Lexmark C93x, C93, C935 Service Manual

Edition: May 13, 2009

• Table of contents

• Start diagnostics

Lexmark™C93x Printer

5057-XXX

• 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.

Edition: May 13, 2009
The following paragraph does not apply to any country where such prov isions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [e-mail]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you.

References in this publication to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or
imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
user’s responsibility.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States
and/or other countries.

PCL® is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of the i r resp ective owners.

© 2007 Lexmark International, Inc.

All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.

5057-XXX

P/N 12G9765

5057-XXX

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Laser notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Size and weight — without finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Basic model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Configured model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Printer theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SFP paper path rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SFP sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Rear media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

End guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Detection of media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media feed unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media feed/lift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Sensor (media out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Sensor (media level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Sensor (feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Multi-purpose feeder (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

MPF feed roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

MPF pick solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Sensor (MPF media out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Sensor (MPF media width) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Sensor (registration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Sensor (transparency detect) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Registration clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Media transport roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Registration roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Transfer belt drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Transfer belt cleaning assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Transfer belt unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Transfer belt steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2nd transfer roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2nd transfer roll retract motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Sensor (2nd transfer roll HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Printhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Printhead shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

iii

5057-XXX

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

Heat roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

Pressure belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Heater lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Front thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Rear thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Fuser exit sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Standard media exit roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Sensor (standard bin full) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Standard media exit shift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -19

Duplex diverter gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

K developer/transport drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

MPF/transport drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

CMYK PC cartridge drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

CMY developer drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21

K developer clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -21

CMYK toner add motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21

Waste toner agitator motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Electrical components and controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Switch (main power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Finisher AC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Switch (printer front door interlock) and switch (printer left door interlock) . . . . . . . . . . . . . . . .1-22

Switch (printer left lower door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Fuser cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

AC drive card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

5V LVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

24V LVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

CMYK transfer roll HVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Developer roll HVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Charge roll HVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Upper printer engine card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Lower printer engine card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

RIP card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Media size control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Printhead control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Rotation of printhead motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Determination of printhead ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Printhead reference value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Fuser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Fuser control method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Main/sub heater lamps on/off control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Fuser warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Xerographic process during a print cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27

Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -29

Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31

Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31

Auto density sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

TTM theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -33

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35

Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35

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Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

Rear media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Tray 2 media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Tray 3 or 4 media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

TTM media feed units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Media feed unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Media feed lift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Switch (TTM media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Sensor (media out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Sensor (media level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Switch (tray module left door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Sensor (tray 2 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Sensor (tray 3 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Sensor (tray 4 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Tray module media transport roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Tray module drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

TTM tray 4 media transport motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

TTM controller card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

Switch (TTM media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

3TM theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

Rear media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Tray 2, 3, 4 media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

3TM media feed units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Media feed unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Media feed lift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Sensor (media out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Sensor (media level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Switch (tray module left door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Sensor (tray 2 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Sensor (tray 3 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Sensor (tray 4 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Tray module media transport roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

Tray module drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

3TM controller card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

1TM theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

Rear media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Tray 2 media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

1TM media feed units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Media feed unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Media feed lift motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

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Sensor (media out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53

Sensor (media level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53

Switch (tray module left door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53

Sensor (tray 2 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-54

Tray module media transport roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -54

Tray module drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-54

1TM controller card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-54

Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-55

Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-56

Layout of media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57

Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57

Switch (duplex left door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57

Sensor (duplex wait) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57

Duplex media transport roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57

Duplex controller card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-58

Duplex drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-58

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-60

Diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Confirm the installation status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Power-on Reset sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

To enter the diagnostic menu: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

200.00 Sensor (registration) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

200.01 Sensor (registration) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

200.02 Sensor static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

200.03 Sensor (media on belt) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

201.00 Sensor (fuser exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

202.00 Sensor (fuser exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

230.00 Sensor (duplex wait) late jam (duplex media feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

231.00 Sensor (registration) late jam (duplex feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

231.01 Sensor (registration) late jam (duplex media feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

241.00 Sensor (tray 1 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

242.00 Sensor (tray 2 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

242.01 Sensor (tray 1 feed-out) late jam (feeding from tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

243.00 Sensor (tray 3 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

243.01 Sensor (tray 2 feed-out) late jam (feeding from tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

244.00 Sensor (tray 4 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

244.01 Sensor (tray 3 feed-out) on jam (feeding from tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

250.00 Sensor (registration) late jam (feeding from the MPF) . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Black toner cartridge detection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

<Color> toner cartridge detection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Incorrect black toner cartridge error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Incorrect <color> toner cartridge error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Tray 1 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Tray 2 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Tray 3 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Tray 4 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Tray 1 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Tray 2 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Tray 3 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Tray 4 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

841.00 Image pipeline ASIC error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

849.00 Hard drive/configuration ID mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

900.XX RIP card assembly software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

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901.xx RIP card assembly software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

902.00 General upper engine error fuse #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

902.01 General upper engine error fuse #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

902.02 General upper engine error fuse #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

902.03 General lower engine error fuse #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

902.04 General lower engine error fuse #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

902.05 General lower engine error fuse #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

902.06 General lower engine error fuse #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

902.07 General lower engine error fuse #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

903.00 K developer/transport drive assembly motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

903.01 K PC drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

903.02 CMY PC drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

903.03 Developer drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

904.00 Sensor (transfer belt HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

904.01 Transfer belt position failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

904.02 Sensor (transfer belt edge) failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

904.03 Sensor (2nd transfer roll retract HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

904.04 Sensor (2nd transfer roll retract HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

904.05 Sensor (CMY transfer roll retract HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

904.06 Sensor (CMY transfer roll retract HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

904.07 CMY transfer roll retract motor time out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

905.00 NVM read/write cannot be executed error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

905.01 Marking device video error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

905.02 Marking device Xerographics error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

905.03 Marking device other1 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

905.04 Marking device paper handling error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

905.05 Marking device other2 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

907.00 Printhead polygon mirror motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

907.01 Y laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

907.02 C laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

907.03 M laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

907.04 K laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

907.05 Printhead control error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

908.00 Waste toner full error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

911.00 24V LVPS cooling fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

911.01 Transfer belt drive motor cooling fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

911.02 Fuser cooling fan lock error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

918.00 Standard media exit shift error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

920.00 Fuser main lamp overheat error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

920.01 Front thermistor disconnection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

920.02 Fuser sub lamp overheat error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

920.03 Rear thermistor disconnection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

920.04 Main lamp warm up error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

920.05 Main lamp on-time error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

920.06 Sub lamp warm-up failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

920.07 Sub lamp on-time error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

924.00 Yellow toner RFID communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

924.01 Magenta toner RFID communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

924.02 Cyan toner RFID communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

924.03 Black toner RFID communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

925.00 Sensor (Y ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

925.01 Sensor (M ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

925.02 Sensor (C ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

925.03 Sensor (K ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

940.00 MPF tray 5 size sensing error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

941.00 Switch (media size) size sensing error (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

941.01 Sensor (media level) late error (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

942.00 Switch (media size) size sensing error (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

942.01 Sensor (media level) late error (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

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943.00 Switch (media size) size sensing error (tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95

943.01 Sensor (media level) late error (tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96

944.00 Switch (media size) size sensing error (tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97

944.01 Sensor (media level) late error (tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-98

950.00 through 950.29 EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99

950.30 through 950.60 EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-100

951.XX RIP card assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-101

952.XX Interconnect card assembly NVRAM CRC failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-101

953.XX Operator panel assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102

954.XX Interconnect card assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102

955.XX RIP card assembly NAND CRC failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-103

956.00 RIP card assembly processor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-103

956.01 RIP card assembly processor over temperatur e failure . . . . . . . . . . . . . . . . . . . . . . . .2-103

956.02 RIP card assembly cooling fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-104

956.03 RIP card assembly FPGA failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-104

980.00 Communication error with 1TM, 3TM, or TTM assembly . . . . . . . . . . . . . . . . . . . . . . . .2-104

980.01 HVPS controller communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-105

980.02 Communication error between printer and RIP card assembly . . . . . . . . . . . . . . . . . . .2-106

980.03 Communication error with finisher controller card assembly . . . . . . . . . . . . . . . . . . . .2-106

1TM, 3TM or TTM left door assembly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-107

Duplex left door assembly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-108

Media size mismatch in width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109

Media size mismatch in width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109

No media in the selected media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-110

Paper is installed (short edge) in the media paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112

PC cartridge end of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112

Printer front door assembly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-113

Printer left door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-114

Transfer belt access door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115

Printer left lower door assembly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115

100K maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-116

600K maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-116

ADF maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117

Standard media bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117

Toner cartridge error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117

Toner cartridge set error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118

Waste toner cartridge full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118

Waste toner cartridge not detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119

Waste toner cartridge nearly full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-120

(Color) PC cartridge not detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-120

(Color) PC cartridge invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121

CMY PC cartridges nearly exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121

CMY PC cartridges exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

K PC cartridge nearly exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

K PC cartridge exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

(Color) toner cartridge nearly empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123

(Color) toner cartridge empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-124

Image quality trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126

Printer Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-126

Image quality symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-126

Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127

Faint print (Low contrast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127

Blank print (no print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solid black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-131

Vertical lines and bands (process direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-132

Horizontal white stripes or bands (side to side direction) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-134

Vertical stripes (process direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136

Horizontal stripes (side to side direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138

Partial lack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-140

. . . .2-129

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Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142

After image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143

Background (fog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147

Media damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149

No fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-151

Color misregistration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152

Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153

High frequency bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Entering Diagnostics Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MOTOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Input Source Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Sensor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Sensor Test (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Feed Tests (output bins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Feed To All Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Sensor Test (output bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

FINISHER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Staple Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Hole Punch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Feed Tests (Finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Sensor Test (Finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

BASE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

PAGE COUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Engine Setting 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Display the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Print the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Clear the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Trans Belt HP Fail Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Dev Unit Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Fuser Temp Fail Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

ATC SENSOR FAILURE CLEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

ENGINE ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Color registration (RegCon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Booklet Fold Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Finisher Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

ix

5057-XXX

Exiting Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Maintenance Counter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Reset Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Black Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Print Quality Pages (Configuration Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

A5/Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

B5/Executive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

EVENT LOG (Configuration Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Envelope Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Require Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Short Edge Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Tray Low Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Exiting Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Repeating defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Before starting service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Printer front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Right cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Rear cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Rear left middle cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Rear left upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Printer left lower door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

MPF feed unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Front left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Duplex media inverter assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Duplex unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Sensor (duplex wait) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Switch (duplex left door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Duplex media exit turn guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Duplex drive motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Duplex controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Fuser unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Transfer belt unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Transfer belt cleaning assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Standard media exit shift assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Standard media exit bin full actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Switch (printer left door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Sensor (standard media bin full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Media feed unit assembly 1 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Sensor (media level) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Sensor (fuser exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Printer left door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Printer left door damper removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Sensor (media on belt) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

x Printer Service Manual

5057-XXX

2nd transfer roll retract cam assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Sensor (2nd transfer roll retract HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

2nd transfer roll retract motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

2nd transfer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Registration / transport roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Registration clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Sensor (registration) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Sensor (transparency detect) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Waste toner cartridge cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Waste toner cartridge sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Sensor (waste toner cartridge full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Switch (waste toner cartridge interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Inner cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Waste toner agitator motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

PC cartridge unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Image density sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -44

CMY toner add assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

K toner add assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Developer interlock plate assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Developer unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Developer carrier removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Photoconductor (PC) unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Transfer belt lift latch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Transfer belt steering motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

CMY erase lamp assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

K erase lamp assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Printhead shutter motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Switch (printer front door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Sensor (printer left lower door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

RIP card cooling fan cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Controller box assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 72

Switch (main power) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Bridge card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

