ( Files will be lost/Go or Stop? is displayed to warn the user.
Page 196: Printer Setup
5026 Printer Setup Previous Defaults U.S./Non-U.S. defaults changes whether the printer uses the U.S. factory defaults or the non-U.S. factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of Next measure. Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone. Go Back Page Counts You can view, but not change any of the three counts displayed under PAGE COUNTS.
Page 197: Motor Calibration
5026 To set the configuration ID: Previous Select Printer Setup from the Diagnostic mode. Select Configuration ID from the Printer Setup menu. Submitting Selection displays, followed by the value for Configuration ID 1. Enter the Configuration ID 1. Next To select a digit or character to change, press until the digit or character is underlined.
Page 198: Ep Setup
5026 EP Setup Previous EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes this is used to help correct print quality problems. Next To restore EP Defaults: Go Back Select EP SETUP from DIAGNOSTICS, and press Select ( Select EP Defaults, and press Select ( Select Restore to reset the values to the factory settings, and select Do Not Restore to exit without...
Page 199: Exit Diagnostics
• Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the event log: Select EVENT LOG from DIAGNOSTICS, and press Select (...
Page 200: Configuration Menu (Config Menu)
5026 Previous Configuration menu (CONFIG MENU) Available tests The tests display on the operator panel in the order shown. Next Reset Fuser Cnt “Reset Fuser Cnt” on page 3-25. Go Back Color Lock Out “Color Lock Out” on page 3-25. Prt Quality Pgs “Prt Quality Pgs”...
Page 201: Reset Fuser Cnt
5026 Reset Fuser Cnt Previous Resets the fuser count value to zero. The Event Log records each time that a user executes the Reset Fuser Count operation. See for more information. This setting only appears if the “Event Log” on page 3-26 Maintenance Warning and Intervention function is enabled in the printer Configuration ID.
Page 202: Reports
5026 Reports Previous Menu Settings Page The Menu Settings Page generates a list of Configuration Menu settings and the current values. Next Event Log This menu item lets the system support person print a limited set of the information contained in the Diagnostics Go Back mode version of the printed Event Log.
Page 203: Ppds Emulation
5026 PPDS Emulation Previous Activates or deactivates (default) the Personal Printer Data Stream (PPDS) emulation language. This menu item only appears if the PPDS interpreter is available. Download Emuls Next This menu item allows the system support person turn the download emulator off temporarily. This menu item only appears if at least one download emulator is installed.
Page 204: Auto Align Adj
5026 Auto Align Adj Previous Controls whether the printer executes the automatic alignment calibration after an initiating event occurs. When an event initiates a TPS operation, the printer performs a toner density calibration, (TPS) an alignment calibration, or both of the calibrations. Next Toner Patch Sensing (TPS) is a diagnostic mechanism that automatically adjusts the printer toner density and alignment settings.
Page 205: Motor Calibration
5026 Motor Calibration Previous This test is run to calibrate the leading edge of the paper to each transfer station. to select Motor Calibration from the Config Menu. Calibrating displays, and the printer prints Press Select eight blank pages and then returns to the Config Menu. Next Note: This test should be run at 600 dpi resolution and with duplex disabled.
Page 206: Disk Encryption
5026 Disk Encryption Previous Controls whether the printer encrypts the information that it writes to the hard disk. Warning: When the value for Disk Encryption, the printer completely formats the hard disk which means that all information on the disk is deleted. Next Note: If an encrypted disk is removed from the printer and another disk is installed, the Disk Corrupted.
Page 207: Clear Custom Status
5026 Clear Custom Status Previous This operation erases any strings that have been defined by the user for the Default or Alternate custom messages. USB Speed Next Full or Auto (default) Go Back Exit Config Menu Press Select to exit the Config Menu. The printer performs a power-on reset and returns to normal mode. Diagnostic aids 3-31...
Page 208: Front Cover Locked In Place
5026 Previous Front cover locked in place The front door locks during certain Busy events, and unlocks when those events are complete. This is a normal function. You can hear the door lock into place when one of these events take place. However, if the printer is turned off, or has an error while the front door is locked (for example, while printing or calibrating), the front door Next may not unlock.
Page 209 5026 Press the waste toner release latch (C), swing the front of the waste toner assembly away from the printer, Previous and remove. Next Go Back Remove the two screws (D) on the bottom and one screw higher up (E). Press the locking tab (F).
Page 210 5026 Lift the rear of the left cover out, and rotate it out of position. Previous Note: It will not come completely off with the front cover locked. Next Go Back With a flatblade screwdriver, turn the camshaft counterclockwise until the door unlocks. Open the front cover.
Page 211: Printhead Verification
5026 Previous Printhead verification You can verify that the printhead is the failing FRU by following this procedure: Turn the printer off, and remove the power cord from the outlet. Remove all cords and cables from the Next printer before beginning. Locate the printer on a corner of a work area so the front and back can be accessed.
Page 212 5026 Remove the rear frame cover. Previous Loosen the eight screws on the rear frame cover (A). Note: Do not remove the screws. Lift up on the rear frame cover to remove it from the back of the printer. Next Go Back Service Manual 3-36...
Page 213 5026 Carefully unplug the printhead ribbon (B) and the mirror motor cables (C) from the system board, and Previous carefully connect the printhead ribbon and mirror motor cables from the new printhead into the system board. It is important to position the laser in the printhead down into the packaging as shown. Note: Use the packaging that came with the printhead FRU to prop the printhead up..
Page 214: Paper Jams
5026 Previous Paper Jams Error jam locations The following illustration shows the location and error codes generated for specific paper jams and the Next corresponding locations of these jams. Go Back Service Manual 3-38...
Page 215: Clearing Jams
Use only recommended paper or specialty media. • For more information, refer to the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com/publications. Do not load too much paper. Make sure the stack height does not exceed the indicated maximum height.
Page 216 5026 200 paper jams Previous If paper jams behind the inner door, but not under the photoconductor units, 200.xx Paper jam appears. Note: To avoid overexposing the photoconductor units, do not leave the front door open longer than 10 minutes. Next Open the front door.
Page 217 5026 Remove each photoconductor unit, and place it on a flat surface. Previous Next Go Back Remove the jammed paper, and then replace each photoconductor unit. Close the front door. Press Select ( 201 paper jam If paper is jammed under the fuser or the top cover, 201.xx Paper jam appears. Open the front door, and then open the top cover.
Page 218 5026 Lift the unit and pull forward to remove it. Previous Next Go Back Remove the jammed paper. Replace the fuser unit, and then turn the screws to the right to fasten it securely. Close the top cover, and then close the front door. Press Select ( 202 paper jam If paper is jammed both under the fuser unit and in the slot behind the fuser unit, 202.xx Paper jam appears.
Page 219 5026 If the paper is jammed behind the fuser, you will need to remove the fuser unit. Previous Turn the screws on the fuser unit to the left. Next Go Back Lift the unit and pull forward to remove it. Pull the paper gently out of the printer or up toward the standard exit bin to remove it.
Page 220 5026 203 paper jam Previous If paper is jammed under the rollers near the fuser, or in the standard exit bin 203.xx Paper jam appears. Grasp the paper that is visible in the standard exit bin, and pull it away from the bin. Next Go Back Open the front door, and then open the top cover.
Page 221 5026 Reinsert tray 1. Previous Press Select ( 240 paper jam If paper is jammed in Tray 1, 241.xx Paper jam appears. If paper is jammed in any of the optional trays, 24x.xx Next Paper jam appears. If the jammed paper is located in tray 1, follow these steps to remove the paper from tray 1. •...
Page 222 5026 250 paper jam Previous If paper is jammed in the multipurpose tray, 250.xx Paper jam appears. Press the paper release lever, and then remove the jammed pages from the multipurpose tray. Next Go Back Load new paper into the multipurpose tray. Press Select ( Service Manual 3-46...
Page 223: Repair Information
5026 4. Repair information Previous CAUTION—POTENTIAL INJURY: The printer weight is greater than 54 lbs (24.5kg), and requires two or more trained personnel to lift safety. Next Go Back Safety information The safety of this product is based on testing and approvals of the original design and specific •...
Page 224: Handling Esd-Sensitive Parts
5026 Previous Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing electronic cards: Next •...
Page 225: Screw And Retainer Identification Table
5026 Previous Screw and retainer identification table The following table contains screw types and retainers, locations, and quantities necessary to service the printer. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly. Next Sizes are as close to actual as possible, as long as the printout is not scaled or resized.
Page 226 5026 Screw identification table (continued) Previous Screw type Location 18B0832 Taptite M3 L6 Laser support plate to lower plate panhead Left camshaft lock assembly to printer frame Next Left frame assembly to laser support plate Left frame assembly to lower plate Lower plate to left frame assembly Go Back (Cont.)
Page 227 5026 Screw identification table (continued) Previous Screw type Location 27S2837 M3.5X1.34 panhead Left cover to lower frame 8L, black Rear left cover through lower swingout frame into left cover Next Rear right cover to rear upper cover Rear upper cover to top cover Top cover to right cover Go Back 27S2838...
Page 228 5026 Screw identification table (continued) Previous Screw type Location 88A0293 Plastite M2.2 L5 Contact spring cap to left guide assembly Next Go Back 88A0312 Plastite M2.9 L6 Backup springs to reference edge plate assembly Cartridge cooling fan duct to top cover Cartridge left guide assembly to leftside plate assembly (exterior side of plate assembly) Cover mount to rightside plate...
