Lexmark C93 x Service Manual

Revision: February 21, 2012

• Tabl e of conte n t s

• Start diagnostics

Lexmark™C93x Printer

5057-XXX

• Safet y 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: February 21, 2012
The following paragraph does not apply to any country where such provisions are inc onsistent 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; there fore, this statement ma y not apply to you.

This publication could include tec hnical inaccuraci es or typographical er rors. Changes are period ically made to the
information herein; these changes wil l 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, Kentuck y 40550 , U.S.A or e-mail at ServiceI nfoAndTr ai ning@Lex mark.com. Lexmar k may use or dist ribu te any
of the information you supply in any way it believes appropriate wi thout incurring any obligation to you.

References i n this publication to products, programs, or services do not i mp ly 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 t hat produ ct, pr ogra m, or serv ice may be used. Any funct ional ly equi valent pro duct, progr am, or servi ce that
does not infringe any existing intellectual property right may be used instea d. Eval uation and verifi cation of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
user’s respons ibility.

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark Internat ional, Inc., registered in the United States
and/or other coun tries.

PCL® is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of their respective 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 ex pense.

5057-XXX

P/N 12G9765

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5057-XXX

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

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

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

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

Change history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i-xxvi

Navigation buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii-xxvi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvii

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

Printe r th e o ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

iii

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5057-XXX

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

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

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 exi t roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 19

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

Standard media exi t shi ft 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 interloc k) . . . . . . . . . . . . . . . .1-22

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

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

AC drive card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2 3

5V LVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 3

24V LVPS card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 3

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- 2 5

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 contr ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 sens ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

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

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

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

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

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

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 l eft 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 tra nsport 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 l eft 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 tra nsport 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

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

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

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

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

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

Switch (tray module l eft door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53

Sensor (tray 2 feed-out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 5 4

Tray module media tra nsport roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-54

Tray module drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 4

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

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

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

Layout of media transport path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 7

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

Switch (duplex lef t door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 5 7

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 servi ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59

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

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

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

Confirm the installa tion status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

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

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

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

200.00 Sensor (registration) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

200.01 Sensor (registration) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 4

200.02 Sensor static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

200.03 Sensor (media on belt) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

201.00 Sensor (fuser exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 8

202.00 Sensor (fuser exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3 0

230.00 Sensor (duplex wait) late jam (duplex media feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

231.00 Sensor (registration) late jam (duplex feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

231.01 Sensor (registration) late jam (duplex media feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

241.00 Sensor (tray 1 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

242.00 Sensor (tray 2 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

242.01 Sensor (tray 1 feed-out) late jam (feeding from tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

243.00 Sensor (tray 3 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

243.01 Sensor (tray 2 feed-out) late jam (feeding from tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

244.00 Sensor (tray 4 feed-out) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

244.01 Sensor (tray 3 feed-out) on jam (feeding from tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

250.00 Sensor (registration) late jam (feeding from the MPF) . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

Black toner cartr idge detecti on error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

<Color> toner cartridge detection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5 2

Incorrect black toner cartridge error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 2

Incorrect <color> toner cartridge error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2

Tray 1 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 3

Tray 2 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 3

Tray 3 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 4

Tray 4 media size mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 5

Tray 1 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

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

Tray 3 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

Tray 4 media type mismatch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

841.00 Image pipeline ASIC error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 5 9

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849.00 Hard drive/configuration ID mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

900.xx System software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

901.xx RIP card assembly software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

902.00 General upper engine error fuse #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

902.01 General upper engine error fuse #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

902.02 General upper engine error fuse #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

902.03 General lower engine error fuse #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

902.04 General lower engine error fuse #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

902.05 General lower engine error fuse #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

902.06 General lower engine error fuse #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

902.07 General lower engine error fuse #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

903.00 K developer/transport drive assembly motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

903.01 K PC drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

903.02 CMY PC drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

903.03 Developer drive motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

904.00 Sensor (transfer belt HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

904.01 Transfer belt position failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

904.02 Sensor (transfer belt edge) failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

904.03 Sensor (2nd transfer roll retract HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

904.04 Sensor (2nd transfer roll retract HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

904.05 Sensor (CMY transfer roll retract HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

904.06 Sensor (CMY transfer roll retract HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

904.07 CMY transfer roll retract motor time out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

905.00 NVM read/write cannot be executed error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

905.01 Marking device video error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

905.02 Marking device Xerographics error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

905.03 Marking device other1 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

905.04 Marking device paper handling error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

905.05 Marking device other2 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

907.00 Printhead polygon mirror motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

907.01 Y laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

907.02 C laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

907.03 M laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97

907.04 K laser SOS internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97

907.05 Printhead control error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

908.00 Waste toner full error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

911.00 24V LVPS cooling fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

911.01 Transfer belt drive motor cooling fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

911.02 Fuser cooling fan lock error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

918.00 Standard media exit shift error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

920.00 Fuser main lamp overheat error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

920.01 Front thermistor disconnection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

920.02 Fuser sub lamp overheat error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

920.03 Rear thermistor disconnection error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

920.04 Main lamp warm up error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

920.05 Main lamp on-time error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

920.06 Sub lamp warm-up failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

920.07 Sub lamp on-time error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

924.00 Yellow PC smartchip communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

924.01 Magenta PC smartchip communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

924.02 Cyan PC smartchip communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107

924.03 Black PC smartchip communi cation error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107

925.00 Sensor (Y ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

925.01 Sensor (M ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

925.02 Sensor (C ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

925.03 Sensor (K ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1 1 0

930.00 Black toner RFI D communi cation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

930.01 Cyan toner RFID communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111

930.02 Magenta toner RFID communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111

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930.03 Yellow toner RFID communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-111

940.00 MPF tray 5 size sensing error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112

941.00 Switch (media size) size sensing error (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112

941.01 Sensor (media level) late error (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-113

942.00 Switch (media size) size sensing error (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-114

942.01 Sensor (media level) late error (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115

943.00 Switch (media size) size sensing error (tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-116

943.01 Sensor (media level) late error (tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117

944.00 Switch (media size) size sensing error (tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118

944.01 Sensor (media level) late error (tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119

950.00 through 950.29 EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-120

950.30 through 950.60 EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-120

951.XX RIP card assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121

952.XX Interconnect card assembly NVRAM CRC failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121

953.XX Operator panel assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

954.XX Interconnect card assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

955.XX RIP card assembly NAND CRC failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123

956.00 RIP card assembly processor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123

956.01 RIP card assembly processor over temperature failure . . . . . . . . . . . . . . . . . . . . . . . .2-124

956.02 RIP card assembly cool ing fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-124

956.03 RIP card assembly FPGA fai lur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-124

980.00 Communication error with 1TM, 3TM, or TTM assembly . . . . . . . . . . . . . . . . . . . . . . . .2-125

980.01 HVPS controller communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-125

980.02 Communication error between printer and RIP card assembly . . . . . . . . . . . . . . . . . . .2-126

980.03 Communicat ion error with finisher controller card assembly . . . . . . . . . . . . . . . . . . . .2-126

1TM, 3TM or TTM left door assembly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127

Duplex left door assembl y open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-128

Media size mismatch in width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-129

Media size mismatch in width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-130

No media in the selected media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-131

Paper is installed (short edge) in the media paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-132

PC cartridge end of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-133

Printer front door assembly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-133

Printer left door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-134

Transfer belt acc ess door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135

Printer left lower door assem bly open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136

100K maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136

600K maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137

ADF maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137

Standard media bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137

Toner cartridge error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-138

Toner cartridge set error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-138

Waste toner cartridge full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-139

Waste toner cartridge not detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-139

Waste toner cartridge nearly full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-140

(Color) PC cartridge not detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-141

(Color) PC cartridge invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-141

CMY PC cartridges nearly exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-142

CMY PC cartridges exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-142

K PC cartridge nearly exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-142

K PC cartridge exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-143

(Color) toner cartridge nearly empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-143

(Color) toner cartridge empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144

Image quality trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146

Printer Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146

Image quality symp toms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146

Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147

Faint print (Low contrast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147

Blank print (no print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149

viii Printer Service Manual

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Solid black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-151

Vertical lin e s and bands(process direct ion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152

Horizontal white stripes or bands (side to side direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154

Vertical stripes (process direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-156

Horizontal stripes (side to side direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158

Partial lack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-160

Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-162

After image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-163

Background (fog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-165

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-167

Media damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-169

No fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-171

Color misregistration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172

Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-173

High frequency bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-174

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 Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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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