RIP card access cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

RIP card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Hard drive removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Interconnect card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Upper printer engine card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Upper printer engine card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Lower printer engine card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Lower printer engine card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Transfer belt drive motor cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Transfer belt drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Switch (transfer belt access door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Laser diode power card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

24V LVPS card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

24V LVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88

5V LVPS card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88

5V LVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89

24V LVPS cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89

Rear lower cooling fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

CMY developer drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91

CMYK PC cartridge drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91

Fuser cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Main power switch actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CMYK toner add motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

CMYK transfer HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

Printhead assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

Transfer belt waste toner auger assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

. 4-93

xi

5057-XXX

K developer / transport drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-97

K developer clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100

AC drive card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100

Noise filter assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-101

Rear upper cooling fan bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102

Rear upper cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-103

Developer / transfer roll HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104

Charge roll HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-105

MPF / transport drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-106

Feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-107

Pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-108

Separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-109

Sensor (RFID toner cartridge) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-110

Fuser exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111

MPF media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111

Sensor (MPF media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-112

MPF pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-112

Media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-114

Switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-115

2000-sheet dual input (TTM) removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116

2000-sheet dual input (TTM)–top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116

2000-sheet dual input (TTM)–foot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116

2000-sheet dual input (TTM)–right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-117

2000-sheet dual input (TTM)– tray module left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-117

2000-sheet dual input (TTM)–rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-118

2000-sheet dual input (TTM)–caster removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-118

2000-sheet dual input (TTM)–tray support roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

2000-sheet dual input (TTM)–TTM media tray 4 assembly removal . . . . . . . . . . . . . . . . . . . . .4-121

2000-sheet dual input (TTM)–TTM media tray 3 assembly removal . . . . . . . . . . . . . . . . . . . . .4-122

2000-sheet dual input (TTM)–tray 3 front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

2000-sheet dual input (TTM)–tray 3 rear cable assembly removal . . . . . . . . . . . . . . . . . . . . . .4-123

2000-sheet dual input (TTM)–tray 3 front cable assembly removal . . . . . . . . . . . . . . . . . . . . .4-125

2000-sheet dual input (TTM)–media tray 4 front cover removal . . . . . . . . . . . . . . . . . . . . . . . .4-126

2000-sheet dual input (TTM)–TTM tray 4 media transport assembly removal . . . . . . . . . . . .4-126

2000-sheet dual input (TTM)–tray 4 rear cables removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-126

2000-sheet dual input (TTM)–tray 4 front cables removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-129

2000-sheet dual input (TTM)–media feed unit assembly removal (tray 4) . . . . . . . . . . . . . . . .4-130

2000-sheet dual input (TTM)–sensor (tray 4 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . .4-132

2000-sheet dual input (TTM) switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-133

2000-sheet dual input (TTM)–switch (TTM media size) removal . . . . . . . . . . . . . . . . . . . . . . . .4-134

2000-sheet dual input (TTM)–media feed unit assembly 2 removal . . . . . . . . . . . . . . . . . . . . .4-135

2000-sheet dual input (TTM)–media feed unit assembly removal (tray 3) . . . . . . . . . . . . . . . .4-135

2000-sheet dual input (TTM)–sensor (tray 3 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . .4-137

2000-sheet dual input (TTM)–sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . .4-138

2000-sheet dual input (TTM)–media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-138

2000-sheet dual input (TTM)–one-way clutch / gear assembly removal . . . . . . . . . . . . . . . . .4-140

2000-sheet dual input (TTM)–media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-142

2000-sheet dual input (TTM)–sensor (media level) removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-143

2000-sheet dual input (TTM)–sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-144

2000-sheet dual input (TTM)–feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-145

2000-sheet dual input (TTM)–feed roll one-way clutch removal . . . . . . . . . . . . . . . . . . . . . . . .4-146

2000-sheet dual input (TTM)–one-way 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-147

2000-sheet dual input (TTM)–separation roll one-way friction clutch removal . . . . . . . . . . . .4-148

2000-sheet dual input (TTM)–separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-149

2000-sheet dual input (TTM)–pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-151

2000-sheet dual input (TTM)–left door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-152

2000-sheet dual input (TTM)–switch (TTM left door interlock) removal . . . . . . . . . . . . . . . . . .4-153

2000-sheet dual input (TTM)–tray 3 lift gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . .4-154

2000-sheet dual input (TTM)–tray 4 lift gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . .4-154

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2000-sheet dual input (TTM)–tray lift coupling assembly removal . . . . . . . . . . . . . . . . . . . . . 4-155

2000-sheet dual input (TTM)–tray module drive motor assembly removal . . . . . . . . . . . . . . 4-155

2000-sheet dual input (TTM)–TTM tray 4 transport motor removal . . . . . . . . . . . . . . . . . . . . . 4-157

2000-sheet dual input (TTM)–TTM controller card assembly removal . . . . . . . . . . . . . . . . . . 4-157

3X 500-sheet drawer (3TM) removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158

3X 500-sheet drawer (3TM)–top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158

3X 500-sheet drawer (3TM)–foot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-159

3X 500-sheet drawer (3TM)–right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-159

3X 500-sheet drawer (3TM)–tray module left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-160

3X 500-sheet drawer (3TM)–rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-160

3X 500-sheet drawer (3TM)–caster removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-161

3X 500-sheet 3TM)–media feed unit assembly removal (tray 4) . . . . . . . . . . . . . . . . . . . . . . . 4-161

3X 500-sheet drawer (3TM)–sensor (tray 4 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-162

3X 500-sheet drawer (3TM)–sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-163

3X 500-sheet drawer (3TM)–switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164

3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 3) . . . . . . . . . . . . . . . . 4-165

3X 500-sheet drawer (3TM)–media feed unit assembly removal (tray 2) . . . . . . . . . . . . . . . . 4-167

3X 500-sheet drawer (3TM)–sensor (tray 3 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-168

3X 500-sheet drawer (3TM)–media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169

3X 500-sheet drawer (3TM)–one-way clutch / gear assembly removal . . . . . . . . . . . . . . . . . . 4-170

3X 500-sheet drawer (3TM)–media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171

3X 500-sheet drawer (3TM)–sensor (media level) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-172

3X 500-sheet drawer (3TM)–sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173

3X 500-sheet drawer (3TM)–feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-174

3X 500-sheet drawer (3TM)–feed roll one-way clutch removal . . . . . . . . . . . . . . . . . . . . . . . . 4-175

3X 500-sheet drawer (3TM)–one-way 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-176

3X 500-sheet drawer (3TM)–separation roll one-way friction clutch removal . . . . . . . . . . . . 4-177

3X 500-sheet drawer (3TM)–separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-178

3X 500-sheet drawer (3TM)–pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180

3X 500-sheet drawer (3TM)–3TM left door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-181

3X 500-sheet drawer (3TM)–switch (tray module left door interlock) removal . . . . . . . . . . . . 4-181

3X 500-sheet drawer (3TM)–tray module drive motor assembly removal . . . . . . . . . . . . . . . 4-182

3X 500-sheet drawer (3TM)–3TM controller card assembly removal . . . . . . . . . . . . . . . . . . . 4-183

1X 500-sheet drawer (1TM) removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184

1X 500-sheet drawer (1TM)–top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184

1X 500-sheet drawer (1TM)–foot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185

1X 500-sheet drawer (1TM)–right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185

1X 500-sheet drawer (1TM)–tray module left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186

1X 500-sheet drawer (1TM)–rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186

1X 500-sheet drawer (1TM)–caster removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-187

1X 500-sheet drawer (1TM)–media feed unit assembly removal (tray 2) . . . . . . . . . . . . . . . . 4-187

1X 500-sheet drawer (1TM)–sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-188

1X 500-sheet drawer (1TM)–switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189

1X 500-sheet drawer (1TM)–media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-190

1X 500-sheet drawer (1TM)–one-way clutch / gear assembly removal . . . . . . . . . . . . . . . . . . 4-190

1X 500-sheet drawer (1TM)–media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192

1X 500-sheet drawer (1TM)–sensor (media level) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-193

1X 500-sheet drawer (1TM)–sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194

1X 500-sheet drawer (1TM)–feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-195

1X 500-sheet drawer (1TM)–feed roll one-way clutch removal . . . . . . . . . . . . . . . . . . . . . . . . 4-196

1X 500-sheet drawer (1TM)–one-way 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-197

1X 500-sheet drawer (1TM)–separation roll one-way friction clutch removal . . . . . . . . . . . . 4-198

1X 500-sheet drawer (1TM)–separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-199

1X 500-sheet drawer (1TM)–pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-200

1X 500-sheet drawer (1TM)–tray module left door assembly removal . . . . . . . . . . . . . . . . . . 4-201

1X 500-sheet drawer (1TM)–switch (tray module left door interlock) removal . . . . . . . . . . . . 4-202

1X 500-sheet drawer (1TM)–tray module drive motor assembly removal . . . . . . . . . . . . . . . 4-203

1X 500-sheet drawer (1TM)–1TM controller card assembly removal . . . . . . . . . . . . . . . . . . . 4-203

Setup and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-204

xiii

5057-XXX

Sensor (ATC) setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-204

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-205

Color registration (RegCon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-208

Measurement cycle test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-209

Control sensor check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-210

Control sensor cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-210

Belt edge learn test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-211

Skew fine setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-211

In/out setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-216

Center setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-220

Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Parts catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Assembly 4: PC cartridge and developer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 5: ID sensor and transfer belt steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Assembly 6: Media tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 7: Printer left lower door and media feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Assembly 8: Media feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 9: MPF feed unit assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 10: MPF feed unit assembly 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Assembly 11: MPF feed unit assembly 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 12: Registration / transport roll assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Assembly 13: Printer left door and duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 14: Printer left door assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Assembly 15: Printer left door assembly 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 16: Duplex media inverter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Assembly 17: Duplex 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 18: Standard media exit shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Assembly 19: Printhead assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 20: Xerographic and waste toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Assembly 21: Erase lamps and developer interlock plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 22: Transfer belt lift 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Assembly 23: Transfer belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 24: Transfer belt lift 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Assembly 25: Toner Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 26: Developer unit assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Assembly 27: Fuser assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 28: Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Assembly 29: Electrical 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 30: Electrical 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 31: Electrical 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Assembly 32: Electrical 4

Assembly 33: 1TM covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

Assembly 34: 1TM feed unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 35: 1TM media feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Assembly 36: 1TM left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Assembly 37: 1TM drive and electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

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Assembly 38: 3TM covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

Assembly 39: 3TM feed unit assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

Assembly 40: 3TM media feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

Assembly 41: 3TM left door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

Assembly 42: 3TM drive and electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55

Assembly 43: TTM covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

Assembly 44: TTM media trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

Assembly 45: TTM media tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

Assembly 46: TTM media tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

Assembly 47: TTM media tray 4 transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

Assembly 48: TTM media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

Assembly 49: TTM left door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

Assembly 50: TTM tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

Assembly 51: TTM drive and electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67

Assembly 52: Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

xv

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xvi Printer Service Manual

Notices and safety information

The following laser notice labels may be affixed to this printer.

Laser notice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Cla ss I (1)
laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC
60825-1.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

5057-XXX

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung,
die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant
les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1
relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est
équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont
conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 77 0 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.

Notices and safety information xvii

5057-XXX

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1)
establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en
los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de
Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a
795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse
afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR
Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto
laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de
comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma
a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I
durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten
zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

xviii Printer Service Manual

Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) ­lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.

Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan
5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen
ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luok an IIIb (3b) 5
milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on
suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin
toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.

5057-XXX

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av
en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för
laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan
föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Notices and safety information xix

5057-XXX

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe
I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795
nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la
radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.

xx Printer Service Manual

5057-XXX

Notices and safety information xxi

5057-XXX

xxii Printer Service Manual

Safety information

• The safety of this product is based on testing and approvals of the original design and specific

components. The manufacturer is not responsible for safety in the event of use of unauthorized
replacement parts.