Page 229 5026 Screw identification table (continued) Previous Screw type Location 88A0412 M2.9x5.2 Plastite GS COD bellcranks to guide NGS COD bellcranks to guide Next Top access door assembly to fuser retract link Top cover left link to cover Go Back Repair information...
Page 230: Adjustments
5026 Previous Adjustments Printhead alignment Next Overview When aligning the printhead, it is important to keep in mind that the printhead mounting screws should be initially loose enough to just hold the printhead in the printer. This allows the pages to be printed that will be used to Go Back align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw.
Page 231 5026 Loosen the printhead mounting screws in the following order: D1, D2, and D3. Previous Next Go Back Remove the printhead alignment screw cover (E). Reinstall the transfer module with the photoconductor units still attached. Reconnect the transfer module cable. Replace the toner cartridges.
Page 232 5026 Align the printhead skew for black. Previous Enter the Diagnostic menu (turn off the printer, press and hold , turn on the printer, and release the buttons when the clock graphic displays). Select REGISTRATION from the DIAGNOSTICS menu, and press Select ( Select Skew, and press Select ( to set the Skew to zero, and press Select ( Next...
Page 233 5026 Adjust the printhead alignment screw (G) to change the skew and straighten the image on the Previous printout. Next Go Back If the top right alignment marks are lower than the top left alignment marks, rotate the alignment screw counterclockwise a full revolution, and print the Quick Test page. Repeat adjusting the screw and printing the Quick Test until the top alignment marks are the same distance from the top of the media.
Page 234 5026 Tighten the printhead mounting screws. Previous Turn off the printer. Disconnect the power cord from the electrical outlet. Disconnect the transfer module cable. Press the two tabs on either side of the transfer module, and lift out the transfer module with the photoconductor units in place.
Page 235 5026 Registration (black) Previous Top Margin Reconnect the power cord to the electrical outlet, but do not turn on the printer yet. Enter Diagnostic mode (press and hold , turn on the printer, and release the buttons when the Next clock graphic displays).
Page 236 5026 Left Margin Previous Adjust the left margin until the points of the left alignment marks touch the edge of the page. Increasing the value ( ) moves the left alignment marks away from the edge of the page. • Decreasing the value ( ) moves the left alignment marks toward on the edge of the page.
Page 237 5026 Select Quick Test in the Cyan menu, and press Select ( Previous Two pages print. You may have to print these pages several times until you get T (Top Margin) and Z (Skew) aligned. Do not go to step 2 until T and Z are aligned. The first page is similar to the following: Next Go Back Repair information...
Page 238 5026 Determine the line under Fine Adjustment that is closest. If the value is beyond the Fine Adjustment scale, Previous use either of the Coarse Adjustment scales. Next Go Back Enter the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the “T”...
Page 239 5026 Repeat this process for skew (Z). Don't forget to subtract the T value and add the current cyan Z value to Previous obtain the new skew (Z) value. An example is shown below: Next Go Back Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin (T), the Skew (Z), and on the second page of the Quick Test page, the Left Margin (L), Right Margin (R), and Bow (P).
Page 240: Printer Removal Procedures
5026 Previous Printer removal procedures Precautions to take before maintenance work Do not implement any operation, removal, or modification and so on, which is not presented in this manual. Next Turn the printer power off and unplug the power cable from the outlet prior to starting removals or checks.
Page 241: Cover Removals
5026 Previous Cover removals Front access cover assembly removal See Front access door cover assembly for the part number for the models you need on Next page 7-3. Remove the paper tray. Disconnect the transfer module cable (A). Go Back Press the two tabs (B) to release the front access door cover assembly.
Page 242 5026 Looking down at the keyed end of the restraint (D), twist the end clockwise, slide the restraint upward Previous through the slit (E), and slip the end of the restraint through the keyed hole (F). Repeat for the other side. Next Go Back Service Manual...
Page 243: Left Cover Removal
5026 Close the front access door assembly. Previous Remove the two screws (G) that attach the pivot pin to the front access door cover assembly. Remove the bracket (H). Next Go Back Remove the front access cover assembly. Left cover removal for the part number.
Page 244 5026 Remove the screws (D) from the rear left cover. Previous Next Go Back Lift, and remove the left cover and rear left cover together. Note: Because the paper tray dust cover is loose at this point, set it aside. Note: If you are removing the left cover to access another part, leave the left cover and the rear left cover attached, and you are done.
Page 245 5026 Separate the left cover and rear left cover by sliding the left rear cover as shown to disengage the latch (E). Previous Next Go Back Repair information 4-23...
Page 246: Operator Panel Assembly Removal
5026 Operator panel assembly removal Previous for the part number. “Operator panel assembly, with card” on page 7-3 Warning: When replacing any one of the following components: • Operator panel assembly Next • System board • Top access cover assembly Go Back Only replace one component at a time.
Page 247 5026 Remove the four screws (B) from the operator panel card. Previous Note: Observe the position of the ground cable (C). Next Go Back Disconnect the operator panel cable (D). Repair information 4-25...
Page 248 5026 Gently turn the operator panel card over, and disconnect both display cables (E). Previous Note: The ribbon cable has a latch (F) that needs to be lifted to disconnect the cable. Next Go Back Turn the top access cover assembly over. Gently use a flathead screwdriver to pry out the lens from the bezel back cover.
Page 249 5026 Remove the display from the lens. Previous Note: The operator panel assembly consist of the display and the operator panel card. Next Go Back Repair information 4-27...
Page 250: Operator Panel Bezel Removal
5026 Operator panel bezel removal Previous See Operator panel bezel on for the part number. page 7-3 Open the front cover. Rotate the operator panel to its highest position. Next Using a flathead screwdriver or similar tool, unsnap the locking tabs on the upper left and the upper right of the bezel.
Page 251: Operator Panel Buttons Removal
5026 Operator panel buttons removal Previous Remove the top access door cover assembly. See “Top access cover assembly removal” on page 4-40. Turn the top access cover assembly over. Remove the nine screws (A) securing the position guide. Next Go Back Remove the four screws (B) from the operator panel card.
Page 252 5026 Disconnect the operator panel cable (D). Previous Next Go Back Turn over the operator panel card. Note: Do not disconnect the display cables. Be sure not to put any pressure on the ribbon cable. Remove the clear shield over the number pad. Remove the buttons (E) from the top access door cover.
Page 253: Output Bin Extension Cover Removal
5026 Output bin extension cover removal Previous for the part number. “Output bin extension cover” on page 7-3 Turn the printer around, so the back is toward you. Rotate the output bin extension cover toward the front of the printer. Next Use a flathead screwdriver to ease the posts from the holes on one side.
Page 254: Paper Tray Dust Cover Removal
5026 Paper tray dust cover removal Previous for the part number. “Dust cover assembly” on page 7-3 Remove the paper tray. Remove the left cover. See “Left cover removal” on page 4-21. Next Remove the paper tray dust cover assembly. Go Back Installation notes: Place the paper tray dust cover into position.
Page 255: Rear Frame Cover Removal
5026 Rear frame cover removal Previous for the part number. “Rear frame cover” on page 7-3 Remove paper tray Loosen the eight screws (A) on the rear frame cover. Next Note: Do not remove the screws. Lift up on the rear frame cover to remove it from the back of the printer. Go Back Repair information 4-33...
Page 256: Rear Left Cover Removal
5026 Rear left cover removal Previous Remove the left cover. See “Left cover removal” on page 4-21. Separate the left cover and rear left cover by sliding the left rear cover as shown to disengage the latch (A). Next Go Back Service Manual 4-34...
Page 257: Rear Right Cover Removal
5026 Rear right cover removal Previous for the part number. “Rear right cover” on page 7-3 Remove the right cover. See “Right cover removal” on page 4-37. Press the two tabs (A) to separate the right cover from the rear right cover. Next Go Back Repair information...
Page 258: Rear Upper Cover Removal
5026 Rear upper cover removal Previous Remove the two screws (A). Next Go Back Slide the cover up and remove the rear upper cover. Note: If you are removing the rear upper cover to access another part, leave the cooling fan filter attached, and you are done.
Page 259: Right Cover Removal
5026 Right cover removal Previous for the part number. “Right cover” on page 7-3 Remove the power cord from the printer. Remove the paper tray. Next Remove the rear upper cover. See “Rear upper cover removal” on page 4-36. Open the front cover. Open the top access cover.
Page 260 5026 Remove the three screws (C). Previous Next Go Back Lift the bottom of the cover out, pull up at the points shown, and remove the cover. Note: There are posts on the top access cover and the paper tray dust cover (D). When you reinstall, be sure to verify that the top access cover opens correctly and that the paper tray dust cover swings properly.
Page 261 5026 Press the two tabs (F) to separate the right cover from the rear right cover. Previous Next Go Back Repair information 4-39...
Page 262: Top Access Cover Assembly Removal
5026 Top access cover assembly removal Previous for the part number. “Top access cover assembly” on page 7-3 Warning: When replacing any one of the following components: • Operator panel assembly Next • System board • Top access cover assembly Go Back Only replace one component at a time.
Page 263 5026 Disconnect the two screws (D), one on either side of the printer, that connects the links. Previous Next Go Back Extract the cables (E). Repair information 4-41...
Page 264 5026 Slide the top access cover to the rear, and remove. Previous Next Go Back Note: If you are removing the top access cover assembly to access another FRU, then leave the operator panel bezel attached, and you are done. If you are replacing the top access cover assembly FRU, then continue with the next step to disconnect the separate operator panel bezel FRU.