Exiting Diagnostic s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 4

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

Maintenance Counter Val ue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Reset Maintenance Counte r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

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

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

Printer front door assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Right cover assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 inverte r 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 controll er card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Fuser unit assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 5

Transfer belt unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 6

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 int erlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

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

Media feed unit assembly 1 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2 1

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

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

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

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

Printer left door asse mbly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

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

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

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

Left transfer belt lift assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Transfer belt lift handle assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Transfer belt steering motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

CMY erase lamp assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

K erase lamp assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Printhead shutter motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Switch (printer front door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Sensor (printer lef t lower door interlo ck) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

RIP card cooling fan cover assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Controller box assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Switch (main power) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Bridge card assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

RIP card access cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

RIP card assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Hard drive removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Interconnect car d assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88

Upper printer engine card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88

Upper printer engine card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Upper printer engine card assembly re-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91

Lower printer engine card bracket assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Lower printer engine card assembly remo val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Transfer belt drive motor cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Transfer belt dr ive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Switch (transf er belt access door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

Laser diode power card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

24V LVPS card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

24V LVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

5V LVPS card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

5V LVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98

24V LVPS cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99

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Rear lower cooling fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -99

CMY developer drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100

CMYK PC cartridge drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-101

Fuser cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102

Main power switch actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102

CMYK toner add motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-103

CMYK transfer HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104

Printhead assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104

Transfer belt waste toner auger assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-105

K developer / transport dri ve m otor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-106

K developer clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-108

AC drive card bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-109

Noise filter assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-110

Rear upper cooling fan bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111

Rear upper cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111

Developer / transfer roll HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-112

Charge roll HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-113

MPF / transport drive moto r assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-114

Feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-115

Pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116

Separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-117

Sensor (RFID toner cartridge) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-117

Fuser exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-118

MPF media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-118

Sensor (MPF media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-119

MPF pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-119

Media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-120

Switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-121

2000-sheet dual in put (TTM) removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

2000-sheet dual input (TTM)—top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

2000-sheet dual input (TTM)—foot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

2000-sheet dual input (TTM)—right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-123

2000-sheet dual in put (TTM)— tray module left cover removal . . . . . . . . . . . . . . . . . . . . . . . . .4-123

2000-sheet dual input (TTM)—rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-124

2000-sheet dual in put (TTM)—caster rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-124

2000-sheet dual in put (T TM)—tray support rol l re moval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-125

2000-sheet dual input (TTM)—TTM media tray 4 assembly removal . . . . . . . . . . . . . . . . . . . . .4-127

2000-sheet dual input (TTM)—TTM media tray 3 assembly removal . . . . . . . . . . . . . . . . . . . . .4-128

2000-sheet dual input (TTM)—tray 3 front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-128

2000-sheet dual in put (TTM)—tray 3 rear cable assembly removal . . . . . . . . . . . . . . . . . . . . . .4-129

2000-sheet dual in put (TTM)—tray 3 front cable assembly removal . . . . . . . . . . . . . . . . . . . . .4-131

2000-sheet dual input (TTM)—media tray 4 front cover removal . . . . . . . . . . . . . . . . . . . . . . . .4-132

2000-sheet dual input (TTM)—TTM tray 4 media transport assembly removal . . . . . . . . . . . .4-132

2000-sheet dual input (TTM)—tray 4 rear cables removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-132

2000-sheet dual input (TTM)—tray 4 front cables removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-135

2000-sheet dual in put (TTM)—media feed unit assembly removal (tr ay 4) . . . . . . . . . . . . . . . .4-136

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

2000-sheet dual input (TTM) switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-139

2000-sheet dual input (TTM)—switch (TTM media size) removal . . . . . . . . . . . . . . . . . . . . . . . .4-140

2000-sheet dual in put (TTM)—media feed unit assembly 2 remo val . . . . . . . . . . . . . . . . . . . . .4-141

2000-sheet dual in put (TTM)—media feed unit assembly removal (tr ay 3) . . . . . . . . . . . . . . . .4-141

2000-sheet dual input (TTM)—sensor (tray 3 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . .4-143

2000-sheet dual input (TTM)—sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . .4-144

2000-sheet dual input (TTM)—media feed lift motor remova l . . . . . . . . . . . . . . . . . . . . . . . . . . .4-144

2000-sheet dual in put (TTM)—one-way clut ch / gear assembly removal . . . . . . . . . . . . . . . . .4-146

2000-sheet dual input (TTM)—media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-148

2000-sheet dual in put (TTM)—sensor (media level) removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-149

2000-sheet dual input (TTM)—sensor (media out) remov a l . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-150

2000-sheet dual input (TTM)—feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-151

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2000-sheet dual input (TTM)—feed roll one-way clutch removal . . . . . . . . . . . . . . . . . . . . . . . 4-152

2000-sheet dual input (TTM)—one-way 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-153

2000-sheet dual in put (TTM)—separati on roll one-way friction clutch removal . . . . . . . . . . . 4-154

2000-sheet dual input (TTM)—separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-155

2000-sheet dual input (TTM)—pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-157

2000-sheet dual in put (T TM)—left door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158

2000-sheet dual input (TTM)—switch (TTM left door interlo c k ) removal . . . . . . . . . . . . . . . . . 4-159

2000-sheet dual in put (TTM)—tray 3 lift gea r assem bly removal . . . . . . . . . . . . . . . . . . . . . . . 4-160

2000-sheet dual in put (TTM)—tray 4 lift gea r assem bly removal . . . . . . . . . . . . . . . . . . . . . . . 4-160

2000-sheet dual in put (TTM)—tray lift coupling assembly rem oval . . . . . . . . . . . . . . . . . . . . . 4-161

2000-sheet dual in put (TTM)—tray module dri ve m otor assembly removal . . . . . . . . . . . . . . 4-161

2000-sheet dual input (TTM)—TTM tray 4 transport motor removal . . . . . . . . . . . . . . . . . . . . . 4-163

2000-sheet dual in put (TTM)—TTM controll er card assembly removal . . . . . . . . . . . . . . . . . . 4-163

3X 500-sheet drawer (3TM) removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164

3X 500-sheet drawer (3TM)—top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164

3X 500-sheet drawer (3TM)—foot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-165

3X 500-sheet drawer (3TM)—right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-165

3X 500-sheet drawer (3TM) —tray module left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-166

3X 500-sheet drawer (3TM)—rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-166

3X 500-sheet drawer (3TM)—caster removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-167

3X 500-sheet 3TM)—medi a feed unit assembly removal (tray 4) . . . . . . . . . . . . . . . . . . . . . . . 4-167

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

3X 500-sheet drawer (3TM)—sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-169

3X 500-sheet drawer (3TM)—switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-170

3X 500-sheet drawer (3TM)—media feed unit assem bly removal (tray 3) . . . . . . . . . . . . . . . . 4-171

3X 500-sheet drawer (3TM)—media feed unit assem bly removal (tray 2) . . . . . . . . . . . . . . . . 4-173

3X 500-sheet drawer (3TM)—sensor (tray 3 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-174

3X 500-sheet drawer (3TM)—media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-175

3X 500-sheet drawer (3TM)—one-way clutch / gear assembly removal . . . . . . . . . . . . . . . . . . 4-176

3X 500-sheet drawer (3TM)—media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-177

3X 500-sheet drawer (3TM)—sensor (med ia l evel) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-178

3X 500-sheet drawer (3TM)—sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-179

3X 500-sheet drawer (3TM)—feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180

3X 500-sheet drawer (3TM)—feed roll one-way clutch removal . . . . . . . . . . . . . . . . . . . . . . . . 4-181

3X 500-sheet drawer (3TM)—one-way 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-182

3X 500-sheet drawer (3TM)—separation roll one-way friction clutch removal . . . . . . . . . . . . 4-183

3X 500-sheet drawer (3TM)—separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184

3X 500-sheet drawer (3TM)—pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186

3X 500-sheet drawer (3TM)—3TM left door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-187

3X 500-sheet drawer (3TM) —s witch (tray module left door interlo ck) r emoval . . . . . . . . . . . . 4-187

3X 500-sheet drawer (3TM) —tray module drive motor assembly removal . . . . . . . . . . . . . . . 4-188

3X 500-sheet drawer (3TM)—3TM contro ller card assembly removal . . . . . . . . . . . . . . . . . . . 4-189

1X 500-sheet drawer (1TM) removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-190