• The maintenance information for this product has been prepared for use by a professional service person

and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during disassembly and servicing of

this product. Professional service personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the

product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume
aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve
de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

5057-XXX

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle
parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.

• A TTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.

Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.

Safety information xxiii

5057-XXX

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und

bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in die se m

Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten
an den Strom angeschlossen sein muß.

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones
necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes

específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição
não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e feriment os graves durante a desmontagem e manutenção deste produto.

Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para
realizar a tarefa necessária.

xxiv Printer Service Manual

Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components

específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està

destinada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.

5057-XXX

Safety information xxv

5057-XXX

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution indicates there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you be gin, or use caution if the
product must receive power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution indicates a tipping hazard.

Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to

repair it. Special tools and test equipment, as well as general environmental and safety instructions, are
discussed.

2. Diagnosti c in format ion contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair information provides instructions for making printer adjustments and removing and installing

FRUs.

5. Connector locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to prevent

problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Appendix A contains service tips and information.
Appendix B contains representative print samples.

Conventions

Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.

There are several types of caution statements:

xxvi Printer Service Manual

1. General information

The Lexmark™ C935 is color laser printer. All information in this service manual pertains to both models unless
explicitly noted.

Printer technology

• Color laser

Processor

• 1.25 GHz

Memory

• Standard: 512 MB

• Maximum: 1024 MB

• Hard Drive: 80 GB

Acoustics

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All measurements were made in accordance with ISO 7779 and reported in conformance with ISO 9296.

Mode Sound pressure level (dBA) Sound power level (Bels)

Printing 52 6.9
Copying 53 7.2
Scanning

Standby mode

Environment

Specified operating environment

Operating temperature 15.6 C to 32.2 C (6o to 90°F
Relative humidity 8% to 80%
Altitude 2,500 meters (8,200 feet)

Connectivity

• Standard - USB and internet

• Optional - parallel and serial

Size and weight — without finisher

• Size: H x W x D — 42 x 27 x 25 in. (1153 x 660 x 810 mm)

• Weight: 383 lb. (174 kg)

54
32

7.0

General information 1-1

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Duplex unit

Multipurpose
feeder
(MPF)

Tray 1 and tray 2
(500 sheet trays)

Tray 3 and tray 4
850+1150 sheet dual
input tray (TTM)

Operator
panel

ADF

Printer overview

CAUTION: Do not set up this product or make any electrical or cabling connections, such as the

power cord or options and features, during a lightning storm.

Basic model

The following illustration shows a printer with its base features.

1-2 Printer Service Manual

Configured model

Finisher*

Bridge unit*
(Used in conjunction
with finisher)

Duplex unit

Multipurpose
feeder
(MPF)

Tray 1 and tray 2
(500 sheet trays)

Tray 3 and tray 4
850+1150 sheet dual
input tray (TTM)

Operator
panel

ADF

The following illustration shows a fully configured printer. Items denoted with an asterisk (*) are options.

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General information 1-3

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MPF

MPF pick roll

MPF Transport Roll ASM

MPF ASM

Media feed

unit ASM

Media feed

unit ASM

Pick roll

Pick roll

Separation roll

Separation roll

Feed roll

Media transport roll ASM

Tray 1

Tray 2

Feed roll

Registration roll ASM

2nd Transfer roll ASM

Transfer belt

Heat roll

Pressure belt

Fuser unit ASM

Fuser media

exit roll assembly

Duplex mediatransport roll ASM

Standard

media exit

Media feed

unit ASM

Pick roll

Separation roll

Tray 3

Feed roll

Media feed

unit ASM

Pick roll

Separation roll

Tray 4

Feed roll

Print exit

Standard media exit roll assembly

Printer theory

Media transport

Media transport path

Media is supplied from the MPF , tray 1, 2, 3 or 4, and is transported to the printer along the media transport path
shown below.

1-4 Printer Service Manual

SFP paper path rolls

MPF

Tray 1

Registration roll assembly

Bridge unit assembly
(included with finisher)

Standard media exit
roll assembly

Fuser exit
roll assembly

Duplex media
transport roll

assembly

Fuser

Finisher

(optional)

Booklet maker unit
(optional)

Finisher media entrance
roll assembly

Upper media exit
roll assembly

Upper media
transport roll assembly

Buffer roll assembly

Lower media exit
roll assembly

Booklet media
transport roll assembly

Booklet media
entrance roll assembly

Booklet media
exit roll assembly

Booklet folding
roll assembly

Media eject
roll assembly

2nd transfer roll assembly

MPF pick roll

Media transport roll assembly

Tray 2
Tray 3
Tray 4

3TM (optional)

Tray module transport
roll assembly

1TM (optional)

Tray 2

Tray module transport
roll assembly

Tray 2

Tray 3

Tray 4

TTM

Tray 4 transport roll assembly

Pick roll

Feed roll

Separation roll

Bridge unit bin exit
roll assembly

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General information 1-5

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MPF

Tray 1

Sensor (fuser exit)

Sensor (media on belt)

Sensor (duplex wait)

Sensor (tray 1 feed out)

Sensor (registration)

Sensor (bridge unit
media entrance)

Sensor (bridge
unit media exit)

Sensor (standard
bin media full)

Tray 2

1TM (optional)

Sensor (tray 2 feed out)

Sensor (bridge unit
media bin exit)

Tray 2

Tray 3
Tray 4

3TM (optional)

Sensor (tray 3 feed out)

Sensor (tray 2 feed out)

Sensor (tray 4 feed out)

Tray 2

Tray 3

Tray 4

TTM (optional)

Sensor (tray 3 feed out)

Sensor (tray 2 feed out)

Sensor (tray 4 feed out)

Fuser

Sensor (upper
media bin full)

Sensor (compiler
media in)

Finisher

(optional)

Booklet maker unit
(optional)

Sensor (diverter gate)

Sensor (buffer path)

Sensor (finisher
media entrance)

Sensor (upper media exit)

Sensor (lower
media exit)

Sensor (booklet
media entrance)

Sensor (booklet
media exit)

SFP sensors

Functions of main components

• Media tray assembly

• Media feed unit assembly

• MPF

• Xerographics

• Transfer

• Fuser

• Drive

• Electrical components and rolls

Media tray assembly

It is necessary to adjust the media tray rear guide and media tray end guide of the media tray assembly to match
the media size.

1-6 Printer Service Manual

Rear media guide

Rear media guide

Bottom plate

End guide

The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear.
The rear guide come into contact with the media and hold it in position.

End guide

The media tray assembly is designed so it can adapt to the media length in the media feed direction by moving
the end guide to the left or right.

Bottom plate

The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed uni t
assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to
come in contact with the pick roll.

Media tray assembly

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Detection of media size

The media size set for the media tray assembly is transmitted to the switch (media size) by moving these guides.
The media size is detected by the on/off information of these switches.

Media feed unit assembly

Since tray 1 and tray 2 are functionally equivalent in terms of the switch (media size), sensor (media out),
sensor (media level) and sensor (pre-feed), only the components of one tray are described here.

The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer.
The driving force, from the media feed lift motor on the media feed unit assembly, is transmitted to the three
media feed rolls to feed media.

When the pick roll picks up media, the remaining media decreases, and the actuator of the sensor (media level)
lowers accordingly. When the sensor (media level) detects the lowering, the media feed lift motor is activated to
lift the lift up shaft and the bottom plate accordingly. Thus, the remaining media is ready to be fed.

General information 1-7

5057-XXX

Media feed lift motor

Sensor

(media level)
Sensor
(media out)

Media feed unit asm

Front

Tray asm

Switch
(media size)

Media feed/lift motor

This motor is activated to feed media and to lift the bottom plate. When feeding media, it rotates forward to drive the
pick roll. When lifting the bottom plate, it rotates reversely to drive the tray module gears to lift the lift up shaft.

Switch (media size)

This switch (media size) sets the size of media supplied from each media tray assembly. A signal indicating the
media size is transmitted as a voltage to the pr in te r engine card assembly.

Sensor (media out)

If media runs out in a media tray assembly, the actuator lowers and the actuator flag, unlocks the sensing area of
the sensor (media out). The sensor light is transmitted. When the sensing area is blocked (media is presen t), the
signal is off.

Sensor (media level)

This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of the
actuator unblocks the sensing area of the sensor (media level), the sensor detects that the media has been lifted.

Sensor (feed-out)

This sensor detects the media just after it is fed from the media feed unit. When the flag of the actuator unblocks the
sensing area of the sensor (feed-out), the sensor detects that the media is present. The sensor (feed-out) is also
used as a relay sensor along the media path up to the sensor (registration) in order for the engine to monitor media
location.

1-8 Printer Service Manual

Multi-purpose feeder (MPF)

MPF pick solenoid

MPF pick rolls

Sensor (MPF media out)

Sensor (MPF media width)

The MPF is a mechanical unit suppling media to the printer. The driving force from the MPF/transport drive

motor is transmitted to the MPF feed roll to feed media.

MPF feed roll

The MPF feed rolls feed media set on the MPF and into the printer.

MPF pick solenoid

The MPF pick solenoid transmits the driving force from the MPF/transport drive to the MPF feed rolls.

Sensor (MPF media out)

The sensor (MPF media out) detects whether media is present on the MPF.

Sensor (MPF media width)

The MPF side guides detects the width (length in the main scanning direction) of media on the MPF.

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Media size

The following table details the standard paper and envelope sizes supported by the Lexmark C935, and options.

Media Width Length

A4 210 mm 297 mm

A5 148 mm 210 mm
A3 297 mm 420 mm
JIS B5 182 mm 257 mm
JIS B4 257 mm 364 mm
Letter 8.5 inches 11 inches
Tabloid 11 inches 17 inches
Legal 8.5 inches 14 inches
Executive 7.25 inches 10.5 inches

General information 1-9

5057-XXX

Media Width Length

Folio 8.5 inches 13 inches
Statement 5.5 inches 8.5 inches
Universal

MPF only

7 3/4 Envelope 98.4 mm

10 Envelope 104.8 mm

DL Envelope 110 mm

CS Envelope 162 mm

Other Envelope 89 mm to 297 mm

Transparencies (Letter and A4) 8.5 inches

140 to 297 mm

5.5 to 11.7 inches
105 to 305 mm

4.1 to 12 inches

3.875 inches

4.12 inches

4.33 inches

6.38 inches

3.5 to 11.7 inches

210 mm

98.4 to 432 mm

3.9 to 17 inches
148 to 482 mm

5.8 to 19 inches

190.5 mm

7.5 inches

241.3 mm

9.5 inches
220 mm

8.66 inches
229 mm

9.01 inches

98.4 to 431 mm

3.8 to 17 inches
11 inches

297 mm

Registration

Sensor (registration)

The sensor (registration) is located just before the registration roll assembly can detect whether media exists in
the registration path.

Sensor (transparency detect)

This sensor is used to detect transparency media in order to automatically adjust feed speed, charge biases and
fuser temperatures.

Registration clutch

The registration clutch transmits the drive force of the K developer/transport drive motor to the registration roll
assembly.

Media transport roll assembly

The media transport roll assembly feeds paper from tray 2, tray 3 and tray 4 toward the registration roll
assembly.

Registration roll assembly

1-10 Printer Service Manual

5057-XXX

Registration
clutch

Sensor
(transparency detect)

Sensor
(registration)

Media transport roll assembly

Transfer belt
steering motor

Transfer belt
drive motor

Transfer belt
cleaning assembly

1st transfer rolls (C,M,Y,K)

CMY transfer roll
retract motor assembly

Sensor (CMY transfer
roll retract HP)

The registration roll assembly feeds the media at the precise moment to ensure that printed images are

precisely placed. The registration roll assembly feeds media from all trays to the transfer belt.

Transfer

Transfer belt drive motor assembly

This motor is used to rotate the transfer belt.

Transfer belt cleaning assembly

This assembly is used to remove residual toner images from the transfer belt after 2nd transfer and before the

next print cycle.