Page 265: Top Cover Assembly Removal
5026 Top cover assembly removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-112. Remove the top access cover assembly. See “Top access cover assembly removal” on page 4-40. Disconnect the connectors in JBLW1 (A), JFUSER1 (B), JFAN1 (C) on the system board. Next Go Back Pull the cables through the openings.
Page 266 5026 Remove the fuser AC cable from the cable restraint (D). Previous Next Go Back Remove the five screws (E). Lift off the top cover assembly. Service Manual 4-44...
Page 267: Printer Removals
5026 Previous Printer removals 5 V interlock switch cable removal for the part number. Next “5 V interlock switch” on page 7-7 Remove the EP drive assembly. See “Electrophotographic (EP) drive assembly removal” on page 4-82. Go Back Disconnect the connector at JINT1 (A) on the system board. Repair information 4-45...
Page 268 5026 Open the front access door cover, and remove the screw (B). Previous Next Go Back Remove the cable from the two cable retainers (C). Service Manual 4-46...
Page 269: Interlock Switch Removal
5026 Remove the 5 V interlock switch and bracket from the printer. Previous Remove the screw (D), and remove the 5 V interlock switch cable from the bracket. Next Go Back 24 V interlock switch removal for the part number. “24 V interlock switch”...
Page 270 5026 Remove the screw (B), and the bracket separates from the 24 V interlock switch. Previous Next Go Back Installation notes: Observe the routing of the 24 V interlock switch cable (C). Service Manual 4-48...
Page 271: Auger Drive Removal
5026 Auger drive removal Previous for the part number. “Auger shaft and gear parts pack” on page 7-11 Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal”. Remove the left cover. See “Left cover removal”. Next Remove the six mounting screws (A) holding the HVPS in place. Go Back Repair information 4-49...
Page 272 5026 Release the locking tab (B) from the front, lower corner of the HVPS. Previous Next Go Back Lay the board to the left. Service Manual 4-50...
Page 273 5026 Grasp the auger shaft (C) , and remove it. Previous Next Go Back Repair information 4-51...
Page 274 5026 Make sure to remove the auger gear (D) on the other side. Previous Next Go Back Installation note: The auger gear needs to go onto the auger shaft as shown, with the flat surfaces going together. Service Manual 4-52...
Page 275: Bin Full Sensor Flag Removal
5026 Bin full sensor flag removal Previous Remove the top access cover assembly. See “Top access cover assembly removal” on page 4-40. Turn the top access cover over, and use a flatblade screwdriver to carefully remove the flag (A). Next Go Back Bin full sensor removal for the part number.
Page 276: Cartridge Guide Wheel Removal
5026 Cartridge guide wheel removal Previous Right cartridge guide wheel Note: Only replace defective cartridge guide wheel(s). Next For yellow, cyan, or magenta: Remove the two screws (A) from the cartridge guide. Go Back Gently pull the cartridge guide, then remove the cartridge guide wheel (B). CAUTION: Do not pull too hard on the cartridge guide to avoid damage.
Page 277 5026 Installation note: Gently pull the cartridge guide, then use a long-nosed pliers to hold the cartridge Previous guide wheel in place when installing a new cartridge wheel. Next Go Back Installation note: Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide.
Page 278 5026 Gently pull the cartridge guide, then remove the cartridge guide wheel (D). Previous CAUTION: Do not pull too hard on the cartridge guide to avoid damage. Next Go Back Installation note: Gently pull the cartridge guide, then use a long-nosed pliers to hold the cartridge guide wheel in place when installing a new cartridge guide wheel.
Page 279 5026 Left cartridge guide wheel Previous Note: Only replace defective cartridge guide wheel(s). For yellow, cyan, or magenta: Remove the two screws (A) from the cartridge guide. Next Go Back Gently pull the cartridge guide, then remove the front (B) or rear (C) cartridge guide wheel. CAUTION: Do not pull too hard on the cartridge guide to avoid damage.
Page 280 5026 Installation note: Gently pull the cartridge guide, then use a long-nosed pliers to hold the cartridge Previous guide wheel in place when installing a new rear cartridge wheel. Next Go Back Service Manual 4-58...
Page 281 5026 Installation note: Make sure to properly align the pins to their proper slot when reinstalling the Previous cartridge guide wheel. Be careful not to damage or bend the pins. Next Go Back Installation note: Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide.
Page 282 5026 For black: Previous Remove the screw (D) from the lower-most cartridge guide. Next Go Back Gently pull the cartridge guide, then remove the front (E) or rear (F) cartridge guide wheel. CAUTION: Do not pull too hard on the cartridge guide to avoid damage. Service Manual 4-60...
Page 283: Cartridge Cooling Fan Removal
5026 Note: When replacing either the front or rear cartridge guide wheel, be careful to not let the non- Previous defective cartridge guide wheel fall off. Installation note: Inspect carefully if the cartridge guide wheel is seated properly on the cartridge guide before reinstalling the screw on the cartridge guide.
Page 284: Cartridge Motor 1/Fuser Cable Removal
5026 Cartridge motor 1/fuser cable removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-112. Disconnect the connectors in JCARTP1 (A) and JCARTS1 (B) on the system board. Next Go Back Disconnect the connectors from the cartridge motor 1 (C) and the fuser motor (D). Service Manual 4-62...
Page 285 5026 Disconnect the camshaft cable connector (E) from the motor card, and unwind the two cables. Previous Next Go Back Remove the cable from the six retainers (F). Installation notes: • Make sure you wrap the camshaft cable around the cartridge motor 1/fuser cable, as shown, to prevent the cables from interfering with the motors or the motors damaging the cables.
Page 286: Cartridge Motor 2/3 Cable Removal
5026 Cartridge motor 2/3 cable removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-112. Disconnect the connectors in JCARTP2 (A) and JCARTS2 (B) on the system board. Next Go Back Disconnect the connectors from the cartridge motor 2 (C) and cartridge motor 3 (D). Service Manual 4-64...
Page 287 5026 Remove the cable from the six retainers (E). Previous Next Go Back Installation notes: Note the routing of the cables and the cable retainers. Repair information 4-65...
Page 288: Color On Demand Assembly Removal
5026 Color on demand assembly removal Previous Remove the print cartridges. Remove the top cover assembly. See “Top cover assembly removal” on page 4-43. Disconnect the connector at JBOR1 (A) on the system board. Next Go Back Remove the five screws (B). Remove the COD assembly.
Page 289 5026 Installation notes: Previous Push the actuators (A) all the way down. Next Go Back Turn the printer around, and verify the actuators are in the correct location by looking inside the front of the printer. The actuators (B) should be visible in the triangular holes in the frame, as shown. Repair information 4-67...
Page 290 5026 Rotate the large COD gear until the stop (C) on the gear is against the housing. Previous Next Go Back Engage the gears on the left side of the COD. Service Manual 4-68...
Page 291 5026 Engage the gears (D) on the right side of the COD. Previous Replace the five screws (E). Next Go Back Verify the actuators can be seen by looking inside the printer at the triangular holes, as in step 2. Check to make sure you can rotate the large COD gear from stop to stop.
Page 292: Contact Springs Kit Removal
5026 Contact springs kit removal Previous for the part number. “Contact springs kit, including:” on page 7-11 Charge roll contact spring removal Next Remove the HVPS. See “High-voltage power supply (HVPS) removal” on page 4-108. Remove the charge roll contact springs (A). Be sure to push the springs under the retainers that hold them in place.
Page 293 5026 HVPS contact springs removal Previous Remove the HVPS. See “High-voltage power supply (HVPS) removal” on page 4-108. Pull out the spring that will be replaced: HVPS DB contact spring (A) • HVPS DR contact spring (B) • Next HVPS TAR contact spring (C) •...
Page 294 5026 Torsion spring removal Previous Remove all the toner cartridges. Remove the screw (A) and the spring cap (B) of the appropriate contact spring. Next Go Back Press the lower half (C, D) of the springs, and remove the springs. Service Manual 4-72...
Page 295 5026 Installation notes: Previous • When installing, make sure the top half (E) of the spring is under the straight spring (F). This is typical for both types of springs. Also make sure the bottom half (D,G) of both springs are compressed and locked by the appropriate locking tabs (H, I).
Page 296: Cooling Fan Removal
5026 Cooling fan removal Previous Remove the rear upper cover. See “Rear upper cover removal” on page 4-36. Remove the rear frame cover. See “Rear frame cover removal” on page 4-33. Disconnect JFAN1 (A). Next Go Back Remove the two screws (B). Remove the cooling fan.
Page 297: Cooling Fan Filter Removal
5026 Cooling fan filter removal Previous Remove the rear upper cover. See “Rear upper cover removal” on page 4-36. Turn the cover over. Squeeze the right side of the filter, and remove it from the tabs (A). Next Go Back Repair information 4-75...
Page 298: Display Detent Spring
5026 Display detent spring Previous Remove the top access cover assembly. See “Top access cover assembly removal” on page 4-40. Turn the top access cover assembly over. Remove the nine screws (A) securing the position guide. Next Go Back Remove the four screws (B) from the operator panel card. Note the position of the ground cable (C).
Page 299 5026 Disconnect the operator panel cable (D). Previous Next Go Back Gently turn the operator panel card over, and disconnect both display cables (E). Note: The ribbon cable has a latch (F) that needs to be lifted to disconnect the cable. Turn the top access cover assembly over.