1X 500-sheet drawer (1TM)—top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-190

1X 500-sheet drawer (1TM)—foot cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-191

1X 500-sheet drawer (1TM)—right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-191

1X 500-sheet drawer (1TM) —tray module left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192

1X 500-sheet drawer (1TM)—rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192

1X 500-sheet drawer (1TM)—caster removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-193

1X 500-sheet drawer (1TM)—media feed unit assem bly removal (tray 2) . . . . . . . . . . . . . . . . 4-193

1X 500-sheet drawer (1TM)—sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-194

1X 500-sheet drawer (1TM)—switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-195

1X 500-sheet drawer (1TM)—media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-196

1X 500-sheet drawer (1TM)—one-way clutch / gear assembly removal . . . . . . . . . . . . . . . . . . 4-196

1X 500-sheet drawer (1TM)—media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-198

1X 500-sheet drawer (1TM)—sensor (med ia l evel) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-199

1X 500-sheet drawer (1TM)—sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-200

1X 500-sheet drawer (1TM)—feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-201

1X 500-sheet drawer (1TM)—feed roll one-way clutch removal . . . . . . . . . . . . . . . . . . . . . . . . 4-202

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1X 500-sheet drawer (1TM)—one-way 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-203

1X 500-sheet drawer (1TM)—separation roll one-way friction clutch removal . . . . . . . . . . . . .4-204

1X 500-sheet drawer (1TM)—separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-205

1X 500-sheet drawer (1TM)—pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-206

1X 500-sheet drawer (1TM) —tray module left door assembly removal . . . . . . . . . . . . . . . . . . .4-207

1X 500-sheet drawer (1TM) —s witch (tray module left door interlo ck) r emoval . . . . . . . . . . . .4-208

1X 500-sheet drawer (1TM) —tray module drive motor assembly removal . . . . . . . . . . . . . . . .4-209

1X 500-sheet drawer (1TM)—1TM contro ller card assembly removal . . . . . . . . . . . . . . . . . . . .4-209

Setup and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-210

Sensor (ATC) setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-210

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-211

Color registration (RegCon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-214

Measurement cycle test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-215

Control sensor check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-216

Control sensor cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-216

Belt edge learn test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-217

Skew fine setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-217

In/out setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-222

Center setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-226

Transfer belt lift mechanism adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-228

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

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

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

Preventive mainte nan ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspect ion 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 f eed 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 rol l assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

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

Assembly 14: Printer left door ass emb ly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Assembly 15: Printer left door ass emb ly 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

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

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

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

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xvi Printer Service Manual

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Notices and safety information

The followi ng laser notice labels may be affixed to this printer.

Laser no tice

The printer is certified in the U.S. to con for m to the requi rements of DHHS 21 CFR Subchapter J for Clas s 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 internall y a Class IIIb (3b) laser
that is nomin all y a 5 milliwatt gallium arsenide laser operating in t he wavelength region of 770-795 nanometers.
The laser system and printer are desi gned so there is never any huma n access to laser radiati on above a Class
I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amt li cher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Tei l 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 ei n Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstr ahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Norma lbetrieb, 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 provi si ons 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 l aser de Classe IIIb (3b) (arséniur e de gallium d’une puissance nominal e 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 stampant e è certificata negli Stati Unit i per essere conforme ai requisit i del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certi fi cata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti del la norma CEI 60825-1 .

I prodotti laser di classe non sono consider at i pericol osi. La st ampant e contie ne al suo interno un laser d i classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati proget tati 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 radi azioni laser superiori al livell o della classe 1.

Notices and safety information xvii

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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 su bcapítulo 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 consi deran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de gali o de funcionamiento nominal a 5 milivatios en una lo ngitud de o nda de 770 a
795 nanómetr os. El sistema láser y la impresora están diseñados de forma que ni nguna persona pueda verse
afectada por ni ngún ti po de radiación láser superior al nivel de la Clase I dur ante su uso normal, el
mantenimiento realizado por el usuario o cual quier otra situación de servicio técnic o.

Declaração sobre Laser

A impressora e stá cer tific ada n os E.U.A . em conf ormidade com os r equisi tos da regu lamentaç ão DHHS 21 CFR
Subcapítulo J para a Clas se I (1) de produt os laser . Em outr os locai s, est á cer tific ada co mo um produ to laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos lase r da Class e I não são cons id erados per igosos . Inte rnamen te, a impress ora contém um produ to
laser da Classe IIIb (3b), design ado 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 radiaç ão laser superior a um nível de Classe I
durante a operação nor m al, a manutenção f eita 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 eis en vastgelegd in DHHS 21 CFR Subchapter J, voor andere la nden in IEC 60825-1.

Laserprodukten van klasse I worden niet al s ongevaarlijk aangemerkt. De printer i s voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gal lium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het laser gedee lte en de print er zijn zo ontworp en dat bij normaal gebr uik, bi j onder houd of repar atie
conform de voorschriften, nooit blootstelli ng mogelijk is aan laserstraling boven een niveau zoals
voorgeschr even is voor kl asse 1.

Lasermeddelelse

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

nominelt er en 5 milli watt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at m ennesker aldrig udsæ ttes for en laserstråling over Klasse
I-niveau ved nor m al dr ift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Laserilmoitus

Tämä tulostin on sertif ioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) ­lasertuot teeksi ja muualla IEC 60825-1 -standardin mukai seksi luokan I lasertuotteeksi.

Luokan I laser tuot teit a ei pi detä hai tall isi na. Tul ostimen sisäl l ä on luok an III b (3b) laser, joka o n ni mellist eholt aan
5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteelt aan sellaisia, että käyttäjä ei joudu al tt iiksi luokkaa 1 suuremmalle säteily lle normaalin käytön,
ylläpidon tai huollon aikana.

Huomautu s las er laitteesta

Tämä kirjoi tin on Yh dysval loiss a luokan I (1) las erlai ttei den DHHS 21 CFR Subc hapt er J -määr ity ksen mukai nen
ja muualla luokan I laserlaitt eiden IEC 60825-1 - määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käytt äjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5
milliwatin gal liumarsenidilaser, joka toi mii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirj oitin on
suunniteltu siten, että käyttäjä ei altistu lu okan I määrityk siä voimakkaamm alle säteilylle kirjoitt imen 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 laserst rålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivar e 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 Kl ass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådli ga. Skrivaren har en inbyggd laser av Klass IIIb (3 b) som består av
en laserenhet av gal lium-arsenid på 5 milliwatt som arbetar i våglängdsomr ådet 770-795 nanometer.
Lasersystem et och skrivaren är utforma de så att det aldrig f inns risk för att någon person utsätts för
laserstrå lning över Klass I-nivå vid nor ma l användning, underhåll som utförs av användaren eller annan
föreskriv en serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J , f or 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 farli ge. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir stråli ng i bølgelen gdeom rådet 770-795 nanometer.
Lasersystem et og skrive ren er utformet slik at personer aldri utsett es for la serstrål i ng ut over klasse I-n ivå under
vanlig bruk, vedlikehold som utføres av brukeren, ell er fo reskrevne serviceoperasjoner.

Notices and safety information xix

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Avís sobre el Làser

Segons ha estat cert ificat als Estats Units, aquesta impressor a compleix els requi sits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha esta t certificat en altres llocs, és un producte làser de cla sse
I que compleix els requisits d’IEC 60825-1.

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

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Notices and safety information xxi

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Safety information

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

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

• The maintenance inf ormation fo r th is 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 servi ce personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there i s a danger from hazardous volta ge i n the area of the

product where you a re work ing. Unp lug th e product be fore y ou begin, or us e cau tion i f th e product
must receive power in order to perform th e task.

Consignes de sécurité

• La sécurité de ce pro duit repose sur des tests et des

agréations por tant sur sa conception d'origine et sur des com posants particuliers. Le fabricant n'assume
aucune respon sabilité concernant la sécurité en cas d'ut ilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparati on 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 néce ssaires.

• 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 tensio n.

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Norme di sicurezza

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

specifici. Il produttor e non è responsabile per la sicurezza in caso di sostituzione non autorizzata dell e
parti.

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

assistenza autorizzato.

• Durante lo smontaggio e la manutenzi one di questo prodo tto,

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

• ATTENZIONE: Questo simbolo indi ca la presenza di tensione pericolosa nell'ar ea del prodotto.