General information 1-11

5057-XXX

Transfer belt unit assembly

The transfer belt unit assembly contains the four 1st transfer rolls; these 1st transfer rolls are referred to as the
CMYK transfer rolls. The CMYK transfer rolls are positively charged to remove the developed toner image from
the four drums. The negatively charged toner image is attracted by positive charges on the surface of the
transfer belt. Thus, the toner image is transferred from the drum surface to the transfer belt surface. During black
(K) only, operation the CMY transfer rolls are retracted to reduce wear on the transfer belt surface and CMY
drums.

Transfer belt steering motor

This motor is used to ensure that the transfer belt is properly tracking. If the transfer belt starts to track off-center
then the transfer belt steering motor will activate to keep the transfer belt centered and tracking properly.

2nd transfer roll assembly

The 2nd transfer roll assembly applies positive charges to the rear surface of the media when the media passes
between the 2nd transfer roll assembly and the transfer belt. The negatively charged toner image is attracted by
positive charges on the surface of the media. Thus, the toner image is transferred from the transfer belt surface
to the media surface.

2nd transfer roll retract motor

The 2nd transfer roll retract motor is used to retract the 2nd transfer roll assembly when printing processes are
not occurring.

1-12 Printer Service Manual

Sensor (2nd transfer roll HP)

Sensor (2nd transfer
roll retract HP)

2nd transfer
roll assembly

2nd transfer roll
retract motor

Transfer belt

The sensor (2nd transfer roll HP) is used to detect the home position of the 2nd transfer roll assembly.

Printhead assembly

The printhead scans the four drum surface with four laser beams. It consists of four components: laser diode

(LD) card assembly, printhead motor, polygon mirror, and four start of scan card assemblies.

5057-XXX

1. LD card assembly – generates a laser beam with the four LDs. The beam is turned on or off according to
a print data signal. The printhead contains 4 LD card assemblies for the colors CMY & K.

2. Printhead motor/polygon mirror – the polygon mirror is mounted to the shaft of the printhead motor, and is
rotated at a high speed by the printhead motor. The mirror rotation shifts the incidence and reflection
angles of a laser beam to scan the laser beam in the drum axial direction. The laser beam reaches the
polygon mirror as it passes through multiple lenses, mirrors, and windows. The laser beam then arrives at
the drum surface.

3. SOS card assembly – when a laser beam hits the SOS sensor on the SOS card assembly, the beam is
converted to an electrical signal (SOS signal), and detects the initial position where a scan starts on each
line.

When a laser beam is scanned across the drum surface from one end to the other while turning on and off the
beam, one line of latent image is created. If the scanning by the laser beam is repeated while rotating the drum,
a two-dimensional image is created. The resolution in the scanning direction (from right to left) is determined by
the rotational speed of the printhead motor, depending on how quickly the laser is adjusted. The resolution in the
process direction (from top to bottom) is determined by the rotational speed of the printhead motor. (The higher
the scanning speed becomes, the sooner the scanning of the next row can be started.)

General information 1-13

5057-XXX

Printhead

Conceptual diagram of an image created by scanning

1-14 Printer Service Manual

5057-XXX

Y Laser Path

Polygon Mirror

Y drum

Sensor
(Y start of scan)

M Laser Path

Polygon Mirror

M drum

Sensor
(M start of scan)

General information 1-15

5057-XXX

C Laser Path

C drum

Sensor
(C start of scan)

Polygon Mirror

K Laser Path

K drum

Sensor
(K start of scan)

Polygon Mirror

Printhead shutter

The printhead shutter tightly covers the slit glass through which laser beams from the printhead pass to write the
four drums. To prevent the seal glass from becoming dirty, the shutter stays closed except when laser beams
are written onto the drums.

The printhead shutter motor assembly is used to prevent contamination from obstructing the printhead slit
glasses. The printhead shutters for yellow, magenta, cyan and black are opened or closed simultaneously by the
printhead shutter motor assembly.

1-16 Printer Service Manual

Fuser

Fuser cooling fan

Heat roll

Sensor (fuser exit)

Pressure

belt
Thumb
screws

5057-XXX

Heat roll

The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The heat
is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media.

General information 1-17

5057-XXX

Heater lamps

Front
thermister

Thermistat

Rear
thermister

Standard media
exit shift motor

Standard media
exit roll assembly

Sensor
(standard bin full)

Pressure belt

The pressure belt is used to apply pressure to the media surface for fusing. Pressure is applied to the media
between the pressure belt and heat roll, pressing the melted toner against the media.

Heater lamp

The heater lamp is a quartz glass tube containing a heater coil. A terminal is mounted to the end of the heater
rod via a harness. Two heater lamps are used: the main heater lamp to heat the entire heat roll, and the sub
heater lamp to heat the central portion of the heat roll.

Thermostat

Exit

If the heat roll temperature exceeds the preset temperature, the thermostat cuts off the circuits of the main
heater lamp and sub heater lamp.

Front thermistor

The front thermistor monitors the surface temperature of the media-feed portion of the hea t roll to control on/off
of the main heater lamp and sub heater lamp.

Rear thermistor

The rear thermistor monitors the surface temperature at the rear side of the heat roll to switch the heater lamp to
on.

Fuser exit sensor

The fuser exit sensor detects the arrival of media at the detection point in the exit area of the fuser, and also
detects the ejection of media from this point.

The standard media exit ejects printed media from the printer to the standard bin 1.

1-18 Printer Service Manual

5057-XXX

Inverter
reverse
clutch

Inverter
forward
clutch

Standard media exit
roll assembly

Duplex diverter
solenoid

Sensor
(duplex wait)

Switch (duplex left
door interlock)

Duplex media
transport roll assembly

Duplex
drive
motor

Duplex
diverter gate

Standard media exit roll assembly

The media exit roll assembly feeds printed media from the fuser to the standard bin.

Sensor (standard bin full)

The sensor (standard bin full) detects whether the standard bin is full by moving the actuator up and down.

Standard media exit shift motor

The standard media exit shift motor allows the standard media exit roll assembly to shift back and forth to
perform off-set sorting.

Duplex diverter gate

The duplex diverter gate switches the media transport path. When the duplex diverter gate is lifted, media is fed
to the standard bin. When it is lowered, media is fed to the duplex.

Drive

K developer/transport drive motor assembly

The K developer/transport drive motor is a DC motor that drives the K developer unit assembly, registration roll,
2nd transfer roll, fuser and standard media exit rolls.

MPF/transport drive motor

General information 1-19

5057-XXX

K developer/transport
drive motor assembly

MPF/transport
drive motor

K drive motor

CMY drive motor

The MPF/transport drive motor is a stepper motor that drives the MPF unit assembly and media transport roll.

CMYK PC cartridge drive motor assembly

The CMYK PC cartridge drive motor assembly uses dual DC brushless motors that drive the four drums in the
four PC cartridges.

1-20 Printer Service Manual

5057-XXX

K developer
clutch

CMY developer drive
motor assembly

Y toner add motor

Y toner add assembly

M toner add motor

M toner add assembly

C toner add motor

C toner add assembly

K toner add motor

K toner add assembly

CMY developer drive motor assembly

The CMY developer drive motor assembly uses a DC brushless motor to drive the three colo r de ve l op e r un it
assemblies.

K developer clutch

This clutch is used to engage the K developer unit assembly and is driven by the K-developer/transfer drive
motor assembly .

CMYK toner add motor assembly

General information 1-21

5057-XXX

Switch (waste toner

cartridge interlock)
Sensor (waste toner
cartridge full)

Waste toner agitator
motor assembly

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

Waste toner agitator motor assembly

The waste toner agitator motor assembly is used to rotate an auger inside the waste toner cartridge in order to
distribute collected waste toner evenly to prevent spillage and overflow.

Electrical components and controller

Switch (main power)

Turning on/off the switch, power supplies/cuts off the main power of the printer.

Finisher AC output

Supplies power to the finisher from the AC drive card assembly.

Switch (printer front door interlock) and switch (printer left door interlock)

The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt
power supply (HVPS) card assembly, printer engine card assembly and to the dual motor assembly, while the
printer front door assembly and the printer left door assembly are open.

Switch (printer left lower door interlock)

The switch (left lower door interlock) detects open or close of the printer left lower door assembly.

1-22 Printer Service Manual

5057-XXX

Charge roll HVPS
card assembly

Developer roll
HVPS card assembly

CMYK transfer
roll HVPS
card assembly

Fuser cooling fan

The fuser cooling fan discharges air from the printer to prevent excessive temperature increase.

AC drive card assembly

The AC drive card assembly accepts the main source voltage and distributes it to secondary power supplies and
circuit boards. It also contains the fuser relay to feed/cut off AC power to the heater lamps of the fuser unit
assembly.

5V LVPS card assembly

The LVPS card assembly generates low voltages 5V for logic circuits, 5 V for laser diodes from AC power.

24V LVPS card assembly

The LVPS card assem bly generates 24 V for motors/clutches from AC power.

CMYK transfer roll HVPS card assembly

The CMYK transfer roll HVPS card assembly generates AC power and feeds it to the CMYK transfer rolls inside
the transfer belt unit assembly.

Developer roll HVPS card assembly

The HVPS card assembly generates AC power and feeds it to the four developer rolls, the transfer belt unit
assembly and the 2nd transfer roll assembly

Charge roll HVPS card assembly

The HVPS card assembly generates AC power and feeds it to the four charge rolls.

General information 1-23

5057-XXX

Rear

Fuser
cooling fan

Rear upper
cooling fan

24V LVPS
cooling fan

AC drive
card Assembly

Rear lower
cooling fan

RIP card
cooling fan

RIP card
Assembly

Upper printer

engine card

assembly

Transfer belt

drive motor

cooling fan

Laser diode

card assembly

Lower printer

engine card

assembly

Upper printer engine card assembly

The upper printer engine card assembly controls printing operation based on the communication with the RIP
card assembly and optional peripherals. It also controls toner dispense, erase lamps and fuser control.

Lower printer engine card assembly

The lower printer engine card assembly controls printing operation based on th e communication with the RIP
card assembly and on sensor/switch information. It also controls many of the drive motors, clutches and
solenoids.

RIP card assembly

The RIP card assembly connected to the printer engine card assembly controls the entire system as well as the
printhead operations.

1-24 Printer Service Manual

Control

Media size control

Media tray assembly feeding
The following table gives the states (on/off) of the switches on the switch (media size), corresponding to the

media sizes of the media tray assembly.
Note: The switches on the switch (media size) are denoted by “S/W2” , “S/W 4”, “S/W3”, “S/W5” , and “S/W1”

respectively from the left side.

5057-XXX

Media size

No media tray assembly Off Off Off Off Off

5.5" X 8.5"SEF/A5 SEF Off Off On Off Off
B5 SEF Off Off On On On

8.5" X 13"SEF Off On Off On Off

8.5" X 14"SEF Off On Off On On
A4 SEF Off On On Off Off

8.5" X 11"SEF Off On On Off On

A4 LEF On O ff On Off Off

A3 SEF On Off On On Off

B5 LEF/executive LEF On On Off Off On

8K SEF(TFX/GCO) On On Off On Off

B4 SEF On On Off On On

8.5" X 11"LEF On On On Off Off

16K LEF(TFX/GCO) On On On Off On

11" X 17"LEF On On On On On

Printhead control

Analog switch

S/W1 S/W2 S/W3 S/W4 S/W5

Digital
switch

Rotation of printhead motor

The on/off control of the printhead motor is performed according to the mode of operation as shown below.

Operation mode PRINTHEAD motor on/off

Standby mode Always off
Print mode Turns on upon receiving the signal from the controller,

Sleep mode Always of f

and turns off after a preset time has passed from the
end of printing. Also turns off if a print command is not
received within 30 seconds from the reception of the
signal.

General information 1-25

5057-XXX

Determination of printhead ready

The printhead goes into ready state after the specified period passes since the reception of the printhead MPA
start signal and the SOS cycle exceeds the reference value.

Printhead reference value

Printhead reference value Description

Ready reference value SOS signal interval (equivalent to 98% or more of the rated RPM of the

Fail reference value SOS signal interval (less than 98% of the rated rpm of the printhead

Fuser control

Fuser control method

The on/off control of the main/sub heater lamps is performed based on the fuser control temperature. The fuser
transmits between the five states (warm up, ready, standby, print, and low power) depending on the heat roll
surface temperature or printer conditions.