Page 300 5026 Remove the screw (G) securing the display detent spring. Previous Next Go Back Rotate the display detent spring (H), and push down to remove the spring. Service Manual 4-78...
Page 301: Duplex Reference Edge Guide Assembly Removal
5026 Duplex reference edge guide assembly removal Previous Remove the paper tray. Disconnect the transfer module cable (A). Press the two tabs (B) to release the front access door cover assembly. Press the two tabs (C) on either side of the transfer module, and lift out the transfer module. Next Note: Leave the photoconductor units on the transport belt when removing.
Page 302 5026 Looking down at the keyed end of the restraint (D), twist the end clockwise, slide the restraint upward Previous through the slit (E), and slip the end of the restraint through the keyed hole (F). Repeat for the other side. Next Go Back Close the front access door assembly.
Page 303 5026 Remove the two screws (G). Previous Next Go Back Remove the duplex reference edge guide assembly. Repair information 4-81...
Page 304: Electrophotographic (Ep) Drive Assembly Removal
5026 Electrophotographic (EP) drive assembly removal Previous for the part number. “EP drive assembly” on page 7-7 Remove the paper tray. Remove the transport belt module and the developer units. See “Transfer module removal” on Next page 4-168. Remove the cartridges. Remove the low-voltage power supply (LVPS).
Page 305 5026 Disconnect the camshaft/transport cable connector (C), and remove the cable from the cable clamps (D). Previous Next Go Back Unwind the camshaft/transport cable and the cartridge 1/fuser cables (E). Note: Be sure to rewind the camshaft/transport cable around the other cables with about four twists to keep them from interfering with or being damaged by the motors.
Page 306 5026 Disconnect the cartridge 2/cartridge 3 motor cable (two connectors) (F), and remove the cable from the Previous cable clamps (G). Next Go Back Disconnect the motor drive cable connector (H), and remove the cable from the cable clamps (J). Remove the two screws (K) to remove the motor driver card assembly.
Page 307 5026 Remove the three screws (M) on the front. Previous Next Go Back Repair information 4-85...
Page 308 5026 Remove the seven screws (N) securing the EP drive. Previous Next Go Back N (First) Service Manual 4-86...
Page 309 5026 Remove the 5 V interlock switch cable from the restraint (N) on the backside of the EP drive. Previous Next Go Back Remove the EP drive. Installation notes: Push the actuator rack all the way to the right (A). Pull the link all the way up (B).
Page 310 5026 Fasten the 5 V interlock cable into the cable retainer (C) on the bottom of the EP drive. Previous Next Go Back Align the gear so the first gear tooth (D) of the top cover camshaft meshes with the first two gear teeth (E) after the flat area in the EP drive actuator rack, and then seat the right side of the top cover camshaft into the boss (F) on the EP drive.
Page 311 5026 Hold the drive in place while replacing the first of the seven screws, then continue replacing the rest of the Previous screws (G). Next Go Back Repair information 4-89...
Page 312 5026 Replace the two screws (H) from the inside. Previous Replace the three screws (J) on front. Next Go Back Wind the camshaft cable (K) around the cartridge 1/fuser cables about four times to make sure they do not interfere with or are damaged by the fuser motor. Connect the cartridge 1/fuser motor cable (two connectors) (L), and place the cables in the cable retainers (M).
Page 313 5026 Connect the cartridge 2/cartridge 3 motor cable (two connectors) (N), and make sure the cable is in the Previous cable clamps (O). Next Go Back Connect the camshaft/transport cable connector (P), and make sure the cable is in the cable clamps (R). Repair information 4-91...
Page 314 5026 Connect the motor drive cable connector (S), and make sure the cable is in the cable clamps (T). Previous Next Go Back Reinstall the low-voltage power supply (LVPS). Replace the right and rear covers. Replace the transport belt module and developer units. Replace the cartridges and the fuser.
Page 315: Front Door Assembly Removal
5026 Front door assembly removal Previous See the part number for the Front door assembly for the specific model you need on page 7-5. Remove the front access cover assembly. See “Front access cover assembly removal” on page 4-19. Remove the rear frame cover. See “Rear frame cover removal”...
Page 316 5026 Open the front door assembly. Previous Unwrap and remove the cable from the left and right pulleys (C). Next Go Back Close the front door assembly, and remove the mounting screw (D) and the cap (E). Service Manual 4-94...
Page 317 5026 Open the front door assembly, slide it to the right, and remove. You need to press firmly to slide the front Previous door assembly to the right. Next Go Back Installation note: See “Front door assembly front cable (left) removal” on page 4-96 “The longer for proper installation of the cable restraints.
Page 318: Front Door Assembly Front Cable (Left) Removal
5026 Front door assembly front cable (left) removal Previous Remove the paper tray. Disconnect the transfer module cable (A). Press the two tabs (B) to release the front access door cover assembly. Press the two tabs (C) on either side of the transfer module, and lift out the transfer module. Next Note: Leave the photoconductor units on the transport belt when removing.
Page 319 5026 Looking down at the keyed end of the restraint (D), twist the end clockwise, slide the restraint upward Previous through the slit (E), and slip the end of the restraint through the keyed hole (F). Repeat for the other side. Next Go Back Repair information...
Page 320 5026 Remove the left cover. See “Left cover removal” on page 4-21. Previous Using a flathead screwdriver, rotate the top cover camshaft clockwise to raise the front door locking mechanism (G). Next Go Back Close the front access door assembly. Release the cable spring (H) from the front door assembly.
Page 321 5026 Remove the end of the cable (J) from the frame. Previous Next Go Back Installation note: The longer cable installs on the left side of the printer. Repair information 4-99...
Page 322: Front Door Assembly Front Cable (Right) Removal
5026 Front door assembly front cable (right) removal Previous Remove the paper tray. Disconnect the transfer module cable (A). Press the two tabs (B) to release the front access door cover assembly. Press the two tabs (C) on either side of the transfer module, and lift out the transfer module. Next Note: Leave the photoconductor units on the transport belt when removing.
Page 323 5026 Looking down at the keyed end of the restraint (D), twist the end clockwise, slide the restraint upward Previous through the slit (E), and slip the end of the restraint through the keyed hole (F). Repeat for the other side. Next Go Back Repair information...
Page 324 5026 Remove the right cover. See “Right cover removal” on page 4-37. Previous Close the front access door assembly. Release the spring (G) from the front door assembly. Note: In order to access the springs, make sure the top access cover is closed. Next Go Back Remove the end of the cable (H) from the frame.
Page 325 5026 Installation notes: Previous The shorter restraint cable installs on the right side of the printer. Note: The frame end needs to be wrapped to inside of post for two full turns Next Go Back Repair information 4-103...
Page 326: Fuser Removal
5026 Fuser removal Previous 7-5, or “Fuser assembly, 115 V” on page 7-5, “Fuser assembly, 230 V” on page “Fuser assembly, for the part number. 100 V” on page 7-5 CAUTION Next The fuser can be extremely hot. Use care when handling to avoid burns. Go Back Turn off the printer.
Page 327: Fuser Ac Cable Removal
5026 Fuser AC cable removal Previous Note: The LVPS to fuser AC cable is black. Remove the top cover assembly. See “Top cover assembly removal” on page 4-43. Turn the top cover assembly over. Next Lift the locking latch (A) on the connector, slide the connector down, and remove the connector from the keyed hole.
Page 328: Fuser Dc Cable Removal
5026 Fuser DC cable removal Previous Note: The fuser to system board autoconnect cable is red. Remove the top cover assembly. See “Top cover assembly removal” on page 4-43. Turn the top cover assembly over. Next Remove the connector (A) from the top cover assembly. Warning: You will damage the old connector in the process.
Page 329: Hard Drive Assembly Removal
5026 Hard drive assembly removal Previous Remove the two screws (A), and squeeze the connector to disconnect the hard disk from the system board (B). Next Go Back Pull the hard disk straight out to pop the hard drive standoffs free of the system board. Repair information 4-107...
Page 330: High-Voltage Power Supply (Hvps) Removal
5026 High-voltage power supply (HVPS) removal Previous for the part number. “High-voltage power supply” on page 7-11 Remove the left cover. See “Left cover removal” on page 4-21. Remove the six mounting screws (A). Next Go Back Release the locking tab (B) from the front, lower corner of the HVPS. Service Manual 4-108...
Page 331 5026 Disconnect the five connectors (C) from the HVPS. Previous Next Go Back Installation notes: Be sure to replace the spring when replacing the HVPS. See the illustration for proper orientation. Repair information 4-109...
Page 332: High-Voltage Power Supply (Hvps) Cable Removal
5026 High-voltage power supply (HVPS) cable removal Previous Remove the top cover assembly. See “Top cover assembly removal” on page 4-43. Disconnect the cable connector at JHVPS1 on the system board. Next Go Back Disconnect the cable connector (B) from the HVPS. Remove the cable from the hole through the frame (C), and from the two cable restraints (D).
Page 333: Left Bellcrank Assembly Removal
5026 Left bellcrank assembly removal Previous for the part number. “Left bellcrank assembly, with spring” on page 7-5 Remove the left cover. See “Left cover removal” on page 4-21. Remove the C-clip (A). Next Go Back Remove the left bellcrank assembly. Repair information 4-111...
Page 334: Low-Voltage Power Supply (Lvps) Removal
5026 Low-voltage power supply (LVPS) removal Previous for the part number. “Low-voltage power supply” on page 7-7 Remove the right cover. See “Right cover removal” on page 4-37. Remove the rear frame cover. See “Rear frame cover removal” on page 4-33.