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

Safet y information xxiii

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Sicherheitshinweise

• Die Sicherheit di eses Produkts bas iert auf Tests und Zul assungen des ursprünglichen Modells und

bestimmter Baut eil e. Bei Verwendun g nicht genehmigter Ersatzteile wird vom Herstell er keine
Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produk t si nd 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 i n diesem

Bereich des Produkts auf tret en kann. Zieh en Sie vor den Arbeit en am Gerät den Netzsteck er des
Geräts, bzw. arbeiten Sie mit großer Vorsi cht, 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

específico s. El fabri cante no es responsable de la seguridad en caso de uso de pi ezas de repuesto no
autorizadas.

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

cualificado de mantenimiento.

• Existe mayor riesgo de de scarga e léc trica y de dañ os pe rsonal es du rante e l desmont aj e y la r eparaci ón 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 otenga cuidado si, para
trabajar con él, debe conectarlo.

Inform a çõ es de Segurança

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

específico s. O fabr icante 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 ferimentos graves durante a desmontagem e manutenção deste produto.

Os profissi onais 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 eléctr ica ou seja cu ida doso caso o pr oduto t enha de estar liga do à c orrent e eléc tric a para
realizar a taref a necessária.

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Informació de Seguretat

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

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

• La informació pel ma nteniment d’aquest producte està orient ada 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 prend re
les mesures con venients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la par t de l 'equip amb la qual esteu

treballan t és perill ós. Abans de començ ar, desendol leu l' equip oextremeu les precaucion s si, per
treballar am b l'equip, l'heu de connectar.

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Safet y info r m a tio n xxv

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Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General infor m a ti o n contains a general description of the printer and the maintenance approach used to

repair it. Speci al tools and test equipment, as well as general environmental and safety instr uctions, are
discussed.

2. Diagnostic information contains an error indicator table, sym ptom 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 infor ma t io n provides instructions for making printer adjustments and removing and i nstalling

FRUs.

5. Connector locati ons uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to pr event

problems.

7. Parts catalog cont ains illust rations and part numbers for individual FRUs.

Appendix A contains service tips and information.
Appendix B contains representative print samples.

Change history

Revision date Updates

2012/02/21 Changed PN 40X0556 to 40X8459 for the USB connector assembly in “Covers 2” on

2012/02/09 Added warning with symbol to the “Upper printer engine car d assem bly removal” on

2011/12/13 Interchanged items 2 and 3 in “Printer left door assembly 1” on page 7-17 to coincide

Navigation buttons

This manual contai ns navigation buttons in the right margin of eac h page, making it eas ier and quicker to
navigate.

Button Description

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page 7-4.

page 4-90and added the “Upper printer engi ne card assembly re-installation” on
page 4-91.

with the art.

Click to move the document view backward by one page.

Click to move the document view for ward by one page.

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Click to return to the last page viewed.

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Conventions

CAUTION

A caution identifies something that might cause a servicer har m.

CAUTION

This type of caution i ndicates there is a danger from hazardous volta ge in t he area of the
product where you are working. Unplug the product before you begi n, or use caution if the
product must recei ve power in order to perform the task.

CAUTION

This type of caution i ndicates a hot surface.

CAUTION

This type of caution i ndicates a tipping hazard.

Note: A note provides additional information.
Warning: A warning identi fi es something th at might damage the product hardware or software.

There are several types of caution statements:

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1. General in formation

The Lexmark™ C935 is color laser printer. All inform ati on in this service manual pertains to both models unless
explicitly noted.

Printer technology

• Color lase r

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 temper atur e 15.6 C to 32.2 C (6o to 90°F
Relative hum idity 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

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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 electri cal or cabling connections, such as the

power cord or options and features, during a light ning storm.

Basic model

The followi ng illustration shows a printer with its base features.

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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 followi ng illustration shows a fully configur ed printer. Items denoted with an asterisk (*) are options.

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General information 1-3

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MPF

MPFpickroll

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 f rom th e MPF, tray 1, 2, 3 or 4, and is transported t o the printer along th e media transport path
shown below.

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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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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 sens o r s

Functions of main components

• Media tray assembly

• Media feed unit ass emb ly

• MPF

• Xerographics

• Transfer

• Fuser

• Drive

• Electrical components and rolls

Media tray assembly

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It is necessa ry to adjust t he media tr ay rear guide and m edia t ray end gui de of th e media tr ay ass embly to mat ch
the media size.

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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 p la te

The force pushing up the bottom plate is transmitted by the driving fo rce of the motor on the media feed unit
assembly. The bottom plate is pushed up by the rotation of the lift up shaf t, which causes the supplied media to
come in contact with the pick roll.

Media tray assembly

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Detection of medi a si z e

The media size s et for t he media t ray ass embly is tr ansmit ted to the swi tch (media s ize) b y movi ng thes e guides.
The media size is dete cted by the on/off i nformation of these switches.

Media feed unit assembly

Since tray 1 and tray 2 are functionally equiva lent in terms of the switch (media size), sensor (media out),
sensor (media lev el) and sensor (pre-feed), only the component s of one tray are descri bed here.

The media feed unit assembly is a mechanical unit supplying media from the m edia tray assembly to the printer.
The driving force, from the media feed lif t motor on the media feed uni t assembly, is transm itted to the three
media feed rolls to fe ed me dia.

When the pick roll picks up media, the rem aining media decreases, and the actuator of the sensor (med ia level)
lowers accord ingly. When the sensor (media lev el) detects the lowering, the med ia f eed lift motor is activated to
lift the lift up shaft and the bott om plat e accordingly. Thus, the remaining media is ready to be fed.

General information 1-7

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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 acti vated t o feed med ia and to lif t the bo ttom pla te. When fee ding me dia, it r otates forward to dri ve the
pick roll . When lifting the bottom plate, it rotates reversely to drive t he tray module gears to lift the li ft up shaft.

Switch (media size)

This switch (media size) sets the size of media supplied from each medi a tr ay assembly. A signal indicating the
media size is transm itted as a voltage to the printer engine card assembly.

Sensor (media out)

If media runs out in a media tray assembly, the actuator lowers and the actuat or flag, unlocks the sensing area of
the sensor (media out). The sensor light is transmitted. When the sensing area is blocked (media is present), the
signal is off.

Sensor (media level)

This sensor de tects by t he actuat or posi tion whether med ia in the med ia tr ay as sembly i s lif ted. When the flag o f the
actuator unbl ocks the sensi ng area of the sensor (media level), t he sensor detects that the media has been lifted.

Sensor (feed-out)

This sensor de tects t he med ia jus t afte r it is f ed fro m the med ia feed unit. When t he flag of the ac tuator unbloc ks 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 rel ay sensor along the medi a path up to the sensor (registration) in order for the engine to monitor media
location.

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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/t ransport 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 pr inter.

MPF pick solenoid

The MPF pick solenoid t ransmits the driving force from the MPF/transport drive to the MP F feed r oll s.

Sensor (MPF media out)

The sensor (MPF media out) detects whether medi a is present on the MPF.

Sensor (MPF media width)

The MPF side guides detect s the width (lengt h 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 C93 5, 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

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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 (regi stration) is located just before the registration roll assembly can detect whether media exist s in
the registration path.

Sensor (transparency detect)

This sensor is used to det ect tr ansparen cy medi a in order to automat ical ly adj ust fee d speed, charge bi ases and
fuser temperat ures.

Registration clutch

The registr ation clutch transmits the drive force of the K developer/transport drive motor to the registration roll
assembly.

Media transpo r t r o l l as sembly

The media transpor t rol l assembly fe eds paper from tray 2, tray 3 and tray 4 toward the registrati on roll
assembly.

Registration roll assembly

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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 mo me nt t o 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 rot ate the transfer belt.

Transfer belt cleaning a ssembly

This assembly is us ed to re mo ve residual toner images from the transfer belt after 2nd transfer and before the

next print cyc le.

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Transfer belt unit ass embly

The transfer belt unit assembl y contains the four 1st transfer rolls; these 1st transfer rolls are referred to as the
CMYK transfer rolls . The CMYK tr ansfer rolls are positively charged to remove the developed toner image from
the four drums. The neg ati vely charged toner image is attracted by posi tive charges on the surface of the
transfer b elt. Thus, t he toner image i s trans ferr ed from t he dr um surfa ce to t he t ransfe r belt surfa ce. During b la ck
(K) only, operati on the CMY transfer rolls are retract ed to reduce wear on the transfer belt surface and CMY
drums.

Transfer belt steering mot or

This motor is used to en sure tha t the transf er belt is proper ly tra cking. If the trans fer bel t start s to tra ck off-cent er
then the transfer belt steeri ng m otor will activat e to keep the transfer belt centered and tracking properly.