The fuser temperature control starts when the fuser ready in the AC drive card assembly is turned on after a
preset time period has passed from power on. If a failure occurs, the heater lamps are turned off, the fuser ready
is turned off, and then the fuser temperature control is stopped.

Main/sub heater lamps on/off control

The front and rear thermistors detect the heat roll surface temperature (fuser temperatur e) to regulate the
temperature at the target control temperature by turning on or off the main/sub heater lamps.

Fuser warm-up

The fuser warm-up starts at the time of power on, interlock open or close, jam reset, or return from the low power
mode, and ends when the ready temperature is attained, when a failure occurs, or when executing diagnosis.

printhead motor)

motor)

1-26 Printer Service Manual

Xerographic process during a print cycle

K

C

M

Y

K toner

C toner M toner

Y toner

2nd transfer
roll assembly

Printhead

Transfer belt

Fuser

Cleaning roll

Transfer belt
cleaning
assembly

Cleaning blade

Photo conductor drum

Charge roll

Sensor (ATC)

Erase Lamp

Developer
unit

K transfer roll

C transfer roll

M transfer roll

Y transfer roll

Registration roll

5057-XXX

General information 1-27

5057-XXX

HVPS

(-VDC)

(-VDC)

Ground

Conductive Tube

Photoconductive
Surface

0V

-VDC value

DRUM

Drum Surface
Voltage

Drum Surface
Image

Ground

Charge roll

HVPS

(-VDC)

(-VDC)

Ground

Conductive Tube

Photoconductive
Surface

0V

-VDC value

DRUM

Drum Surface
Voltage

Drum Surface
Image

Ground

Charge roll

Charge

The Charge Roll places a uniform negative electrostatic charge on the surface of the drum. The drum surface is
made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness.
Light striking the drum discharges the surface charge.

The charge roll is a conductive roll that is positioned slightly above the surface of the drum. The HVPS supplies
the charge roll with two voltages; a negative DC charge voltage and an AC discharge voltage that is used for
electrically cleaning the drum.

1-28 Printer Service Manual

5057-XXX

Modulated
Laser Beam

0V

DRUM

Drum Surface
Image

Drum Surface
Voltage

Laser Beam

Discharge
Level

Invisible Latent Image

Laser Beam

Printhead

Exposure

The Printhead generates a beam of laser light. Image data received from the RIP card assembly modulates this
beam, turning it on and off according to image information that is received from the host computer and software.

Through the use of a series of rotating and stationary mirrors within the Printhead, the beam scans the negative
charged drum surface. Whenever the print controller sends a command to print a black pixel, the laser switches
on long enough to shine onto the drum at a single pixel point. That point is now discharged and slightly less
negative than the surrounding negative charge. The less negative areas are considered positive. This
discharge/no discharge process creates an invisible, electrostatic image on the surface of the drum. This image
is called a latent image.

Development

The toner contained within the PC Cartridge has a magnetic property that causes it to adhere to the Magnetic
Roll. The Metering Blade spreads the toner into a very thin layer on the Magnetic Roll. Friction between the
Magnetic Roll and the CM Blade generates a small electrical charge that is transferred to the toner.

The surface of the Magnetic Roll is made up of a thin sheet of conductive material. The HVPS supplies the
Magnetic Roll with two voltages: a DC voltage and an AC voltage. The DC voltage is used to transfer toner from

the Magnetic Roll to the surface of the drum. The AC voltage agitates the toner on the Magnetic Roll, making
toner transfer easier.

The Magnetic Roll maintains a negative DC electrical potential. Negative charged areas of the drum have a
lower electrical potential, or higher relative negative value than the Magnetic Roll. Discharged areas of the drum
have a higher electrical potential, or lower relative negative value, than the Magnetic Roll. A discharged point on
the surface of the drum now appears less negative in relation to the negative charge on the Magnetic Roll.

General information 1-29

5057-XXX

Magnet roll

Augur

Magnetic
Roll

Metering
Blade

Toner

HVPS

DRUM

-VDC

Drum Surface
Voltage

Drum Surface
Image

Toner at

-VDC Developer
Bias value

Discharge
Level

0V

Visible Developed Image

The toner adhering to the Magnet Roll is always in contact with the drum surface. When a less negative point on
the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet Roll, toner
transfers from the Magnet Roll to that point on the drum. There is now a visible toner image on the drum surface.
The image is called a developed image.

Transfer

As the paper travels between the 2nd transfer Roll and the transfer belt surface, the Transfer Roll applies a
positive charge to the back of the printing paper. This positive charge transfers the negative charged toner
image from the transfer belt to the top surface of the paper. The toner image is now on the paper and the paper

1-30 Printer Service Manual

5057-XXX

Sheet of paper

HVPS

-VDC

DRUM

Transfer roll

-VDC

Cleaning Blade

Used Toner

Charge roll

DRUM

-VDC

is now stuck to the transfer belt due to the relative electrical differences between the negative electrical charge
of the inner conductive layer of the drum and the positive electrical charge of the paper.

Cleaning

The Cleaning Blade removes any toner that remains on the drum after the transfer process. The toner that the
Cleaning Blade removes is collected inside the sealed PC Cartridge and reused.

Discharge

At both the start and the end of each individual printer cycle, the erase lamps electrically clean the drum. The
light emitted removes any residual DC charge that was left from the previous print cycle.

General information 1-31

5057-XXX

DRUM

Ground

Erase lamp LED array

Image density
sensor assembly

At the beginning of each individual printer cycle, the Printhead scans the surface of the drum, further discharging
any residual DC charge that may be left on the drum.

Auto density sensing

The image density sensor assembly uses a reflection type sensor that detects a pre-placed toner patch and
image on the transfer belt and outputs pulses when the central line of the patch image aligns with the central line
of the detector. The sensor outputs pulses at the timing the patch image passes the sensor. Therefore,
observing changes of intervals at which pulses are output leads to color mis-registration detection. If no color
mis-registration occurs, pulses are output at regular intervals.

1-32 Printer Service Manual

TTM theory

5057-XXX

General information 1-33

5057-XXX

Pick roll

Pick roll

Separation roll

Separation roll

Feed roll

Transfer belt

2nd transfer roll assembly

Heat roll

Pressure roll

Fuser unit ASM

Standard media

exit roll assembly

Duplex media transportroll ASM

Duplex media Center transport

roll ASM

Tray 3

Tray 4

Feed roll

Tray module media Transport roll ASM

Media transport roll ASM

Registration roll ASM

Standard media exit

Pick roll

Separation roll

Feed roll

Tray 2

Media transport

Media transport path

Media is supplied from tray 2, tray 3, or tray 4, and is transported to the printer along the media transport path
shown below.

1-34 Printer Service Manual

5057-XXX

MPF

Tray 1

Registration roll assembly

Bridge unit assembly
(included with finisher)

Standard media exit
roll assembly

Fuser exit
roll assembly

Duplex media
transport roll

assembly

Fuser

Finisher

(optional)

Booklet maker unit
(optional)

Finisher media entrance
roll assembly

Upper media exit
roll assembly

Upper media
transport roll assembly

Buffer roll assembly

Lower media exit
roll assembly

Booklet media
transport roll assembly

Booklet media
entrance roll assembly

Booklet media
exit roll assembly

Booklet folding
roll assembly

Media eject
roll assembly

2nd transfer roll assembly

MPF pick roll

Media transport roll assembly

Tray 2
Tray 3
Tray 4

3TM (optional)

Tray module transport
roll assembly

1TM (optional)

Tray 2

Tray module transport
roll assembly

Tray 2

Tray 3

Tray 4

TTM

Tray 4 transport roll assembly

Pick roll

Feed roll

Separation roll

Bridge unit bin exit
roll assembly

Media transport path

The following is a cross section of the printer and the tandem tray module, showing the main components
directly associated with the media path and transport.

Media tray assembly

Functions of main components

When the TTM is installed under the printer, additional trays are available.

It is necessary to adjust the rear side guides in the media tray assembly to match the media size.

Rear media guide

The rear media guide can be adjusted to different media sizes by moving it to the front or rear. The guide comes
into contact with the rear edge of the media and holds it in position.

General information 1-35

5057-XXX

Rear media guide

Bottom plate

End guide

Bottom plate

The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit
assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to
come in contact with the pick roll.

The force pushing up the bottom plate of tray 3 is transmitted by the driving force of the media feed lift motor on
the media feed unit assembly to the media lift shaft assembly through the tray lift gear assembly 3. The bottom
plate is lifted up via the rear tray cables, front right cable and front left cable by the rotation of the tray lift shaft
assembly, which causes the supplied media to come into contact wi th the pick roll.

The force pushing up the bottom plate of tray 4 is transmitted to the tray lift shaft assembly through the tray lift
gear assembly 4. The bottom plate is lifted up via the front tray cables and rear tray cables by the rotation of the
tray lift shaft assembly, which causes the supplied media to contact the pick roll.

Tray 2 media tray assembly

1-36 Printer Service Manual

Tray 3 or 4 media tray assembly

Rear lift cables

Rear media guide

Bottom plate

F/R lift cable

F/L lift cable

5057-XXX

General information 1-37

5057-XXX

TTM media feed units

Media feed unit assembly

Since the tray 3 and tray 4 are functionally equivalent in terms of the switch (TTM media size), sensor (media
out), sensor (media level) and sensor (pre-feed), only the components of one tray are described here.

The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer.
The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll
assemblies to feed media.

When the pick roll picks up sheets of media and the remaining media decreases, the media level actuator of the
sensor (media level) lowers accordingly.

Media feed lift motor

The media feed lift motor is activated to feed media and to lift the bottom plate. While feeding media, it rotates
forward to drive the pick roll. When lifting the bottom plate, it rotates in reverse to drive the tray module gears to
turn the lift up shaft.

Switch (media size)

This switch (media size) sets the size of media supplied from each media tray assembly. A signal indicating the
media size is transmitted as a voltage to the printer engine card assembly.

Switch (TTM media size)

The switch (TTM media size) switches the setting of the size of media supplied from each media tray assembly.
A signal indicating the set size is transmitted as a voltage to the printer engine card assembly.

Sensor (media out)

If there is no media in the media tray assembly, the media out actuator lowers and the flag of the media out
actuator that has stayed in the sensor (media out) sensing area leaves there. Thus, the light of the sensor is
transmitted. When the sensing area is blocked (media is present), the signal turns off.

Sensor (media level)

This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of
the actuator leaves the sensor (media level) sensing area, the sensor detects that the media has been lifted.

1-38 Printer Service Manual

5057-XXX

Front

Switch (TTM media size)

Media feed lift motor

Sensor (media level)

Sensor (media out)

Media feed unit assembly

Main components

Switch (tray module left door interlock)

The switch (tray module left door interlock) detects open/close of the tray module left door assembly.

Sensor (tray 2 feed-out)

The sensor (tray 2 feed-out) detects media fed from trays 2, 3, or 4.

Sensor (tray 3 feed-out)

The sensor (tray 3 feed-out) dete cts media fed from the tray 3 or tray 4.

Sensor (tray 4 feed-out)

The sensor (tray 4 feed-out) detects media fed from the tray 4.

Tray module media transport roll assembly

The tray module transport roll assembly feeds media from the tray 3 or tra y 4 to the printer.

General information 1-39

5057-XXX

Switch TTM

(media size)

Switch (tray module interlock)

TTM controller
card assembly

Tray module
drive motor

TTM tray 4 media
transport drive motor

Front

Sensor
(tray 2 feed-out)

Sensor
(tray 3 feed-out)

Sensor (tray 4 feed-out)

Switch
(media size)

Tray module drive motor

This motor is used to drive the media transport mechanism in the tray module.

TTM tray 4 media transport motor

This motor is used in the TTM to transport media from the tray 4 towards the tray module left door assembly.