Page 335 5026 Installation note: Previous • When installing the new LVPS, make sure the voltage switch (A) is set for the proper value (115 V or 230 V), depending on the country. Note: Not all LVPS FRUs have a switch. Others are switched automatically. Next Go Back Install the LVPS, and make sure the AC fuser cable is in the cable guides, and not behind the LVPS.
Page 336: Motor Driver Card Removal
5026 Motor driver card removal Previous Remove the right cover. See “Right cover removal” on page 4-37. Disconnect the three cables (A). Remove the two screws (B), and remove the motor driver card. Next Go Back Service Manual 4-114...
Page 337: Motor Driver Cable Removal
5026 Motor driver cable removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-112. Disconnect the connector in JDVR1 (A) on the system board. Next Go Back Disconnect the connector on the motor driver card (B). Remove the cable from the cable from the four cable retainers (C).
Page 338: Multipurpose Feeder (Mpf)/Duplex Gear And Housing Removal
5026 Multipurpose feeder (MPF)/duplex gear and housing removal Previous See the multipurpose feeder/duplex gear and housing kit for the part number. Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on page 4-127. Next Remove the two E-clips (A) from the gears. Go Back Remove the three screws (B).
Page 339 5026 Slide a flathead screwdriver up and under the front cover. Previous Slide the remaining two gears and housings off. Next Go Back Repair information 4-117...
Page 340: Multipurpose Feeder (Mpf)/Duplex Motor Assembly Removal
5026 Multipurpose feeder (MPF)/duplex motor assembly removal Previous for the part number. “MP feeder/duplex drive parts packet, including” on page 7-5 Remove the low-voltage power supply (LVPS). See “Low-voltage power supply (LVPS) removal” on page 4-112. Next Remove the multipurpose feeder/duplex gear and housing. See “Multipurpose feeder (MPF)/duplex gear and housing removal”...
Page 341 5026 Installation notes: Previous Connect the cable (A) at the motor. Slide the cable tie (B) onto the motor. Next Go Back Insert the motor into the frame. Repair information 4-119...
Page 342 5026 Replace the screws (C). Previous Next Go Back Slide the housing onto the motor, making sure the four tabs of the housing slide under the cable tie. Service Manual 4-120...
Page 343: Multipurpose Feeder (Mpf)/Duplex Motor Cable Removal
5026 Multipurpose feeder (MPF)/duplex motor cable removal Previous Remove the multipurpose feeder/duplex motor. See “Multipurpose feeder (MPF)/duplex motor assembly removal” on page 4-118. Disconnect the connector from JDX1 (A) on the system board. Next Go Back Remove the cable from the cable retainers (B). Repair information 4-121...
Page 344: Operator Panel Cable Removal
5026 Operator panel cable removal Previous Remove the top access cover assembly. See “Top access cover assembly removal” on page 4-40. Remove the nine screws (A), and remove the position guide. Next Go Back Disconnect the operator panel cable connector (B) from the operator panel card. Service Manual 4-122...
Page 345 5026 Remove the cable from the two cable retainers (C) and routing posts (D). Previous Next Go Back Installation note: Note the routing of the cable and the cable retainers. Repair information 4-123...
Page 346: Operator Panel Ground Cable Assembly Removal
5026 Operator panel ground cable assembly removal Previous Remove the top access cover assembly. See “Top access cover assembly removal” on page 4-40. Remove the nine screws (A), and remove the position guide. Next Go Back Remove the screw (B), and remove the ground cable connector. Disconnect the ground cable (C).
Page 347: Option Cable Removal
5026 Option cable removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-112. Disconnect the cable connector at JOPT1 (A) on the system board. Next Go Back Replace the rear frame cover to protect the system board. Position the printer on its back.
Page 348 5026 Press the tabs together to remove the option cable connector. Previous Note: Be sure to note the cable routing for reinstallation. Next Go Back Service Manual 4-126...
Page 349: Paper Pick Mechanism Assembly Removal
5026 Paper pick mechanism assembly removal Previous for the part number. “Paper pick assembly” on page 7-5 Remove the paper tray. Remove the waste toner assembly. See “Waste toner assembly removal” on page 4-174. Next Remove the rear frame cover. See “Rear frame cover removal”...
Page 350 5026 Remove the transfer module with the photoconductor units attached. Previous Disconnect the transfer module cable (D). Press the two tabs (E) to release the front access cover assembly, and lower the front access door cover. Press the two tabs (F) on either side of the transfer module, and lift out the transfer module. Note: Leave the photoconductor units on the transport belt when removing.
Page 351 5026 Remove the four screws (G) from the bottom pan. Previous Next Go Back With one hand, disengage the gear (H), then grasp the paper pick assembly, and pull forward and downward to disengage the assembly until the front (J) and rear locking tabs release (not visible). Repair information 4-129...
Page 352 5026 Lower the paper pick mechanism, and remove through the front of the printer. Previous Note: Make sure the JTRAY1 and JTRAY2 connectors do not bind when passing through the frame access hole. Next Go Back Installation notes: Remove the waste toner assembly. See “Waste toner assembly removal”...
Page 353 5026 Reach into the printer, and replace the front right screw (C) to secure the paper pick assembly. Previous Set the printer upright. Secure the remaining three screws (D). Next Go Back Remove the rear frame cover. Route the cables through the hole in the frame, and connect them to JFDPCK1 (E) and JTRAY1 (F). Replace the rear frame cover.
Page 354: Photoconductor Unit Removal
5026 Photoconductor unit removal Previous Not a FRU Warning: To avoid damaging the photoconductor drum, hold the photoconductor units by their handle and place the photoconductor units on a clean surface. See “Handing the photoconductor unit” on Next for additional information. page 4-2 Open the front access door.
Page 355: Pick Arm Roll Removal And Replacement
5026 Pick arm roll removal and replacement Previous for the part number. “Pick arm roll” on page 7-5 The autocompensator pick roll tires are located in the base printer. There are also tires in all input options. If you have additional input options, and you are having problems with media picking, replace these tires also. Always Next replace the pick arm rolls in pairs.
Page 356: Printer Pad Removal
5026 Installation notes: Install the new rubber tires with the surface texture turning in the direction as shown. Previous Note: Feel the rubber surface to verify it turns properly in the direction shown. Next Go Back Printer pad removal Slide the corner of the printer containing the damaged pad over the corner of the table. Remove the side cover that corresponds to the damaged pad so you can see if the pad fully seats in the installation holes.
Page 357: Printhead Removal, Installation, And Adjustment
5026 Printhead removal, installation, and adjustment Previous for the part number. “Printhead assembly” on page 7-9 Service tip—Testing the new printhead Next for quick way to verify that the existing printhead is failing “Printhead verification” on page 3-35 before installing the new printhead. If the new printhead also fails, the existing printhead is probably working properly, so the system board is probably the failing component.
Page 358 5026 period of time. Place a clean, dry cloth over the transfer module and photoconductor units until they are Previous required. Next Go Back Remove all of the toner cartridges. Remove the right cover and the right side cover (attached). See “Right cover removal”...
Page 359 5026 Remove the three printhead mounting screws (D). Previous Next Go Back Repair information 4-137...
Page 360 5026 Remove the printhead alignment screw cover (E). Previous While still holding the printhead in place, loosen the printhead alignment screw (F) until the printhead comes out. Warning: Secure the printhead when loosening the printhead alignment screw. Failure to do this allows the printhead to fall out of the printer, potentially damaging the printhead.
Page 361 5026 Loosely attach the three printhead mounting screws (B). Previous Warning: Do not fully tighten the printhead mounting screws until skew has been adjusted. Next Go Back Lightly tighten the alignment screw (C). Feed the ground cable through the hole in bottom leftside frame. Repair information 4-139...
Page 362 5026 Replace the system board support shield screws (E): Previous Loosely attach the two mounting screws (E2) Set the system board support shield in place. Check that the ribbon mirror motor cable (white) and the printhead cable (bottom) do not rub against the edges of the frame.
Page 363 5026 Replace the system board. Previous Place the system board in position. Check that the mirror motor cable and the printhead cable do not rub against the edges of the frame. Replace the nine screws (F) in the system board in the following order: Loosely attach the four corners (F1) in a clockwise order, beginning with the left top corner.
Page 364 5026 Replace all the screws (G) from the left side of the printer, including: Previous • Ethernet port connector (1 screws) Modem shield (1 screws) • • Hard disk shield (2 screws) Ground screw (1 screw) • Note: Be sure to attach the ground wire (H) to the ground screw. Next Go Back Reconnect all the cables to the system board.
Page 365 5026 Replace the LVPS. Previous Install the LVPS, and make sure the cable is in the cable guides, and not behind the LVPS. Reconnect the cable to the LVPS. Replace the five LVPS mounting screws. Reconnect the cable in connector JLVPS1 on the system board. Replace the right cover.
Page 366 5026 Scroll down to Quick Test, and press Select . A page similar to this one prints: Previous Next Go Back Service Manual 4-144...
Page 367 5026 Adjust the printhead alignment screw (A) to change the skew and straighten the image on the Previous printout. Next Go Back If the top right alignment marks are lower than the top left alignment marks, rotate the alignment screw counterclockwise a full revolution, and print the Quick Test page. Repeat adjusting the screw and printing the Quick Test until the top alignment marks are the same distance from the top of the media.