2nd transfer roll assembly

The 2nd transfer roll assembly appl ies positive charges to the rear surface of the media when the media passes
between the 2nd transfer roll ass em bly and the transfer belt. The negatively charged toner image is attracted by
positive charges on the surface of the media. Thus, the toner image i s 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 occurrin g.

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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 surf ace 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.

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1. LD card assembl y — gen erates a laser beam with the four LDs. The beam is turned on or off according to
a print data signal . The pr int head contain s 4 LD card assemblies for t he colors CMY & K.

2. Pr inthe ad motor/p olygon mir ror — the poly gon mirro r is mounted to the shaft of t he printhead m otor, and is
rotated at a high speed by the printhead m otor. The mirror rotation shif ts the incidence and reflecti on
angles of a laser beam to scan the laser beam in the dru m axial direction. The laser beam reaches the
polygon mirror as it passes through multiple lenses, mirr ors, and windows. The laser beam then arrives at
the drum surface.

3. SOS car d assem bly — 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 turni ng on and off the
beam, one line of latent image is created. If t he scanning by the laser beam is repeat ed while rotating the drum,
a two-dimensional image is created. The resolut ion in the scanning direction (from right to left) is determined by
the rotational sp eed of th e print head mo tor, dependi ng on how quick ly the laser i s adju ste d. The res olution i n the
process direction (fr om 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.)

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Printhead

Conceptual diag ram of an i m age created by scanning

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Y Laser Path

Polygon Mirror

Y drum

Sensor
(Y start of scan)

M Laser Path

Polygon Mirror

M drum

Sensor
(M start of scan)

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C Laser Path

C drum

Sensor
(C start of scan)

Polygon Mirror

K Laser Path

K drum

Sensor
(K start of scan)

Polygon Mirror

1-16 Printer Service Manual

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 gla ss from becoming dir ty, the shutter stays closed except when laser beams
are written onto the drums.

The printhead shutter motor assem bly is used to prevent contamination from obstructing the printhead slit
glasses. The print head shutte rs for yell ow, magent a, cyan and b lac k are ope ned or clos ed simul tan eously by the
printhead shut ter motor assembly.

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Fuser

Fuser cooling fan

Heat roll

Sensor (fuser exit)

Pressure

belt
Thumb
screws

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Heat roll

The heat roll is a ho llow meta l tube wi th a coate d surfac e. This tube is heated by the inne r hea ter lamp . The heat
is applied to the media passing between the heat roll and pre ssure roll, fusing the toner on the media.

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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 gl ass 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 temp erature exceeds the preset temperature, the thermostat cuts off the ci rcuits of the main
heater lam p and sub heater lamp.

Front thermistor

The front thermistor monitors the surface temperature of the medi a-feed portion of the heat roll to control on/of f
of the main heater lamp and sub heater lamp.

Rear thermistor

The rear thermis tor monitor s the surf ace tem peratur e at the rear si de of the heat roll to swi tch the heat er lamp to
on.

Fuser exit sensor

The fuser exit sen sor detects the arr ival 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 exi t ejects print ed m edia from the printer to the standard bin 1.

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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 (standa rd bin full) detects whether the standard bin is full by moving the actuator up and down.

Standard media exit sh i ft motor

The standard media exi t 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, med ia i s 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

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K developer/transport
drive motor assembly

MPF/transport
drive motor

K drive motor

CMY drive motor

The MPF/transport dri ve m otor is a stepper motor that drives the MPF unit assembly and media transport roll.

CMYK PC cartridge drive motor assembly

The CMYK PC car tridge drive motor assembly uses dual DC brushless motors that drive the four drums in the
four PC cart ridges.

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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 brus hless motor to driv e the th ree color developer unit
assemblies.

K developer clutch

This clutch is used to engage the K developer unit assembly and is driven by the K-de veloper/transfer drive
motor assembly.

CMYK toner add motor assembly

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Switch (waste toner

cartridge interlock)
Sensor (waste toner
cartridge full)

Waste toner agitator
motor assembly

The CMYK toner add motor assembl y consists of 4 separate DC motors. Each color of toner has its own motor
that is used to rotat e the t oner 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
distribu te col lected 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 (printe r left door interlock)

The switch is a safety switch to cut off a 24 VDC power supply f rom 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.

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Charge roll HVPS
card assembly

Developer roll
HVPS card assembly

CMYK transfer
roll HVPS
card assembly

Fuser cooling fan

The fuser cooli ng fan discharg es air from the printer to prevent excessive temperature increase.

AC drive card assem b ly

The AC drive card a ssembly ac cept s the ma in sour ce volt age and di st ributes i t to sec ondar y power su ppl ies and
circuit boards. It also cont ains the fuser rel ay to feed/cut off AC powe r to t he heater lamps of the fuser unit
assembly.

5V LVPS card assem b ly

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 car d assembly generates 24 V for motor s/clutches from AC power.

CMYK tr an sfer 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 assem bly

Charge ro l l HVPS card as sembly

The HVPS card assembly generates AC power and feeds it to the four charge rolls.

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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 ca rd assembly

The upper printer engine card assembly controls printing operat ion based on the communication with the RIP
card assembly and opti onal peripherals. It also controls toner dispense, erase lamps and fuser control.

Lower printer engine card assembly

The lower printer engine card assembly controls printing oper ati on based on the 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 oper ations.

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Control

Media size control

Media tray assembly feeding
The following tabl e gives the states (on/off) of the switches on the sw it ch (media size), corresponding to the

media sizes of the medi a tray assembly.
Note: The switches on the switch (media size) are denoted by “S/W2”, “S/W4”, “S/W3”, “S/W5” , and “S/W1”

respectivel y 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 Off 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 printhea d motor

The on/off control of the printhead motor is perfor med according to t he 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,

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.

Sleep mode Always off

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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 re ference value.

Printhea d re ference 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 cont rol of the main/ sub heater lamps is performed based on the fuser control temperature. The fuser
transmits bet ween the five states (warm up, ready, standby, pri nt, and low power) depending on the heat roll
surface temperature or prin ter conditions.

The fuser temperat ure control starts when the fuser ready in the AC drive card assembly is turn ed on after a
preset time per iod has p assed from power on . If a f ailure occ urs , the heater lamps are turn ed off, the fuse r ready
is turned off, and then the fuser temperature cont rol is stopped.

Main/sub heater lamps on/off control

The front and rear thermistors detect the heat roll surface temperature (fuser temperature) to regulate the
temperature at the ta rget control temperature by turning on or off the main/sub heater lamps.

Fuser warm-up

The fuser warm- up star ts at t he ti me of p ower on, inter lock op en or cl ose, j am res et, or return f rom t he low powe r
mode, and ends when the ready te mp erature is attained, when a failure occurs, or when executing diagnosis.

printhead motor)

motor)

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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

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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 ele ctrostatic charge on the surface of the drum. The drum surface is
made of a photoconducti ve 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 conducti ve roll that is positioned slightly above the sur face of the drum. The HVPS supplies
the charge roll with two voltages; a negative DC charge voltage and an AC discharge vol tage that is used for
electricall y cleaning the drum.

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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 soft ware.

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 cont roller sends a command to print a black pixel, the laser swi tches
on long enough to shine onto the drum at a single pixel point. That poi nt 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, electros tat ic image on the surface of the drum. This image
is called a latent image.

Development

The toner contained within the PC Cartridge has a magnet ic property that causes it to adhere to the Magnetic
Roll. The Metering Bl ade spreads the toner into a very thin layer on the Magnetic Roll . Friction between the
Magnetic Roll and the CM Blade generates a small el ectrical charge that is transferred to the t oner.

The surface of the Magnetic Roll is made up of a thin sheet of conductive materi al. The HVPS suppli es 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 th e surf ace of the drum. The AC voltage agitates th e toner on the Magnetic Rol l, mak ing
toner transfer easier.

The Magnetic Roll maintains a negative DC electrical potential. Negative char ged areas of the drum have a
lower electrical potential, or higher rel ative negative value t han the Magnetic Roll. Discharged areas of the drum
have a higher electri cal poten tial, or l ower relati ve negati ve value, than the Magnetic Rol l. A discha rged point on
the surface of the drum now appears less negative in relation to the negative charge on the Magnetic Roll.

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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 adherin g to the Magnet Roll is alway s in contact with the drum surf ace. Whe n a less negative poi nt on
the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet Roll , to ner
transfers from the Magn et Roll to that poi nt on the d rum. There is now a visi ble tone r image on t he drum surf ace.
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 appli es a
positive charge to the back of the pri nting paper. This positive charge tran sfers 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

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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 rel ative electr ical differences between the negative electrical charge
of the inner conductive layer of the drum and the positive electri cal charge of the paper.