TTM controller card assembly

The TTM controller card assembly, which contains a CPU, controls media feed in the tandem tray module upon
receiving a command from the upper printer engine card assembly and sensor/switch information.

1-40 Printer Service Manual

5057-XXX

Switch (TTM media size)

The following table gives on/off states of the switches on the switch (TTM media size), corresponding to the
media sizes of the media tray assembly.

Note: The switches (TTM media size) are denoted by “S/W1” and “S/W3” respectively from the left side.

Media Size

S/W1 S/W3

No Tray Off Off
B5L/7.25” x 10.5”L Off On

8.5” x 1 1 ”L On Off
A4L On On

Analog switch

General information 1-41

5057-XXX

3TM theory

1-42 Printer Service Manual

Media transport

Pick roll

Pick roll

Separation roll

Separation roll

Feed roll

Transfer belt

2nd transfer roll assembly

Heat roll

Pressure roll

Fuser unit ASM

Standard media

exit roll assembly

Duplex media transportroll ASM

Duplex media Center transport

roll ASM

Tray 3

Tray 4

Feed roll

Tray module media Transport roll ASM

Media transport roll ASM

Registration roll ASM

Standard media exit

Pick roll

Separation roll

Feed roll

Tray 2

Media transport path

Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown
below.

5057-XXX

General information 1-43

5057-XXX

MPF

Tray 1

Registration roll assembly

Bridge unit assembly
(included with finisher)

Standard media exit
roll assembly

Fuser exit
roll assembly

Duplex media
transport roll

assembly

Fuser

Finisher

(optional)

Booklet maker unit
(optional)

Finisher media entrance
roll assembly

Upper media exit
roll assembly

Upper media
transport roll assembly

Buffer roll assembly

Lower media exit
roll assembly

Booklet media
transport roll assembly

Booklet media
entrance roll assembly

Booklet media
exit roll assembly

Booklet folding
roll assembly

Media eject
roll assembly

2nd transfer roll assembly

MPF pick roll

Media transport roll assembly

Tray 2
Tray 3
Tray 4

3TM (optional)

Tray module transport
roll assembly

1TM (optional)

Tray 2

Tray module transport
roll assembly

Tray 2

Tray 3

Tray 4

TTM

Tray 4 transport roll assembly

Pick roll

Feed roll

Separation roll

Bridge unit bin exit
roll assembly

Media transport path

The following is a cross section of the printer and the tandem tray module, showing the main components
directly associated with the media path and transport.

Media tray assembly

Functions of main components

When the 3TM is installed under the printer, additional trays are available.

It is necessary to adjust the rear and the end guide in the media tray assembly to match the media size.

Rear media guide

The rear media guide can be adjusted to different media sizes by moving it to the front or rear. The guide comes
into contact with the rear edge of the media and holds it in position.

1-44 Printer Service Manual

5057-XXX

Rear media guide

Bottom plate

End guide

Bottom plate

The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed uni t
assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to
come in contact with the pick roll.

Tray 2, 3, 4 media tray assembly

3TM media feed units

Media feed unit assembly

Since the tray 2, tray 3, and tray 4 are functionally equivalent in terms of the switch (media size), sensor (media
out), sensor (media level) and sensor (pre-feed), only the components of one tray are described here.

The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer.
The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll
assemblies to feed media.

When the pick roll picks up sheets of media and the remaining media decreases, the media level actuator of the
sensor (media level) lowers accordingly.

Media feed lift motor

The media feed lift motor is activated to feed media and to lift the bottom plate. While feeding media, it rotates
forward to drive the pick roll. When lifting the bottom plate, it rotates in reverse to drive the tray module gears to
turn the lift up shaft.

Switch (media size)

The switch (media size) switches the setting of the size of media supplied from each media tray assembly. A
signal indicating the set size is transmitted as a voltage to the printer engine card assembly.

Sensor (media out)

If there is no media in the media tray assembly, the media out actuator lowers and the flag of the media out
actuator that has stayed in the sensor (media out) sensing area leaves there. Thus, the light of the sensor is
transmitted. When the sensing area is blocked (media is present), the signal turns off.

Sensor (media level)

General information 1-45

5057-XXX

This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of
the actuator leaves the sensor (media level) sensing area, the sensor detects that the media has been lifted.

Main components

Switch (tray module left door interlock)

The switch (tray module left door interlock) detects open/close of the tray module left door assembly.

Sensor (tray 2 feed-out)

The sensor (tray 2 feed-out) detects media fed from trays 2, 3, or 4.

Sensor (tray 3 feed-out)

The sensor (tray 3 feed-out) dete cts media fed from the tray 3 or tray 4.

Sensor (tray 4 feed-out)

The sensor (tray 4 feed-out) detects media fed from the tray 4.

1-46 Printer Service Manual

5057-XXX

Tray module media transport roll assembly

The tray module transport roll assembly feeds media from the tray 3 or tra y 4 to the printer.

Tray module drive motor

This motor is used to drive the media transport mechanism in the tray module.

3TM controller card assembly

The 3TM controller card assembly, which contains a CPU, controls media feed in the tandem tray module upon
receiving a command from the upper printer engine card assembly and sensor/switch information.

General information 1-47

5057-XXX

Switch (media size)

The following table gives on/off states of the switches on the switch (media size), corresponding to the media
sizes of the media tray assembly.

Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side.

Media Size

S/W1 S/W3

No Tray Off Off
B5L/7.25” x 10.5”L Off On

8.5” x 1 1 ”L On Off
A4L On On

Analog switch

1-48 Printer Service Manual

1TM theory

5057-XXX

General information 1-49

5057-XXX

Pick roll

Pick roll

Separation roll

Separation roll

Feed roll

Transfer belt

2nd transfer roll assembly

Heat roll

Pressure roll

Fuser unit ASM

Standard media

exit roll assembly

Duplex media transportroll ASM

Duplex media Center transport

roll ASM

Tray 3

Tray 4

Feed roll

Tray module media Transport roll ASM

Media transport roll ASM

Registration roll ASM

Standard media exit

Pick roll

Separation roll

Feed roll

Tray 2

Media transport

Media transport path

Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown
below.

1-50 Printer Service Manual

5057-XXX

MPF

Tray 1

Registration roll assembly

Bridge unit assembly
(included with finisher)

Standard media exit
roll assembly

Fuser exit
roll assembly

Duplex media
transport roll

assembly

Fuser

Finisher

(optional)

Booklet maker unit
(optional)

Finisher media entrance
roll assembly

Upper media exit
roll assembly

Upper media
transport roll assembly

Buffer roll assembly

Lower media exit
roll assembly

Booklet media
transport roll assembly

Booklet media
entrance roll assembly

Booklet media
exit roll assembly

Booklet folding
roll assembly

Media eject
roll assembly

2nd transfer roll assembly

MPF pick roll

Media transport roll assembly

Tray 2
Tray 3
Tray 4

3TM (optional)

Tray module transport
roll assembly

1TM (optional)

Tray 2

Tray module transport
roll assembly

Tray 2

Tray 3

Tray 4

TTM

Tray 4 transport roll assembly

Pick roll

Feed roll

Separation roll

Bridge unit bin exit
roll assembly

Media transport path

The following is a cross section of the printer and the 1TM, showing the main components directly associated
with the media path and transport.

Media tray assembly

Functions of main components

When the 1TM is installed under the printer, additional trays are available.

It is necessary to adjust the rear and the end guide in the media tray assembly to match the media size.

Rear media guide

The rear media guide can be adjusted to different media sizes by moving it to the front or rear. The guide comes
into contact with the rear edge of the media and holds it in position.

General information 1-51

5057-XXX

Rear media guide

Bottom plate

End guide

Bottom plate

The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit
assembly. The bottom plate is pushed up by the rotation of the lift up shaft, which causes the supplied media to
come in contact with the pick roll.

Tray 2 media tray assembly

1TM media feed units

Media feed unit assembly

The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer.
The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll
assemblies to feed media.

When the pick roll picks up sheets of media and the remaining media decreases, the media level actuator of the
sensor (media level) lowers accordingly.

Media feed lift motor

The media feed lift motor is activated to feed media and to lift the bottom plate. While feeding media, it rotates
forward to drive the pick roll. When lifting the bottom plate, it rotates in reverse to drive the tray module gears to
turn the lift up shaft.

1-52 Printer Service Manual

5057-XXX

Switch (media size)

The switch (media size) switches the setting of the size of media supplied from each media tray assembly. A
signal indicating the set size is transmitted as a voltage to the printer engine card assembly.

Sensor (media out)

If there is no media in the media tray assembly, the media out actuator lowers and the flag of the media out
actuator that has stayed in the sensor (media out) sensing area leaves there. Thus, the light of the sensor is
transmitted. When the sensing area is blocked (media is present), the signal turns off.

Sensor (media level)

This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of
the actuator leaves the sensor (media level) sensing area, the sensor detects that the media has been lifted.

Main components

Switch (tray module left door interlock)

The switch (tray module left door interlock) detects open/close of the tray module left door assembly.

General information 1-53

5057-XXX

Sensor (tray 2 feed-out)

The sensor (tray 2 feed-out) detects media fed from the tray 2.

Tray module media transport roll assembly

The tray module transport roll assembly feeds media from the tray 2.

Tray module drive motor

This motor is used to drive the media transport mechanism in the tray module.

1TM controller card assembly

The 1TM controller card assembly, which contains a CPU, controls media feed in the 1TM upon receiving a
command from the upper printer engine card assembly and sensor/switch information.

1-54 Printer Service Manual

5057-XXX

Switch (media size)

The following table gives on/off states of the switches on the switch (media size), corresponding to the media
sizes of the media tray assembly.

Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side.

Media Size

S/W1 S/W3

No Tray Off Off
B5L/7.25” x 10.5”L Off On

8.5” x 1 1 ”L On Off
A4L On On

Analog switch

General information 1-55

5057-XXX

Duplex

1-56 Printer Service Manual

Layout of media transport path

Inverter
reverse
clutch

Inverter
forward
clutch

Standard media
exit roll assembly

Standard
media bin

Exit duplex diverter gate

Fuser unit assembly

Transfer belt

Registration clutch

Registration

Sensor
(registration)

MPF

Registration roll assembly

Fuser
exit roll
assembly

Sensor
(fuser exit)

The main components associated with the media path and transport with the duplex installed.

5057-XXX

Functions of main components

When the duplex is installed to the left of the printer, duplex (double-sided) printing is available with the printer.
The following outlines the functions of the main components of the duplex.

Switch (duplex left door interlock)

The switch (left door interlock) detects open/close of the left door.

Sensor (duplex wait)

The sensor (duplex wait) detects whether media is remaining in the duplex.

Duplex media transport roll assembly

The two duplex media transport roll assemblies and the duplex media center transport roll assembly re-feeds
the media printed on the front side through the duplex to print on the rear side.

General information 1-57

5057-XXX

Inverter
reverse
clutch

Inverter
forward
clutch

Standard media exit
roll assembly

Duplex diverter
solenoid

Sensor
(duplex wait)

Switch (duplex left
door interlock)

Duplex media
transport roll assembly

Duplex
drive
motor

Duplex
diverter gate

Duplex controller card assembly

The duplex controller card assembly that contains a CPU controls media feed in the duplex upon receiving a
command from the upper printer engine card assembly and sensor/switch information.

Duplex drive motor

The duplex drive motor transmits driving force to the two duplex media transport roll assemblies and the duplex
media center transport roll assembly middle that feeds media.