Page 368 5026 Remove all of the toner cartridges. Previous Tighten the printhead mounting screws in the following order: B1, B2, and B3. Next Go Back Replace the printhead alignment screw cover (C). Be sure to replace the screw cover so that the notch in the cover faces to the rear of the printer. This makes it much easier to remove the next time.
Page 369 5026 Registration (black) Previous Top Margin Reconnect the power cord to the electrical outlet, but do not turn on the printer yet. Enter Diagnostic mode (press and hold , turn on the printer, and release the buttons when the Next clock graphic displays).
Page 370 5026 Left Margin Previous Adjust the left margin until the points of the left alignment marks touch the edge of the page. Increasing the value ( ) moves the bottom alignment marks up on the page. • Decreasing the value ( ) moves the bottom alignment marks down on the page.
Page 371 5026 Select Quick Test in the Cyan menu, and press Select ( Previous Two pages print. You may have to print these pages several times until you get T (Top Margin) and Z (Skew) aligned. Do not go to step 2 until T and Z are aligned. The first page is similar to the following: Next Go Back Repair information...
Page 372 5026 Determine the line under Fine Adjustment that is closest. If the value is beyond the Fine Adjustment scale, Previous use either of the Coarse Adjustment scales. Next Go Back Enter the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the “T”...
Page 373 5026 Repeat this process for skew (Z). Don't forget to subtract the T value and add the current cyan Z value to Previous obtain the new skew (Z) value. An example is shown below: Next Go Back Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin (T), the Skew (Z), and on the second page of the Quick Test page, the Left Margin (L), Right Margin (R), and Bow (P).
Page 374: Right Bellcrank Assembly Removal
5026 Right bellcrank assembly removal Previous for the part number. “Right bellcrank assembly, with spring” on page 7-5 Remove the right cover. See “Right cover removal” on page 4-37. Remove the C-clip (A). Next Go Back Remove the right bellcrank assembly. Service Manual 4-152...
Page 375: System Board Removal
5026 System board removal Previous See the system board part number for the model you need on page 7-9. CAUTION Next This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations.
Page 376 5026 Disconnect all the cables from the system board. Previous Warning: Do not use tools to remove the printhead ribbon cable (B). A flat ribbon cable can be damaged and should be removed gently by hand. Next Go Back Remove the nine screws (C) from the system board. Remove the system board.
Page 377 5026 Installation notes: Previous Place the system board in position. Note: Check that the mirror motor cable and the printhead cable do not rub against the edges of the frame. Replace the nine screws (A) in the system board in the following order: Next Loosely attach the four corners (A1) in a clockwise order, beginning with the left top corner.
Page 378 5026 Replace all the screws (B) from the left side of the printer, including: Previous • Ethernet port connector (1 screws) Modem shield (1 screws) • • Hard disk shield (2 screws) Ground screw (1 screw) • Note: Be sure to attach the ground wire (C) to the ground screw. Next Go Back Reconnect all the cables to the system board.
Page 379: System Board Support Shield Removal
5026 System board support shield removal Previous for the part number. “System board support shield” on page 7-9 Remove the system board. See “System board removal” on page 4-153. Remove the right cover. See “Right cover removal” on page 4-37. Next Pull the cables through the access holes on the right side of the printer.
Page 380 5026 Remove the five mounting screws (D) from the top and bottom of the support shield. Previous Note: Only the ribbon and mirror motor cables come through the access holes in the system board support shield. Next Go Back Lower and remove the support shield. Be careful not to damage the ribbon cable that routes through the bottom frame of the printer.
Page 381 5026 Replace the remaining system board support shield screws in the following order: Previous • Replace the four screws (B) from the inner right side of the support shield. Tighten the two mounting screws (A) to the top of the support shield. •...
Page 382: Toner Level Sensor Removal
5026 Toner level sensor removal Previous for the part number. “Toner level sensor” on page 7-11 Note the locations of the toner sensors. Next Go Back Remove the HVPS. See “High-voltage power supply (HVPS) removal” on page 4-108. For the upper two sensors: These sensors are more difficult to reach because the toner is difficult to reach: Service Manual 4-160...
Page 383 5026 It is difficult to press both locking tabs at the same time. Using a spring hook, press the locking tab (A), and Previous disengage the sensor on that side. Press the other locking tab (B), and remove the sensor. Note: Use a slight pressure on the cable to keep the first locking tab from relatching, while you disconnect the second locking tab.
Page 384: Top Cover Camshaft Assembly Removal
5026 Top cover camshaft assembly removal Previous for the part number. “Top cover camshaft assembly” on page 7-12 Open the front cover access door cover. Open the top access cover. Next Remove the two screws (A) from the links on either side, and disengage the links. Go Back Rotate the top access cover back, and place a screwdriver in the cable hole in the frame to hold the cover in place.
Page 385 5026 Remove the fuser. See “Fuser removal” on page 4-104. Previous Remove the top screw (B), and loosen the other screw (C). This will allow you to flex the EP drive. Next Go Back Remove the two screws (D). Repair information 4-163...
Page 386 5026 Rotate the camshaft up using the camshaft actuator handles (E) so you can access the other two Previous screws (F), and remove them. Next Go Back Flex the EP drive assembly to remove the right side of the camshaft from the boss (G), and lift to remove the camshaft.
Page 387 5026 Installation notes: Previous On the left side, align the mark on the idler gear (A) with the mark on the camshaft gear (B), and slide the camshaft into place, meshing the gears on the left side. Next Go Back Repair information 4-165...
Page 388 5026 Rotate the camshaft up using the camshaft actuator handle (C), and make sure the gears on the right side Previous mesh so the first gear tooth of the camshaft aligns with the first two gear teeth of the EP drive actuator rack (D).
Page 389 5026 Rotate the camshaft using the camshaft actuator handle, and replace the two screws (G). Previous Next Go Back Replace the screw in the EP drive that allowed you to flex the EP drive, and tighten the other screw (see step 6 of the removal).
Page 390: Transfer Module Removal
5026 Transfer module removal Previous for the part number. “Transfer module” on page 7-5 Disconnect the transfer module cable (A). Press the two tabs (B) to release the front access cover assembly. Next Press the two tabs (C) on either side of the transfer module, and lift out the transfer module. Note: Leave the photoconductor units on the transport belt when removing.
Page 391 5026 Note: If you are removing the transfer module to access another part, leave the photoconductor units attached, Previous and you are done. If you need to replace the transport belt, continue with the next step to remove the separate photoconductor units.
Page 392: Transport Cable Removal
5026 Transport cable removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-112. Remove the transport belt assembly. Leave the photoconductor units in place. See “Transfer module removal” on page 4-168. Disconnect the transport cable from the system board at JTPS1 connector (A). Next Note: The cable connector on the system board end of the cable is smaller than the connector on the front access door, and it may be easier to get that end through the openings.
Page 393 5026 Extract the cable through the opening in the frame to the right side of the printer (B). Previous Remove the cable from the five cable restraints (C). Remove the cable from the three openings in the cable channel (D) on the right side of the front access door.
Page 394: Transport Motor Cable Removal
5026 Remove the cable through the cable channel (F). Previous Next Go Back Transport motor cable removal Remove the right cover. See “Right cover removal” on page 4-37. Disconnect the cable from the transport motor drive (A). Disconnect the cable from the transport motor (B). Remove the cable.
Page 395: Usb Connector Cable Removal (Front Panel)
5026 USB connector cable removal (front panel) Previous Remove the top access door cover assembly. See “Top access cover assembly removal” on page 4-40. Remove the nine screws (A), and remove the position guide. Next Go Back Repair information 4-173...
Page 396: Waste Toner Assembly Removal
5026 Disconnect the cable connector (B), Previous Disconnect the ground cable (C) from the grounding assembly, and release the ground cable from the cable clamp (D). Next Go Back Remove the USB connector. Waste toner assembly removal Not a FRU. Press the waste toner release latch (A).
Page 397: Wireless Network Antenna Removal
5026 Wireless network antenna removal Previous Remove the wireless network card. see “Wireless network card removal” on page 4-189. Disconnect the wireless network antenna cable (A) from the wireless network card. Next Go Back With pliers, squeeze the inner tabs (B), and pull the antenna out. Pull the cable through, and remove the antenna with the cable.
Page 398: Waste Toner Hv Contact Assembly Removal
5026 Waste toner HV contact assembly removal Previous for the part number. “Waste toner HV contact assembly” on page 7-11 Disconnect the transfer module cable (A). Press the two tabs (B) to release the front access door cover assembly. Next Press the two tabs (C) on either side of the transfer module, and lift out the transfer module.
Page 399 5026 Remove the six mounting screws (D) holding the HVPS in place. Previous Next Go Back Release the locking tab (E) from the front, lower corner of the HVPS. Repair information 4-177...
Page 400 5026 Lay the board to the left. Previous Next Go Back Disconnect the three top toner level sensor cables (F) from the HVPS. Service Manual 4-178...
Page 401 5026 Remove the two screws (G). Previous Next Go Back G (18B1236) Repair information 4-179...
Page 402 5026 Remove the cleaner shutter actuator (H) from the waste toner HV contact assembly. Previous Next Go Back Service Manual 4-180...
Page 403 5026 Remove the four screws (J), the two screws (K), and the screw (L). Tilt the Waste toner HV contact Previous assembly forward and up to remove it. Next Go Back L (27S2838) J (18B0832) K (88A0313) Repair information 4-181...