Cleaning

The Cleaning Blade remo ves any toner that remains on the drum after the transfer process. The toner that the
Cleaning Blade remo ves is collected insi de the sealed PC Cartridge and reused.

Discharge

At both the start and the end of each indivi dual printer cycle, the erase lamps electrically clean the drum. Th e
light emit ted removes any residual DC charge that was left from the previous print cycle.

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DRUM

Ground

Erase lamp LED array

Image density
sensor assembly

At the beginning of e ach indi vidual pri nte r cycl e, the Pri nth ead scans t he s urface of the d rum, fu rther dischar ging
any residual DC charge that may be left on the drum.

Auto density sensing

1-32 Printer Service Manual

The image density sensor assembl y uses a ref lection type sensor that detects a pre-placed toner patch and
image on the tran sfer bel t and out puts pul ses when th e cent ral lin e of the pat ch image al igns wi th 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-regi stration detection. If no color
mis-regist ration occurs, pulses are output at regular intervals.

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TTM theory

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General information 1-33

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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 transport roll 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 pat h
shown below.

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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 cro ss section of the printer and the tandem tray module , showi ng the main compo nents
directly associated with the media path and transport.

Media tray assemb ly

Functions of main components

When the TTM is installed under the printer, additional trays are available.

It is necessary to adj ust the rear side guides in the media tray assembl y to match the media size.

Rear media guide

The rear media guide can be adjust ed to diff erent medi a sizes by movin g it to the front or rear. The guide comes
into contact wit h the rear edge of the media and holds it in position.

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Rear media guide

Bottom plate

End guide

Bottom p la te

The force pushing up the bottom plate is transmitted by the driving fo rce of the motor on the media feed unit
assembly. The bottom plate is pushed up by the rotation of the lift up shaf t, which causes the supplied media to
come in contact with the pick roll.

The force pushi ng up the bottom plate of tray 3 is transmitted by the driving force of the media feed li ft mo tor on
the media feed unit assembly to the media lift shaft assembly through t he tray lift gear assembly 3. The bottom
plate is lifted up via the rear tray cables, front right cable and fr ont left cable by t he rotation of the tray lift shaft
assembly, which causes the supplied media to come into contact with 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 b y the rotation of the
tray lift shaf t assembly, which causes the supplied media to cont act the pick roll .

Tray 2 med i a tray assembly

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Tray 3 or 4 m ed i a tr ay assembl y

Rear lift cables

Rear media guide

Bottom plate

F/R lift cable

F/L lift cable

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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 m edia tray assembly to the printer.
The driving force f rom the media feed lift mo tor on the media feed unit assem bly is transmitted to the three roll
assemblies to fe ed me dia.

When the pick roll picks up sheets of media and the remaining media decreases, the media level actuator of the
sensor (media lev el) lowers accordingly.

Media feed l i ft mo tor

The media feed lift motor is activated to feed media and to lif t the bottom plate. While feedi ng me dia, it rotates
forward to dr ive the pick rol l. 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) set s the size of media supplied from each medi a tray assembly. A signal indicatin g the
media size is transm itted 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 supplie d from each media tray assembly.
A signal indicati ng the set size is transmitted as a voltage to the printer engine card assembly.

Sensor (media out)

If there is no media in the med ia t ray 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
transmitt ed. When the sensing ar ea is blocked (media is present), the signal turns off.

Sensor (media level)

This sensor detec ts by the actuat or pos ition wheth er medi a in the media tray assembly is lifted. When the flag of
the actuator leaves the sensor (med ia level) sensi ng area, the sensor detects that the media has been lifted.

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Front

Switch (TTM media size)

Media feed lift motor

Sensor (media level)

Sensor (media out)

Media feed unit assembly

Main components

Switch (tray module le ft door interlock)

The switch (tray mo dule left door interlock) detects open/close of the tray m odule left door assembly.

Sensor (tray 2 fee d-out)

The sensor (tray 2 feed- out) detects media fed from trays 2, 3, or 4.

Sensor (tray 3 fee d-out)

The sensor (tray 3 feed-out) detects media fed from the tr ay3 or tray 4.

Sensor (tray 4 fee d-out)

The sensor (tray 4 feed-out) detects media fed from the tr ay4.

Tray module media transport roll assembly

The tray module transport roll assembly feeds media from the tray 3 or tray 4 to the printer.

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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 dri ve the media trans port me chanism 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 assemb ly.

TTM controller card as sembly

The TTM controll er card assembl y, which contains a CPU, controls media feed in the tandem tray modul e upon
receiving a command from the upper printer engine card assembly and sensor/switch information.

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Switch (TTM media size)

The followi ng table gives on/off states of the switches on the switch (TTM media size), corresponding to the
media sizes of the medi a tray assembly.

Note: The switches (TTM media size) are denoted by “S/W1” and “S /W3” respectively from the left side.

Media Size

Analog switch

S/W1 S/W3

No Tray Off Off
B5L/7.25” x 10.5”L Off On

8.5” x 11”L On Off
A4L On On

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3TM theory

1-42 Printer Service Manual

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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 transport roll 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.

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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 cro ss section of the printer and the tandem tray module , showi ng the main compo nents
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 adj ust the rear and the end guide in the media tray assembly t o match the media size .

Rear media guide

The rear media guide can be adjust ed to diff erent medi a sizes by movi ng it to the front or rear. The guide comes
into contact wit h the rear edge of the media and holds it in position.

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Rear media guide

Bottom plate

End guide

Bottom p la te

The force pushing up the bottom plate is transmitted by the driving fo rce of the motor on the media feed unit
assembly. The bottom plate is pushed up by the rotation of the lift up shaf t, which causes the supplied media to
come in contact with the pick roll.

Tray 2, 3, 4 m ed i a tr ay assembl y

3TM medi a feed units

Media feed unit assembly

Since the tra y 2, t ray 3, and tray 4 are functionally equivalent in terms of the switch (medi a size), sensor (media
out), sensor (me dia 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 m edia tray assembly to the printer.
The driving force f rom the media feed lift mo tor on the media feed unit assem bly is transmitted to the three roll
assemblies to fe ed me dia.

When the pick roll picks up sheets of media and the remaining media decreases, the media level actuator of the
sensor (media lev el) lowers accordingly.

Media feed l i ft mo tor

The media feed lift motor is activated to feed media and to lif t the bottom plate. While feedi ng me dia, it rotates
forward to dr ive the pick rol l. 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 si ze) switches the setting of the size of media suppl ied from each media t ray 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 med ia t ray 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
transmitt ed. When the sensing ar ea is blocked (media is present), the signal turns off.

Sensor (media level)

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This sensor detec ts by the actuat or pos ition wheth er medi a in the media tray assembly is lifted. When the flag of
the actuator leaves the sensor (med ia level) sensi ng area, the sensor detects that the media has been lifted.

Main components

Switch (tray module le ft door interlock)

The switch (tray mo dule left door interlock) detects open/close of the tray m odule left door assembly.

Sensor (tray 2 fee d-out)

The sensor (tray 2 feed- out) detects media fed from trays 2, 3, or 4.

Sensor (tray 3 fee d-out)

The sensor (tray 3 feed-out) detects media fed from the tr ay3 or tray 4.

Sensor (tray 4 fee d-out)

The sensor (tray 4 feed-out) detects media fed from the tr ay4.

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Tray module media transport roll assembly

The tray module transport roll assembly feeds media from the tray 3 or tray 4 to the printer.

Tray module drive motor

This motor is used to dri ve the media transport mechanism in the tray module.

3TM controller card assembly

The 3TM controll er card assembly, which contains a CPU, controls media feed i n the tandem tray module upon
receiving a command from the upper printer engine card assembly and sensor/switch information.

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Switch (media size)

The followi ng table gives on/off states of the switches on the swit ch (media size), corresponding to the media
sizes of the media t ray assembly.

Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side.

Media Size

Analog switch

S/W1 S/W3

No Tray Off Off
B5L/7.25” x 10.5”L Off On

8.5” x 11”L On Off
A4L On On

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1TM theory

5057-XXX

General information 1-49

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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 transport roll 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.

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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 adj ust the rear and the end guide in the media tray assembly t o match the media size .

Rear media guide

The rear media guide can be adjust ed to diff erent medi a sizes by movin g it to the front or rear. The guide comes
into contact wit h the rear edge of the media and holds it in position.