1-58 Printer Service Manual

Tools required for service

Flat-blade screwdriver
#1 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic short-blade
Needle nose pliers
Diagonal side cutters
Spring hook
Analog or digital multi meter
Parallel wrap plug 1319128
Twinax/serial debug cable (#1381963)
Coax/serial debug cable (#1381964)

5.5 mm hexdriver (magnetic)
Color toner vacuum
Fine incremental ruler

5057-XXX

General information 1-59

5057-XXX

Acronyms

1TM 1 Tray Module
3TM 3 Tray Module
AC Alternating Current
ADF Automatic Document Feeder
APS Automatic Paper Size
ASIC Application Specific Integrated Circuit
ATC Automatic Toner Control
CRU Customer Replaceable Unit
CSU Customer Setup
CCW Counterclockwise
CW Clockwise
DC Direct Current
DIMM Dual Inline Memory Module
DRAM Dynamic Random Access Memory
EDO Enhanced Data Out
EP Electrophotographic Process
EPROM Erasable Programmable Read-only Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Gigabyte
GFI Ground Fault Interrupter
HCF High-Capacity Feeder
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission of Radiation
LCD Liquid Crystal Display
LD Laser Diode
LED Light-Emitting Diode
LEF Long Edge Feed
LVPS Low Voltage Power Supply
MPF Multi-Pu rpose Feeder
MS Microswitch
NVM Nonvolatile Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
OPT Optical Sensor
PC Photoconductor
PEL Picture element
POR Power-on Reset
POST Power-on Self Test
PPM Pages Per Minute
PSC Parallel Synchronous Communications
PSD Position Sensing Device
PWM Pulse Width Modulation
RFID Radio Frequency Identification
RIP Raster Imaging Processor
ROM Read only Memory
RPM Revolutions Per Minute
SDRAM Synchronous Dual Random Access Memory
SEF Short Edge Feed
SIMM Single Inline Memory Module
SOS Start of scan

1-60 Printer Service Manual

SRAM Static Random Access Memory
TTM Tandem Tray Module
TVOC Total Volatile Organic Compound
UPR Used Parts Return
VVolts
V ac Volts alternating current
V dc Volts direct current

5057-XXX

General information 1-61

5057-XXX

1-62 Printer Service Manual

5057-XXX

General information 1-63

5057-XXX

1-64 Printer Service Manual

2. Diagnostic information

CAUTION

Unplug the power cord from the electrical outlet before you connect or disconnect any cable
electronic board or assembly.

CAUTION

If the printer is kept on, never touch the conductive parts if not specifically required. The power
switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while
the power supply is cut off. Never touch the live parts.

CAUTION

Be careful to avoid burns by safely handling hot parts.

CAUTION

The standard finisher weight is 59 kg (130 lb.) and requires at least two people to lift it safely.
The booklet finisher weight is 87.5 kg (193 lb.) and requires at least four people to lift it safely.
Make sure your fingers are not under the finisher when you lift or set it down.

The MFP weighs approximately 173kg (383 lb.) and requires at least four people to lift it safely.
Make sure your fingers are not under the MFP when you lift or set it down.

Start

5057-XXX

Warning: When operating the driving units using the diagnostics or other tools, be sure to keep them covered

unless otherwise specified.

Warning: When operating the driving units using the diagnostics or other tools, never touch the driving units.

When operating the driving units using diagnostics or other tools, be sure to follow the procedures
in this manual.

Warning: Servicers should wear a wrist band or the like to remove static electricity from their body , grounding

their body while working. Go to “Handling ESD-sensitive parts” on page 4-1.

Note: There may be printer error messages that are not contained in this service manual. Call your next level
support for assistance.

Diagnostic information 2-1

5057-XXX

Confirm the installation status

Be sure to check the following items before starting the troubleshooting procedures.

• With the power cord unplugged from the wall outlet, check that the cord is free from breakage, short-circuit,

disconnected wire, or incorrect connection in the power cord.

• The printer is properly grounded. Check the power cord ground terminal.

• The printer is not installed at a place subjected to extreme temperature, extreme humidity or rapid changes

in temperature.

• The printer is not installed close to water service, humidifier, heat generating unit, fire, in a very dusty

place, or a place exposed to air flow from the air conditioning system.

• The printer is not installed in a place where volatile gas or inflammable gas is generated.

• The printer is not installed in direct sun.

• The printer is installed on a level and stable surface.

• Media meets specifications and is installed properly.

• Customer maintenance parts have been replaced at the specified intervals.

• Check all attached options for proper attachment and electrical connection.

• Refer to the User’s Guide for proper installation.

Power-on Reset sequence

The following is an example of the events that occur during the POR sequence:

1. Turn the machine on.

2. The Lexmark splash screen appears with a progress bar in the center until the code is loaded.

3. The scanner exposure lamp flashes several times.

4. The fuser cool i n g fa n tu rn s on.

5. The fuser unit assembly lamps turn on.

6. The RIP card assembly cooli n g fa n tu rn s on.

7. Operator panel LED becomes solid.

8. The transport motor turns on.

To enter the diagnostic menu:

1. Turn off the printer.

2. Press and hold th e and buttons simultaneously.

3. Turn on the printer.

4. Release the buttons afte r 10 seco nds.

2-2 Printer Service Manual

Error code table

5057-XXX

Error code or

message

200.00
Paper jam

200.01
Paper jam

200.02
Paper jam

200.03
Paper jam

201.00
Paper jam

Error contents Description/Action

Sensor (registration) late jam The media is late reaching the sensor (registration)

Sensor (registration) lag jam The media reached the sensor (registration) but did

Sensor static jam Media remains in the areas shown on the operator

Sensor (media on belt) late
jam

Sensor (fuser exit) late jam The media is late reaching the sensor (fuser exit)

within the specified time after being fed from any
given media tray.

Go to “200.00 Sensor (registration) late jam” on

page 2-22.

not clear it within the specified time.
Go to “200.01 Sensor (registration) lag jam” on

page 2-23.

panel after power on.
Go to “200.02 Sensor static jam” on page 2-25.

The media is late reaching the sensor (media on
belt) within the specified time after reaching the
sensor (registration).

Go to “200.03 Sensor (media on belt) late jam”

on page 2-26.

within the specified time after reaching the sensor
(registration).

Go to “201.00 Sensor (fuser exit) late jam” on

page 2-27.

202.00
Paper jam

230.00
Paper jam

231.00
Paper jam

231.01
Paper jam

241.00
Paper Jam

Sensor (fuser exit) lag jam The media re ached the sensor (fuser exit) but did

Sensor (duplex wait) late jam
(duplex media feed)

Sensor (registration) late jam
(duplex media feed)

Sensor (registration) late jam
(duplex media feed)

Sensor (tray 1 feed-out) late
jam.

not clear it within the specified time.
Go to “202.00 Sensor (fuser exit) lag jam” on

page 2-29.

The media is late reaching the sensor (duplex wait)
within the specified time after the duplex media
inverter clutch is turned on.

Go to “230.00 Sensor (duplex wait) late jam

(duplex media feed)” on page 2-30.

The media is late reaching the sensor (registration)
within the specified time after the duplex drive motor
is turned on.

Go to “231.01 Sensor (registration) late jam

(duplex media feed)” on page 2-34.

The media is late reaching the sensor (registration)
within the specified time after reaching the sensor
(duplex wait).

Go to “231.01 Sensor (registration) late jam

(duplex media feed)” on page 2-34.

The media is late reaching the sensor (tray 1 feed­out) within the specified time after the tray 1 media
feed lift motor is turned on.

Go to “241.00 Sensor (tray 1 feed-out) late jam”

on page 2-36.

Diagnostic information 2-3

5057-XXX

Error code or

message

242.00
Paper jam

242.01
Paper jam

243.00
Paper jam

243.01
Paper jam

Error contents Description/Action

Sensor (tray 2 feed-out) late
jam.

Sensor (tray 1 feed-out) late
jam (feeding from tray 2)

Sensor (tray 3 feed-out) late
jam.

Sensor (tray 2 feed-out) late
jam (feeding from tray3)

The media is late reaching the sensor (tray 2 feed­out) within the specified time after the tray 2 media
feed lift motor is turned on.

Go to “242.00 Sensor (tray 2 feed-out) late jam”

on page 2-38.

The media is late reaching the sensor (tray 1 feed­out) within the specified time after reaching the
sensor (tray 2 feed-out).

Go to “242.01 Sensor (tray 1 feed-out) late jam

(feeding from tray 2)” on page 2-39.

The media is late reaching the sensor (tray 3 feed­out) within the specified time after the tray 3 media
feed lift motor is turned on.

TTM equipped machines go to “243.00 Sensor

(tray 3 feed-out) late jam” on page 2-40.

3TM equipped machines refer to the Options
Service Manual.

The media is late reaching the sensor (tray 2 feed­out) within the specified time after reaching the
sensor (tray 3 feed-out).

TTM equipped machines go to “243.01 Sensor

(tray 2 feed-out) late jam (feeding from tray 3)”
on page 2-42.

3TM equipped machines refer to Options Service
Manual.

244.00
Paper jam

244.01
Paper jam

250.00
Paper jam

280.00
Paper jam

280.01
Paper jam

Sensor (tray 4 feed-out) late
jam.

Sensor (tray 3 feed-out) late
jam (feeding from tray4)

Sensor (registration) late jam
(feeding from the MPF)

Sensor (bridge unit media
entrance) late jam

Sensor (bridge unit media
entrance) static jam

The media is late reaching the sensor (tray 4 feed­out) within the specified time after the tray 4 media
feed lift motor is turned on.

TTM equipped machines go to “244.00 Sensor

(tray 4 feed-out) late jam” on page 2-44.

3TM equipped machines refer to Options Service
Manual.

The media is late reaching the sensor (tray 3 feed­out) within the specified time after reaching the
sensor (tray 4 feed-out).

TTM equipped machines go to “244.01 Sensor

(tray 3 feed-out) on jam (feeding from tray 4)” on
page 2-46.

3TM equipped machines refer to the Options
Service Manual.

The media is late reaching the sensor (registration)
within the specified time after the MPF pick solenoid
is turned on.

Go to “250.00 Sensor (registration) late jam

(feeding from the MPF)” on page 2-48.

The media is late reaching the sensor (bridge unit
media entrance) within the specified time after
reaching the sensor (fuser exit).

Refer to the Finisher Service Manual.
Media remains on the sensor (bridge unit media

entrance).
Refer to the Finisher Service Manual.

2-4 Printer Service Manual

5057-XXX

Error code or

message

281.00
Paper jam

281.03
Paper jam

281.04
Paper jam

281.05
Paper jam

281.06
Paper jam

282.00
Paper jam

Error contents Description/Action

Sensor (bridge unit media
exit) late jam

The media is late reaching the sensor (bridge unit
media exit) within the specified time after reaching
the sensor (bridge unit media entrance).

Refer to the Finisher Service Manual.

Sensor (bridge unit media
exit) static jam

Media remains on the sensor (bridge unit media
exit).

Refer to the Finisher Service Manual.

Sensor (bridge unit exit bin)
late jam.

Sensor (bridge unit exit bin) is not turned on within
the specified time after the sensor (bridge unit
media entrance) is turned on.

Refer to the Finisher Service Manual.

Sensor (bridge unit exit bin)
lag jam.

Sensor (bridge unit exit bin) is not turned off within
the specified time after the sensor (bridge unit exit
bin) is turned on.

Refer to Finisher Service Manual.

Sensor (bridge unit exit bin)
static jam.

Sensor (finisher media
entrance) late jam

Paper remains on the sensor (bridge unit exit bin).
Refer to the Finisher Service Manual.

The media is late reaching the sensor (finisher
media entrance) within the specified time after
reaching the sensor (bridge unit media exit).

Refer to the Finisher Service Manual.

282.01
Paper jam

283.00
Paper jam

283.03
Paper jam

284.00
Paper jam

284.03
Paper jam

284.05
Paper jam

285.00
Paper jam

Sensor (finisher media
entrance) static jam

Paper remains on the sensor (finisher media
entrance).

Refer to the Finisher Service Manual.

Sensor (buffer path) late jam The media is late reaching the sensor (buffer path)

within the specified time after reaching the sensor
(finisher media entrance).

Refer to the Finisher Service Manual.

Sensor (buffer path) static
jam

Sensor (lower media exit) late
jam

Paper remains on the sensor (finisher buffer path).
Refer to the Finisher Service Manual.

The media is late reaching the sensor (lower media
exit) within the specified time after reaching the
sensor (buffer path).

Refer to the Finisher Service Manual.

Sensor (lower media exit) lag
jam

The media reached the sensor (lower media exit)
but did not clear it within the specified time.