Page 404 5026 Previous Installation note: Do the following procedures when re-installing the waste tone HV contact assembly: Remove the fuser. Remove all four toner cartridges Next Remove the four sets of torsion springs. Remove the screw (A) and the spring cap (B) of the appropriate contact spring.
Page 405 5026 Install the waste toner HV contact assembly into place. Route the toner level sensor cables (E) through the Previous holes in the waste toner HV contact assembly while positioning the assembly. Make sure the aligner shaft worm gear is aligned as shown. Ribs aligned Next Go Back...
Page 406 5026 Install the seven screws in the order shown below. Previous Next Go Back Install 3 27S2838 Install 4 Install 1 Install 2 (18B0832) (18B0832) (88A0313) Service Manual 4-184...
Page 407 5026 Use two screws (F) to attach the cleaner shutter actuator to the Waste toner HV contact assembly. Make Previous sure the gear aligns as shown. Ribs aligned Next Go Back F (27S2838) Repair information 4-185...
Page 408 5026 Attach the eight springs (G) to the Waste toner HV contact assembly as shown. Make sure the springs are Previous behind the retainers. Retainer Next Go Back Service Manual 4-186...
Page 409 5026 Install the contact springs. When installing each contact spring, make sure the top half (H) of the spring is Previous under the straight spring (J). This is typical for both types of springs. Also make sure that the bottom half (K,L) of both springs are compressed and locked by the appropriate locking tabs (M,N).
Page 410 5026 Connect the three top toner level sensor cables to the HVPS, making sure the cables (O) are attached Previous properly to the retainers (P). Next Go Back Reassemble the rest of the printer. Service Manual 4-188...
Page 411: Wireless Network Card Removal
5026 Wireless network card removal Previous Remove the rear frame cover. See “Rear frame cover removal” on page 4-33. Disconnect the wireless cable from the system board at J5 (A), by squeezing the tabs at either end together. Next Go Back Remove the two screws (B) that secure the card into place.
Page 412 5026 Pop the posts (C) on the card from the sockets (holes) in the system board. Previous Next Go Back Note: If you are removing the wireless network card to access another part, leave the antenna attached to the card, and you are done. If you need to replace the wireless network card FRU, continue with the next step to remove the separate wireless network antenna FRU.
Page 413: Option Removals
5026 Previous Option removals HCIT media tray assembly removal Note: When removing the high-capacity input tray (HCIT) media tray assembly, it is not necessary to remove it Next from the base machine and the caster base. Open the HCIT media tray assembly (A) until it reaches a stop. Go Back Press the latches (B) on the left and right side of the HCIT tray slides.
Page 414: Hcit Front Tray Cover Removal
5026 HCIT front tray cover removal Previous Note: When removing the high-capacity input tray (HCIT) front tray cover, it is not necessary to remove the HCIT media tray assembly from the base machine and the caster base. Remove the HCIT media tray assembly. See “HCIT media tray assembly removal”...
Page 415: Hcit Rear Cover Removal
5026 HCIT rear cover removal Previous Remove the four screws (A) securing the HCIT rear cover to the drawer. Remove the HCIT rear cover. Next Go Back Repair information 4-193...
Page 416: Hcit Right Cover Removal
5026 HCIT right cover removal Previous Carefully remove the printer or multifunction printer from the high-capacity input tray (HCIT) and remove the HCIT from the caster base. Remove the HCIT media tray assembly. See “HCIT media tray assembly removal” on page 4-191.
Page 417: Hcit Left Cover Removal
5026 HCIT left cover removal Previous Carefully remove the printer or multifunction printer from the high-capacity input tray (HCIT), and remove the HCIT from the caster base. Remove the HCIT media tray assembly. See “HCIT media tray assembly removal” on page 4-191.
Page 418: Feed With Bushing Roller Removal
5026 Feed with bushing roller removal Previous Remove the high-capacity input tray (HCIT) top plate assembly. See “Top plate assembly removal” on page 4-204. Remove the four screws (A) securing the pass thru sensor bracket to the top plate assembly. Note: The bushing may come off when removing the pass thru sensor bracket.
Page 419: Hcit Controller Board Assembly Removal
5026 HCIT controller board assembly removal Previous Remove the HCIT right cover. See “HCIT right cover removal” on page 4-194. Disconnect the seven connectors (A) from the HCIT controller board. Next Go Back Remove the ground screw (B) from the HCIT controller board. Remove the two screws (C) securing the HCIT controller board to the card mount option.
Page 420: Hcit Drawer Slide Assembly Removal
5026 HCIT drawer slide assembly removal Previous The left and right drawer slide assemblies are the same, and only one is in a package. The instructions below are for removing the left slide, but removing the right slide is similar. Remove the HCIT media tray assembly.
Page 421 5026 Release the hooks (B) securing the pass thru sensor to the top plate assembly. Previous Remove the pass thru sensor from the top plate assembly. Release the harness from the clamps (C). Remove the eight screws (D) securing the elevator motor with sensor to the side frame. Next Go Back Remove the elevator motor with sensor.
Page 422: Hcit Pick Arm Roll Removal
5026 HCIT pick arm roll removal Previous Remove the high-capacity input tray (HCIT) media tray assembly. See “HCIT media tray assembly removal” on page 4-191. Pull the autocompensator pick arm (A) down. Next Go Back Remove the pick arm roll (B) from the pick roll assembly (C). Repeat for the other pick arm roll (D).
Page 423: Hcit Slide Assembly With Spring Removal
5026 HCIT slide assembly with spring removal Previous Remove the HCIT controller board assembly. See “HCIT controller board assembly removal” on page 4-197. Disconnect the two springs (A) from the frame. Note: Leave the springs attached to the cam size sensing plate (B) and the actuator switch. Next Slide the cam size sensing plate (B) through the access hole in the rear side frame.
Page 424 5026 Remove the four screws (E) securing the card mount option to the frame. Previous Next Go Back Remove the card mount option. Installation note: Place the card mount option into position, and secure it with the four screws. Reinstall the media size actuator to the card mount option. Reinstall the actuator switch with spring through the inside of the drawer.
Page 425: Photointerrupter Sensor With Cable Assembly Removal
5026 Photointerrupter sensor with cable assembly removal Previous Remove the high-capacity input tray (HCIT) right cover. See “HCIT right cover removal” on page 4-194. Disconnect the photointerrupter sensor cable connector (A) from the HCIT controller board. Next Go Back Turn the drawer rear side down, and use 4.0 mm wrench to remove the four Allen screws (B) securing the counterweight to the rear frame.
Page 426: Top Plate Assembly Removal
5026 Remove the screw (C) securing the sensor to the rear frame, and then release the hooks (D). Previous Note: Remove the cable from the restraint, and observe the routing for reinstallation. Next Go Back Remove the photointerrupter sensor with cable assembly. Top plate assembly removal Remove the high-capacity input tray (HCIT) right cover.
Page 427 5026 Release the hooks (B) securing the pass thru sensor from the top plate assembly. Previous Remove the fourteen screws (C) securing the top plate assembly to the frame. Next Go Back Remove the top plate assembly. Repair information 4-205...
Page 428 5026 Previous Next Go Back Service Manual 4-206...
Page 429: Connector Locations
5026 5. Connector locations Previous Locations Next Go Back Connector locations...
Page 430: Connectors
5026 Previous Connectors System board diagram JFUSER1 JHVPS1 JBLW1 JBIN1 Next JOPP1 JSB1 JFAN1 JBOR1 JMIRR1 JCVR1 Go Back JLVPS2 JCARTP1 JCARTS1 JBOOT1 JUSB1 JDIMM1 JCARTS2 JTLBT1 JCARTP2 JFMUSB1 JTWF1 JTDBUG1 JDVR1 JTPS1 JOPT1 JDX1 JFDS1 JINT1 JFDPCK1 JTRAY1 JSEC1 JPH1 JT12 Service Manual...
Page 431 5026 Previous System board listing “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal Next Ground Internal Service Port (ISP) USBOUT+ Go Back USBOUT- Ground USBIN+ USBIN- Ground RESET +5 V dc I2C_DAT +5 V dc I2C_CLK +5 V dc D_PHY_TX+...
Page 432 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JBLW1 S_BLOW_FG Cartridge blower Next V18_BLOW_RTN BLT_BLOW_FB JBOOT1 +3.3 V dc Go Back +3.3 V dc or Ground JBOR1 V24_BOR- COD BCD motor V24_BOR+ JCARTP1 V48_CART1_WIND_W...
Page 433 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JCFT1 CFT1 Functional tester I/F Next CFT2 Ground CFT3 Go Back CFT4 Ground CFT5 CFT6 JCONF1 PLL_CFG1 +1.8 V dc H Model only PLL_CFG2 JCVR1 V48_25V_CVR...
Page 434 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JFDS1 VS12_FDS Feed thru sensor Next S_FDS_FB Ground JFMUSB1 Ground Go Back Front panel USB port USB_DM1 USB_DP1 Ground JFUSER1 S_FSR_BLT2_SNS GD_FSR_BLT1_RTN Belt, exit, bubble sensors VS_BUB_LED...
Page 435 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JMIRR1 MM_REFR Mirror motor Next TG_MM_LOCK TG_MM_START Ground Go Back +25VC JOPP1 I2C_DATA Operator panel (12C) V12_PANEL+5V I2C_CLK Ground TG_OP_IRQ- +3.3 V dc Ground JOPT1 +25VE...