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Rear media guide

Bottom plate

End guide

Bottom p la te

The force pushing up the bottom plate is transmitted by the driving fo rce of the motor on the media feed unit
assembly. The bottom plate is pushed up by the rotation of the lift up shaf t, which causes the supplied media to
come in contact with the pick roll.

Tray 2 media tr ay ass emb ly

1TM media feed units

Media feed unit assembly

The media feed unit assembly is a mechanical unit supplying media from the m edia tray assembly to the printer.
The driving force f rom the media feed lift mo tor on the media feed unit assem bly is transmitted to the three roll
assemblies to fe ed me dia.

When the pick roll picks up sheets of media and the remaining media decreases, the media level actuator of the
sensor (media lev el) lowers accordingly.

Media feed l i ft mo tor

The media feed lift motor is activated to feed media and to lif t the bottom plate. While feedi ng me dia, it rotates
forward to dr ive the pick rol l. When lifting the bottom plate, it rotates in reverse to drive the tray module gears to
turn the lift up shaft.

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Switch (media size)

The switch (media si ze) switches the setting of the size of media suppl ied from each media t ray 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 med ia t ray 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
transmitt ed. When the sensing ar ea is blocked (media is present), the signal turns off.

Sensor (media level)

This sensor detec ts by the actuat or pos ition wheth er medi a in the media tray assembly is lifted. When the flag of
the actuator leaves the sensor (med ia level) sensi ng area, the sensor detects that the media has been lifted.

Main components

Switch (tray module le ft door interlock)

The switch (tray mo dule left door interlock) detects open/close of the tray m odule left door assembly.

General information 1-53

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Sensor (tray 2 fee d-out)

The sensor (tray 2 feed-out) detects media fed from the tr ay2.

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 dri ve the media trans port me chanism 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/swit ch information.

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Switch (media size)

The followi ng table gives on/off states of the switches on the swit ch (media size), corresponding to the media
sizes of the media t ray assembly.

Note: The switches (media size) are denoted by “S/W1” and “S/W3” respectively from the left side.

Media Size

Analog switch

S/W1 S/W3

No Tray Off Off
B5L/7.25” x 10.5”L Off On

8.5” x 11”L On Off
A4L On On

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Duplex

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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 (doub le- sided) printing is available with the pri nter.
The followi ng outlines the functions of the main components of the duplex.

Switch (duplex left door interlock)

The switch (left door interl ock) 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.

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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 med ia f eed in the duplex upo n recei ving a
command from the upper printer engine card assembly and sensor/swit ch information.

Duplex drive motor

The duplex drive mot or tr ansmits driving force to the two duplex media transport roll assemblies and the duplex
media center tra nsport roll assembly middle that feeds medi a.

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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 increment al ruler

5057-XXX

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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 Integrat ed Circuit
ATC Automatic Toner Control
CRU Customer Replaceabl e 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 Electrostati c Discharge
FRU Field Replaceable Unit
GB Gigabyte
GFI Ground Fault Interrupter
HCF High-Capacity Feeder
HVPS High Voltage Power Suppl y
LASER Light Amplificatio n by Stimu lated Emission of Radiat ion
LCD Liquid Crystal Display
LD Laser Diode
LED Light-Emitting Diode
LEF Long Edge Feed
LVPS Low Voltage Power Supply
MPF Multi-Purpose Feeder
MS Microswitch
NVM Nonvol atile Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
OPT Optical Sensor
PC Photoconductor
PEL Pictur e 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 Rast er Imaging Processor
ROM Read only Memory
RPM Revol utions Per Minute
SDRAM Synchronous Dual Random Access Memory
SEF Short Edge Feed
SIMM Single Inline Memory M odule
SOS Start of scan

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SRAM Static Random Access Memory
TTM Tandem Tra y Module
TVOC Total Volatile Organic Compound
UPR Used Parts Return
VVolts
V ac Volts alternating current
V dc Volts direct current

5057-XXX

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1-62 Printer Service Manual

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General information 1-63

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2. Diagnostic information

CAUTION

Unplug the power cord from the electric al out let before you connect or disconnect any cable
electronic board or assembly.

CAUTION

If the printer is kept on, never t ouch the conduc tive part s if not specif ically requir ed. The power
switch and inlet of the l ow volt age power s upply ca rd ( LVPS card) assembly i s li ve even whi le
the power supply is cut off. Never touch the live parts.

CAUTION

Be careful to avoid burns by saf ely handling hot parts.

CAUTION

The standard finisher weight is 59 kg (130 lb.) and requir es at least two people to l ift it safely.
The booklet fini she r weight is 87. 5 kg (193 l b.) and requir es at l east fo ur pe ople to li ft i t safel y.
Make sure your finge rs are not under the finisher when you lift or set it down.

The MFP weighs approximate ly 173kg (383 lb.) and requires at least four people to lift it safely .
Make sure your finge rs are not under the MFP when you li ft or set it down.

Start

5057-XXX

Warning: When operating the driving units usi ng the di agnos tics or other tools , be sure to kee p them cove red

unless otherwi se specified.

Warning: When operating the driving units using the diagnostics or othe r tools, never t ouch the driving units.

When operating the dr iving units usi ng diagnostics or other tools, be sure to follow the procedure s
in this manual.

Warning: Servicers should wear a wrist band or the li ke to remove st atic el ectrici ty fr om their bod y, groundi ng

their body while work ing. 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 ass istance.

Diagnostic information 2-1

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Confirm the installation status

Be sure to check the following items before starting the troubleshooting procedures.

• With the power co rd un plugged f rom the wal l out let, check th at the co rd is f re e from bre akage, sh ort-c ircui t,

disconnected wire, or incorrect connection in the power cord.

• The printer is properly grounded. Check the power cord ground terminal.

• The printer is no t inst alle d at a plac e subjec ted to extr eme temp erature, e xtrem e humidi ty or r apid chan ges

in temperatur e.

• The printer is not i nstalled close to water service, humidifier, heat generating unit, fire, in a very dusty

place, or a place exposed to air flow from the ai r conditioning system.

• The printer is not installed in a place where volatile gas or inflammable gas is generated.

• The printer is not i nstalled in direct sun.

• The printer is inst alled on a level and stable surface.

• Media meets specificat ions and is installed properly.

• Customer maintenance parts have been replaced at the specified int ervals.

• Check all attached options for proper attachment and electrical connection.

• Refer to th e User’s Guide for proper inst allation.

Power-on Reset sequence

The following is an example of the events that occur during the POR sequence:

1. Tur n the machine on.

2. The Lexmark spla sh screen appears with a progress bar in the center until the code is loaded.

3. The scanner expos ure lamp flash es several times.

4. The fuser cooling fan turns on.

5. The fuser unit assembly lamps turn on.

6. The RIP card assembly cooling fan turns on.

7. Oper ator panel LED becomes solid.

8. The transport m o to r tur n s o n.

To enter the diagnostic menu:

1. Turn off the printer.

2. Press and hold the and buttons simultaneously.

3. Turn on the printer.

4. Release the buttons aft er 10 seconds.

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Error co de ta ble

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 reachi ng the sensor (registration)

within the specified time after being fed from any
given media tray.

Go to “200.00 Sensor (reg istration) late jam” on

page 2-23.

Sensor (registration) lag jam The med ia reached the se nsor (registration) but did

not clear it within the specified time.
Go to “200.01 Sensor (reg istration) lag jam” on

page 2-24.

Sensor static jam Media remains in the areas shown on the operator

panel after power on.
Go to “200.02 Sensor static jam” on page 2-26.

Sensor (media on belt) lat e
jam

The media is late reaching the sensor (media on
belt) within the specified time after reaching the
sensor (regi stration).

Go to “200.03 Sensor (media on belt) late jam ”

on page 2-27.

Sensor (fuser exit) late jam The media i s lat e reaching the sensor (fuser exit)

within the specif ied time after reaching the sensor
(registration).

Go to “201.00 Sensor (fu ser exit) late jam” on

page 2-28.

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 reached the sensor (fuser exit) but did

not clear it within the specified time.
Go to “202.00 Sensor (fu ser exit) lag jam” on

page 2-30.

Sensor (duplex wait) late jam
(duplex media feed)

The media is late reaching the sensor (duplex wait)
within the specif ied time after the duplex media
inverter clutch is turned on.

Go to “230.00 Sensor (dupl ex wait) late jam

(duplex media feed) ” on page 2-31.

Sensor (registration) late jam
(duplex media feed)

The media is late reaching the sensor (registration)
within the spec ifi ed time af ter t he duple x driv e moto r
is turned on.

Go to “231.01 Sensor (reg istration) late jam

(duplex media feed) ” on page 2-35.