Refer to the Finisher Service Manual.

Sensor (lower media exit)
static jam

Sensor (compiler media in)
lag jam

Media remains on the sensor (lower media exit ).
Refer to the Finisher Service Manual.

The media reached the sensor (lower media exit)
but did not clear it within the specified time.

Refer to the

Finisher Service Manual.

286.00
Paper jam

Sensor (compiler media in)
static jam

Media remains on the sensor (compiler media in).
Refer to the Finisher Service Manual.

Diagnostic information 2-5

5057-XXX

Error code or

message

287.00
Paper jam

287.01
Paper jam

287.05
Paper jam

288.00
Paper jam

288.01
Paper jam

288.04
Paper jam

Error contents Description/Action

Sensor (upper media exit)
late jam

Sensor (upper media exit) lag
jam

Sensor (upper media exit)
static jam

Sensor (diverter gate) late
jam

Sensor (diverter gate) static
jam A (to top bin)

Sensor (diverter gate) static
jam B (to stacker bin)

The media is late reaching the sensor (upper media
exit) within the specified time after reaching the
sensor (finisher media entrance).

Refer to the Finisher Service Manual.
The media reached the sensor (upper media exit)

but did not clear it within the specified time.
Refer to the Finisher Service Manual.

Media remains on the sensor (upper media exit).
Refer to the Finisher Service Manual.

The media is late reaching the sensor (diverter gate)
within the specified time after reaching the se nso r
(bridge unit media exit).

Refer to the Finisher Service Manual.
The media reached the sensor (diverter gate) but

did not clear it within the specified time.
Refer to the Finisher Service Manual.

The media reached the sensor (diverter gate) but
did not clear it within the specified time.

Refer to the Finisher Service Manual.

289.00
Paper jam

289.01
Paper jam

289.02
Paper jam

289.03
Paper jam

289.04
Paper jam

289.05
Paper jam

289.06
Paper jam

Sensor (booklet media
entrance) late jam

Sensor (booklet media
entrance) lag jam

Sensor (booklet media
entrance) static jam

Sensor (booklet compiler in)
static jam

Sensor (booklet media exit)
late jam

Sensor (booklet media exit)
lag jam

Sensor (booklet media exit)
static jam

The media is late reaching the sensor (booklet
media entrance) within the specified time after
reaching the sensor (bridge unit media exit).

Refer to the Finisher Service Manual.
The media reached the sensor (booklet media

entrance) but did not clear it within the specified
time.

Refer to the Finisher Service Manual.
Media remains on the sensor (diverter gate).

Refer to the Finisher Service Manual.
Media remains on the sensor (booklet compiler in).

Refer to the Finisher Service Manual.
The media is late reaching the sensor (booklet

media exit) within the specified time after the
booklet folding solenoid is turned on.

Refer to the Finisher Service Manual.
The media reached the sensor (booklet media exit)

but did not clear it within the specified time.
Refer to the Finisher Service Manual.

Media remains on the sensor (booklet media exit).
Refer to the Finisher Service Manual.

31
Missing or

defective black
cartridge

Black toner cartridge
detection error

2-6 Printer Service Manual

The Black toner cartridge is defective not installed.
Go to “Toner cartridge error” on page 2-117.

5057-XXX

Error code or

message

31
Missing or

defective
<color>
cartridge

32
Replace

unsupported
Black cartridge

32
Replace

unsupported
<Color>
cartridge

34
Check tray 1

guides.

34
Check tray 2

guides

Error contents Description/Action

<Color> toner cartridge
detection error

The <Color> toner cartridge is defective or not
installed.

Go to “<Color> toner cartridge detection error”

on page 2-51.

Incorrect black toner cartridge
error.

A black toner cartridge of an incorrect specification
is installed.

Go to “Incorrect black toner cartridge error” on

page 2-51.

Incorrect <color> toner
cartridge error.

A <color>) toner cartridge of an incorrect
specification is installed.

Go to “Incorrect <color> toner cartridge error”

on page 2-51.

Tray 1 media size mismatch
error

The media tray assembly 1 side guide or end guide
is not properly set.

Go to “Tray 1 media size mismatch error” on

page 2-52.

Tray 2 media size mismatch
error

The media tray assembly 2 side guide or end guide
is not properly set.

Go to “Tray 2 media size mismatch error” on

page 2-52.

34
Check tray 3

guides

34
Check tray 4

guides

34
Incorrect paper

type, check
tray 1

34
Incorrect paper

type, check
tray 2

34
Incorrect paper

type, check
tray 3

34
Incorrect paper

type, check
tray 4

Tray 3 media size mismatch
error

Tray 4 media size mismatch
error

Tray 1 media type mismatch
error

Tray 2 media type mismatch
error

Tray 3 media type mismatch
error

Tray 4 media type mismatch
error

The media tray assembly 3 side guide or end guide
is not properly set.

Go to “Tray 3 media size mismatch error” on

page 2-53.

The media tray assembly 4 side guide or end guide
is not properly set.

Go to “Tray 4 media size mismatch error” on

page 2-54.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 1 media type mismatch error” on

page 2-54.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 2 media type mismatch error” on

page 2-55

.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 3 media type mismatch error” on

page 2-56.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 4 media type mismatch error” on

page 2-57.

Diagnostic information 2-7

5057-XXX

Error code or

message

80
Scheduled

maintenance
100K kit

80
Scheduled

maintenance
600K kit

82
Replace waste

toner
82

Waste toner
missing

82
Waste toner

nearly full

84
(color) PC unit

missing

Error contents Description/Action

100K maintenance required Service is required to maintain printer performance.

Go to “100K maintenance required” on

page 2-116.

600K maintenance required Service is required to maintain printer performance.

Go to “600K maintenance required” on

page 2-116.

Waste toner cartridge full Replace the waste toner cartridge.

Go to “Waste toner cartridge full” on page 2-118.

Waste toner cartridge not
detected

Waste toner cartridge nearly
full

(Color) PC cartridge not
detected

Reinstall the waste toner cartridge.
Go to “Waste toner cartridge not detected” on

page 2-119.

Waste toner cartridge is nearing the replacement
interval.

Go to “Waste toner cartridge nearly full” on

page 2-120.

A (color) PC cartridge is not installed or not installed
properly.

Go to “(Color) PC cartridge not detected” on

page 2-120.

849.00
Service hard

drive

84
Black PC unit

life warning

84
Color PC unit

life warning

84
Replace black

PC unit
84

Replace color
PC units

84
Unsupported

(color) PC unit

Hard drive/configuration ID
mismatch

K PC cartridge nearly
exhausted

K PC cartridges nearly
exhausted.

K PC cartridge exhausted The black PC cartridge requires replacing.

CMY PC cartridges
exhausted

(Color) PC cartridge invalid A (color) PC cartridge of an incorrect specification is

The device does not have a hard drive installed,
even though its configuration ID indicates that a
hard drive should be present.

Go to “849.00 Hard drive/configuration ID

mismatch” on page 2-59.

The black PC cartridge is nearing the replacement
interval.

Go to “K PC cartridge nearly exhausted” on

page 2-122.

All color PC cartridges are nearing the replacement
interval.

Go to “K PC cartridge nearly exhausted” on

page 2-122.

Go to “K PC cartridge exhausted” on page 2-122

All color PC cartridges require replacing.
Go to “CMY PC cartridges exhausted” on

page 2-122.

installed.
Got to “(Color) PC cartridge invalid” on

page 2-121.

.

2-8 Printer Service Manual

5057-XXX

Error code or

message

88
(Color) toner

low

88
Replace (color)

toner

900.xx
Service RIP

software

901.xx
Service engine

error

902.00
Service engine

error

902.01
Service engine

error

Error contents Description/Action

(Color) toner cartridge nearly
empty

The (color) toner cartridge is nearing the
replacement interval.

Go to “(Color) toner cartridge nearly empty” on

page 2-123.

(Color) toner cartridge empty The (color) toner cartridge requires replacing.

Go to “(Color) toner cartridge empty” on

page 2-124.

RIP card assembly software
error

A error has occurred in the RIP card assembly
software.

Go to “900.XX RIP card assembly software error”

on page 2-59.

RIP card assembly software
error

A error has occurred in the RIP card assembly
software.

Go to “900.XX RIP card assembly software error”

on page 2-59.

General upper engine card
error

Fuse #1

An error has occurred in the upper engine card
assembly.

Go to “902.00 General upper engine error fuse

#1” on page 2-60.

General upper engine card
error

Fuse #2

An error has occurred in the upper engine card
assembly.

Go to “902.01 General upper engine error fuse

#2” on page 2-61.

902.02
Service engine

error

902.03
Service engine

error

902.04
Service engine

error

902.05
Service engine

error

902.06
Service engine

error

902.07
Service engine

error

General upper engine card
error

Fuse #3

General lower engine card
error

Fuse #1

General lower engine card
error

Fuse #2

General lower engine card
error

Fuse #3

General lower engine card
error

Fuse #4

General lower engine card
error

Fuse #5

An error has occurred in the upper engine card
assembly.

Go to “902.02 General upper engine error fuse

#3” on page 2-62.

An error has occurred in the lower engine card
assembly.

Go to “902.03 General lower engine error fuse

#1” on page 2-62.

An error has occurred in the lower engine card
assembly.

Go to

“902.04 General lower engine error fuse

#2” on page 2-63.

An error has occurred in the lower engine card
assembly.

Go to “902.05 General lower engine error fuse

#3” on page 2-64.

An error has occurred in the lower engine card
assembly.

Go to “902.06 General lower engine error fuse

#4” on page 2-64.

An error has occurred in the lower engine card
assembly.

Go to “902.07 General lower engine error fuse

#5” on page 2-65.

Diagnostic information 2-9

5057-XXX

Error code or

message

903.00
Service motor

error

903.01
Service motor

error

903.02
Service motor

error

903.03
Service motor

error

904.00
Service

transfer belt

Error contents Description/Action

K developer/transport drive
motor error

K PC drive motor error The K PC cartridge drive motor does not rotate at

CMY PC drive motor error The CMY PC cartridge drive motor does not rotate

Developer drive motor error The developer drive moto r does not rotate at the

Sensor (transfer belt HP) late
error

K developer/transport drive motor error does not
rotate at the specified speed.

Go to “903.00 K developer/transport drive

assembly motor error” on page 2-67.

the specified speed.
Go to “903.01 K PC drive motor error” on

page 2-68.

at the specified speed.
Go to “903.02 CMY PC drive motor error” on

page 2-69.

specified speed.
Go to “903.03 Developer drive motor error” on

page 2-69.

The sensor (transfer belt HP) does not detect the
transfer belt home position in the specified time or
the transfer belt is damaged or torn in half.

The transfer belt cleaning assembly is missing.
If this error has occurred more than three times, it

must be reset inside diagnostic mode before
troubleshooting can begin or the machine can
operate.

Go to “904.00 Sensor (transfer belt HP) late

error” on page 2-70.

904.01
Service

transfer belt

904.02
Service

transfer belt

904.03
Service

transfer belt

904.04
Service

transfer belt

Transfer belt position failure The transfer belt is out of correct position or the

Sensor (transfer belt edge)
failure

Sensor (2nd transfer roll
retract HP) late error

Sensor (2nd transfer roll
retract HP) lag error

transfer belt cleaning assembly is missing.
Go to “904.01 Transfer belt position failure” on

page 2-71.

The sensor (transfer belt edge detect) is not
detecting the transfer belt edge properly.

Go to “904.02 Sensor (transfer belt edge) failure”

on page 2-72.

The sensing area of the sensor (2nd transfer roll
retract HP) is not interrupted within the specified
time when the 2nd transfer roll is moving to th e
home position.

Go to “904.03 Sensor (2nd transfer roll retract

HP) late error” on page 2-72.

The sensing area of the sensor (2nd transfer roll
retract HP) remains interrupted within the specified
time when the CMY retract rolls are moving from the
home position.

Go to “904.04 Sensor (2nd transfer roll retract

HP) lag error” on page 2-74.

2-10 Printer Service Manual