Page 436 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JPH1 VDO_SYNC_C Printhead Next VDO_PHR_OK VDO_SYNC_B VDO_LENA Go Back TG_VDO_SHADE_D VS12_+3.3VPH TG_VDO_SHADE_C VS12_JPH1 TG_VDO_SHADE_B VS12_JPH1 TG_VDO_SHADE_A Ground D_VDO_D2+ D_VDO_D2- Ground D_VDO_D+ D_VDO_D- Ground D_VDO_C2+...
Page 437 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JPH1 D_VDO_A- Printhead Next Ground (continued) I2C_CLK_PH TG_VDO_LADJ_CD Go Back I2C_DATA_PH TG_VDO_LADJ_AB JSB1 S_SB_Y Cartridge SB Ground S_SB_C Ground S_SB_M Ground S_SB_K Ground JSEC1...
Page 438 5026 System board listing (continued) Previous “System board diagram” on page 5-2. Connector Pin # Signal Pin # Signal JTWF1 Ground Winflex serial port (engine) Next TG_RXD1 TG_TXD1 +5 V dc or Ground Go Back JUSB1 USB_DEV_VBUS_R USB device port USB_DEVD- USB_DEVD+ Ground...
Page 439: Preventive Maintenance
• Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments • Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
Page 440: Cleaning The Printhead Lenses
5026 Cleaning the printhead lenses Previous Clean the printhead lenses when you encounter print quality problems. Open the front access door. Warning: Potential Damage: To avoid overexposing the photoconductor units, do not leave the front door Next open for more than 10 minutes. Remove all four toner cartridges.
Page 441: Parts Catalog
Model information used in the parts catalog: • Abbreviation Machine type Printer name Description used and model 5026-210 Lexmark C734n Network 5026-230 Lexmark C734dn Duplex and network 5026-280 Lexmark C734dnw Duplex, network, and wireless 5026-410 Lexmark C736n Network 5026-430 Lexmark C736dn Duplex and network 5026-439...
Page 442: Assembly 1: Covers
5026 Assembly 1: Covers Previous Next Go Back Service Manual...
Page 443 5026 Assembly 1: Covers Previous Units/ Units/ Index Description mach 1—1 40X5114 Top access cover assembly Next 40X5120 Operator panel buttons parts package, including: • Back button • Menu button • Stop button Go Back • Navigation select button • Navigation up button •...
Page 444: Assembly 2: Front
5026 Assembly 2: Front Previous Next Go Back Service Manual...
Page 445 5026 Assembly 2: Front Previous Units/ Units/ Index Description mach 2—1 40X5093 Fuser assembly, 115 V Next 40X5094 Fuser assembly, 230 V 40X5095 Fuser assembly, 100 V Printer pad, included in parts packet, screws (P/N 40X5136) Go Back 40X1446 Right bellcrank assembly, with spring 40X5132 MP feeder/duplex drive parts packet, including •...
Page 446: Assembly 3: Right
5026 Assembly 3: Right Previous Next Go Back Service Manual...
Page 447 5026 Assembly 3: Right Previous Units/ Units/ Index Description mach 3—1 40X5290 EP drive assembly Next 40X5124 Low-voltage power supply 40X5126 Motor driver card 40X5131 MP feeder/duplex motor Go Back 40X5128 24 V interlock switch 40X5127 5 V interlock switch Parts catalog...
Page 448: Assembly 4: Rear
5026 Assembly 4: Rear Previous Next Go Back Service Manual...
Page 449 5026 Assembly 4: Rear Previous Units/ Units/ Index Description mach 4—1 40X5123 Printhead assembly Next 40X5107 System board support shield 40X5160 System board (network), 210, 230, 280 40X5154 System board (network), 410, 430, 439 Go Back 40X7850 Unique system board to be used only for the following TLIs: 25C0018 and 25C0021 Note: These unique FRU parts are only necessary for these specific TLI releases.
Page 450: Assembly 5: Left
5026 Assembly 5: Left Previous Next (4 places) (4 places) Go Back (4 places) (4 places) (4 places) 1G (4 places) (8 places) Service Manual 7-10...
Page 451 5026 Assembly 5: Left Previous Units/ Units/ Index Description mach 5—1 40X5137 Contact springs kit, including: Next • A—Torsion PCD contact spring • B—Torsion CR contact spring • C—Contact spring cap • D—Charge roll contact spring Go Back • E—HVPS TAR contact spring •...
Page 452: Assembly 6: Top
5026 Assembly 6: Top Previous Next Go Back Units/ Units/ Index Description mach 6—1 40X5122 Color-On-Demand assembly 40X5109 Cooling fan 40X5130 Top cover camshaft assembly 40X5108 Cartridge cooling fan Service Manual 7-12...
Page 453: Assembly 7: Cable Parts Packet
5026 Assembly 7: Cable parts packet Previous Units/ Units/ Index Description mach 7—1 40X5135 Cables parts packet, including Next • A—Cartridge motor 1 to fuser cable (1) • B—Fuser AC cable (1) • C—Fuser DC cable (1) Go Back • D—MP feeder/duplex motor cable (1) •...
Page 454: Assembly 8: Optional 550-Sheet Media Drawer And Tray
5026 Assembly 8: Optional 550-sheet media drawer and tray Previous Next Go Back Units/ Units/ Index Description 8—1 40X5140 550-sheet tray option (drawer and tray assembly) 40X5168 Pick arm roll, 550-sheet tray 40X5141 550-sheet tray assembly Service Manual 7-14...
Page 455: Assembly 9: Optional Special Media Tray Assembly
5026 Assembly 9: Optional special media tray assembly Previous Next Go Back Units/ Units/ Index Description opt. 9—1 40X5142 Special media assembly, including tray 40X5152 Pick arm roll, 550-sheet drawer 40X5143 Special media tray assembly Parts catalog 7-15...
Page 456: Assembly 10: Optional High-Capacity Input Option (Hcit)
5026 Assembly 10: Optional high-capacity input option (HCIT) Previous Next Go Back Service Manual 7-16...
Page 457 5026 Assembly 10: Optional high-capacity input option (HCIT) Previous Units/ Units/ Index Description option 10—1 40X5157 Top plate assembly Next 40X5168 HCIT pick arm roll 40X5156 Feed with bushing 40X5149 HCIT rear cover Go Back 40X4585 Tray latch with spring 40X5159 HCIT controller card assembly 40X4587...
Page 458: Assembly 11: Options And Features
5026 Assembly 11: Options and features Previous Next Go Back Service Manual 7-18...
Page 459 Traditional Chinese font card 40X5970 Simplified Chinese font card 40X5972 Japanese font card 40X0038 Bar code and Forms card 40X5952 Lexmark PrintCryption™ card 40X4826 MarkNet™ N8120 10/1000 40X4827 MarkNet N8130 10/100 fiber 40X4823 Parallel 1284-B interface card adapter 40X4819 Serial interface card adapter 40X4822 80.0 GB hard disk assembly...
Page 460 5026 Previous Next Go Back Service Manual 7-20...
Page 461: Index
5026 Index Previous MP feeder/duplex motor Numerics 4-121 Next operator panel 4-122 1xx service error codes – 2-16 2-18 operator panel ground 4-124 24 V interlock switch option cable 4-125 parts catalog 7-12 transport cable 4-170 Go Back removal 4-47 transport motor cable 4-172 service check...
Page 462 5026 Prt Quality Pages Transfer 3-25 Previous Reset Fuser Cnt Tray 1 3-25 Size Sensing Print Tests 3-26 USB Speed input source tests 3-31 3-10 Wipe Disk Prt Quality Pgs 3-30 3-11 contact springs Printer Setup Next parts catalog Configuration ID 7-10 3-20 cooling fan...
Page 463 5026 2xx paper jams – service check 2-18 2-29 2-128 Previous 3x–8x attendance messages – 2-15 9xx service error codes – 2-30 2-36 jams error jam locations 3-38 clearing jams 3-39 ESD-sensitive parts common messages (diagram) 3-38 event log paper jam messages Next 2-18 configuration menu...
Page 464 5026 parts catalog residual image 2-137 Previous removal solid color page 4-24 2-138 service check vertical banding 2-131 2-139 display all diamonds, 5 beeps white gapping 2-132 2-139 display all diamonds, no beeps printer pads 2-132 display blank, 5 beeps, LED off parts catalog 2-131 Next...
Page 465 5026 high-voltage power supply cable sensors 4-110 Previous left bellcrank bin full 4-111 7-12 low voltage power supply (LVPS) exit sensor service check 4-112 2-127 motor driver cable input sensor service check 4-115 2-128 motor driver card toner level 4-114 4-160 7-10 multipurpose feeder (MPF)/duplex motor cable...
Page 466 5026 Servo Laser Test 3-18 Previous Size Sensing 3-26 waste toner assembly, removal 4-174 skew Wipe Disk 3-30 duplex skew test 3-16 wireless network antenna 4-175 printhead alignment 4-138 wireless network card 4-189 specifications Next dimensions start Static Sensor Tests 3-17 symptoms Go Back...
Page 467: Part Number Index
5026 Part number index Previous Description Page Next 40X0038 Bar code and Forms card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19 40X0063 Card for IPDS and SCS/TNe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 468 5026 40X5119 Top access cover links (slider cam) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous 40X5120 Operator panel buttons parts package - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 469 5026 40X5970 Simplified Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19 Previous 40X5971...
Page 470 5026 Previous Next Go Back Service Manual I-10...

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C734n Cs736dn C734dnw C736n C736dn