Sensor (registration) late jam
(duplex media feed)

The media is late reaching the sensor (registration)
within the specif ied time after reaching the sensor
(duplex wait).

Go to “231.01 Sensor (reg istration) late jam

(duplex media feed) ” on page 2-35.

Sensor (tray 1 feed-out) late
jam.

The media is late reaching the sensor (tray 1 feed­out) within the spec ified 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 2-37.

Diagnostic information 2-3

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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.

The media is late reaching the sensor (tray 2 feed­out) within the spec ified 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 2-39.

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

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 (tray1 feed-out) late jam

(feeding from tray 2)” on page 2-40.

Sensor (tray 3 feed-out) late
jam.

The media is late reaching the sensor (tray 3 feed­out) within the spec ified time after the tray 3 media
feed lift motor is turned on.

TTM equipped machi nes go to “243.00 Sensor

(tray 3 feed-out) l ate jam” on page 2-41.

3TM equipped machi nes refer to the Options
Service Manual .

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

The media is late reaching the sensor (tray 2 feed­out) within the specified time after reaching the
sensor (tray 3 feed- out).

TTM equipped machi nes go to “243.01 Sensor

(tray 2 feed-out) l ate jam (feeding from tray 3)”
on page 2-43.

3TM equipped machi nes 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 tray 4)

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 spec ified time after the tray 4 media
feed lift motor is turned on.

TTM equipped machi nes go to “244.00 Sensor

(tray 4 feed-out) l ate jam” on page 2-45.

3TM equipped machi nes 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 machi nes go to “244.01 Sensor

(tray 3 feed-out) on jam (feeding from tray 4)” on
page 2-47.

3TM equipped machi nes refer to the Options
Service Manual .

The media is late reaching the sensor (registration)
within the speci fied t ime aft er the MPF pic k solenoi d
is turned on.

Go to “250.00 Sensor (reg istration) late jam

(feeding from the MPF)” on page 2-49.

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 remai ns on the sensor (bridge unit media

entrance).
Refer to the Finisher Service Manual.

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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) la te jam

The media is late reaching the sensor (bridge unit
media exit) withi n the specified t ime after reaching
the sensor (bridge unit media entrance).

Refer to the Finisher Service Manual.

Sensor (bridge unit media
exit) static jam

Media remai ns on the sensor (bridge unit media
exit).

Refer to the Finisher Service Manual.

Sensor (bridge unit exi t bin)
late ja m.

Sensor (bridg e unit exit bin) is not turned on within
the specified ti m e after the sensor (bridge unit
media entrance) is turned on.

Refer to the Finisher Service Manual.

Sensor (bridge unit exi t bin)
lag jam.

Sensor (bridg e unit exit bin) is not turned off within
the specified ti m e after the sensor (bridge unit exit
bin) is turned on.

Refer to Fini sher Service Manual.

Sensor (bridge unit exi t bin)
static jam.

Sensor (finisher medi a
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

286.00
Paper jam

Sensor (finisher medi a
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 specif ied time after reaching the sensor
(finisher media entranc e).

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 (buff er pat h).

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 specif ied 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 specif ied time.

Refer to the Finisher Service Manual.

Sensor (compiler media in)
static jam

Media remai ns on the sensor (compiler media in).
Refer to the Finisher Service Manual.

Diagnostic information 2-5

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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 exi t)
late ja m

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.

Sensor (upper media exit ) la g
jam

The media reached the sensor (upper media exit)
but did not clear it within the specif ied time.

Refer to the Finisher Service Manual.

Sensor (upper media exi t)
static jam

Sensor (diverter gat e) late
jam

Media remai ns on the sensor (upper media exit).
Refer to the Finisher Service Manual.

The media is l ate r eachin g the sens or (div erter gate)
within the specif ied time after reaching the sensor
(bridge uni t media exit).

Refer to the Finisher Service Manual.

Sensor (diverter gate) static
jam A (to top bin)

The media reached the sensor (di verter gate) but
did not clear it withi n the specified time.

Refer to the Finisher Service Manual.

Sensor (diverter gate) static
jam B (to stacker bin)

The media reached the sensor (di verter gate) but
did not clear it withi n 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 medi a
entrance) late jam

Sensor (booklet medi a
entrance) lag jam

Sensor (booklet medi a
entrance) static jam

Sensor (booklet compi ler in)
static jam

Sensor (booklet medi a exit)
late ja m

Sensor (booklet medi a exit)
lag jam

Sensor (booklet medi a exit)
static jam

The media is late reaching the sensor (booklet
media entrance) within the specified time after
reaching the sensor (bridge uni t 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 remai ns on the sensor (diverter gate).

Refer to the Finisher Service Manual.
Media remai ns on the sensor (booklet compiler i n).

Refer to the Finisher Service Manual.
The media is late reaching the sensor (booklet

media exit) withi n the specified t ime 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 specif ied time.
Refer to the Finisher Service Manual.

Media remai ns on the sensor (booklet media exit) .
Refer to the Finisher Service Manual.

31
Missing or

defective bla ck
cartridge

2-6 Printer Service Manual

Black toner cartri dge
detection er ror

The Black toner cartridge is defective not installed.
Go to “Toner cartri dge error” on page 2-138.

5057-XXX

Go Back

Previous

Next

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 tray2

guides

Error contents Description/Action

<Color> toner cartridge
detection er ror

The <Color> toner cartridge i s defective or not
installed.

Go to “<Color> toner cartri dge detection error”

on page 2-52.

Incorrect black t oner cartridge
error.

A black toner cartridge of an incorrect specification
is installed.

Go to “Incorrect bl ack toner cartridge error” on

page 2-52.

Incorrect <color> toner
cartridge error.

A <color>) toner cartridge of an incorrect
specific ati on is install ed.

Go to “Incorrect <color> toner cartridge error”

on page 2-52.

Tray 1 m edia siz e mismatch
error

The media tray assembly 1 side guide or end guide
is not properly set.

Go to “Tray 1 media size mis match error” on

page 2-53.

Tray 2 m edia siz e mismatch
error

The media tray assembly 2 side guide or end guide
is not properly set.

Go to “Tray 2 media size mis match error” on

page 2-53.

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 m edia siz e mismatch
error

Tray 4 m edia siz e 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 mis match error” on

page 2-54.

The media tray assembly 4 side guide or end guide
is not properly set.

Go to “Tray 4 media size mis match error” on

page 2-55.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 1 media type mismat ch error” on

page 2-55.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 2 media type mismat ch error” on

page 2-56.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 3 media type mismat ch error” on

page 2-57.

The sensor (transparency detect) did not detect
transparency media.

Go to “Tray 4 media type mismat ch error” on

page 2-58.

Diagnostic information 2-7

5057-XXX

Go Back

Previous

Next

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 print e r per formance.

Go to “100K maintenance required” on

page 2-136.

600K maintenance required Service is required to maintain print e r per formance.

Go to “600K maintenance required” on

page 2-137.

Waste toner cartridge full Replace the waste toner cartridge.

Go to “Waste toner cartridge full” on page 2-139.

Waste toner cartridge not
detected

Reinstall the wast e toner cartridge.
Go to “Waste toner cartridge not detected” on

page 2-139.

Waste toner cartridge nearly
full

Waste toner cart ridge is nearing the replacement
interval.

Go to “Waste toner cartr idge nearly full” on

page 2-140.

(Color) PC cartridge not
detected

A (color) PC cartridge is not ins talled or not inst alled
properly.

Go to “(Color) PC cartridge not detected” on

page 2-141.

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

The device does not have a hard drive inst alled,
even though its configuration ID indicates that a
hard drive should be present.

Go to “849.00 Hard drive/ configuration ID

mismatch” on page 2-60.

K PC cartridge nearly
exhausted

The black PC cartridge is neari ng the replacement
interval.

Go to “K PC cartridge nearly exhausted” on

page 2-142.

K PC cartridges nearly
exhausted.

All color PC cartridges are nearing the replacement
interval.

Go to “K PC cartridge nearly exhausted” on

page 2-142.

K PC cartridge exhausted The black PC cartridge requires replacing.

Go to “K PC cartridge exhaust ed” on page 2-143.

CMY PC cartridges
exhausted

All color PC cartridges require replacing.
Go to “CMY PC cartridges exhausted” on

page 2-142.

(Color) PC cartridge invalid A ( color ) PC cartrid ge of an inc orrect specif icat ion is

installed.
Got to “(Color) PC cartridge i nvalid” on

page 2-141.

2-8 Printer Service Manual