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Lexmark C930 & C935 Printer 5057-XXX Service Manual

Contents

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5. B B ETN FO tower printer engine gar ASM P530 7 7 6 5V RTN OPTION 1111 5 5V RTN OPTION 122 4 5V RTN ee BA 3 LEVRAN To Scanner Controller Card Asm 81812 1 am 155 ad J719 166 16 1 6j6 g 177 1712 Ga 18 8 18 3 J300 rer A 199 19 4 313 8 D 24VDC TO lower jenter engine og ASM P530 2 20110 2015 21215 2116 111 SVATN 6 26 1 22 7 5 sua T 27 2 J9 238 5V RTN 28 3 24 9 4 5V RTN 29 4 25110 3 SVATN 305 26111 1 TO 5V LVPS C J511 316 2712 U momens aena AIANEI 32 7 JE FRRR Ea 8 88 8815 cia I HLIIL LIFE FB 3318 29114 TO SV LVPS A 4511 2 d a 2 a zi 2 2 2 BE oa 2 2 22a i 30 15 gt 4 3 8 3 amp 3 5 amp A 9 amp S a a a
6. 7 62 TTM tray separation pad 7 62 7 63 TTM tray 4 rear support roll 2 m 7 63 MPF pickup spring lt lt a sarees e ce eee ese eres cheeses 7 13 Bushing 6 mm oia asnes sd rn ee Se ee ee Se ii Se eee 7 27 7 67 Bushing 6 IMM sees eee shee cee ness 7 11 7 44 7 53 Assorted E clip packet e 7 70 Assorted screw packet 7 70 Bushing 6 mm a rrr errr errr errr eee 7 11 7 44 7 53 Marknet N8000 10 100BaseTX ethernet 7 71 Marknet N8020 10 100 1000BaseT Ethernet 7 71 Marknet N8030 10BaseFL amp 100BaseFX Ethernet multimode fiber 7 71 Marknet N8050 802 119 wireless US 7 71 BushINg S MM gt 2220222 e ii e RS eR eek eee Ee PER TE 7 14 32MB flash card r reer rr ree ee eee eee eee eee 7 71 64MB flash card ne ee eee oe ee eee ees 7 71 128MB memory option eee ree eee ee 7 71 256MB memory option rrr o 7 71 512MB memory option c ccc o 7 71 Japanese font card e 7 71 Simplified Chinese font card 2 eee eee eee eee ee ee 7 71 Traditional Chin
7. 7 45 40X4142 1TM front door assembly 2 2 2 7 40 40X4143 Rear non locking caster eer reer reer rere 7 47 7 57 7 69 40X4152 1TM controller card assembly 7 47 56P2129 Lexmark MarkNet N7020e 4 USB ports 1 0 100 1000 w out power cord 7 70 56P2744 N4050e 802 119 Wireless Print Server Americas Argentina A Brazil w out power cord 7 70 56P2745 N4050e 802 119 Wireless Print Server European UK Ireland amp Australia w out power cord 7 70 Part number index l 9 5057 XXX 1 10 Printer Service Manual 5057 Printer 16 17 Fax Card E ASM 20 21 22 J69 23 24 O 25110 2611 2712 28 13 29114 30115 O CO NI O7 Co PO 23 8 J69 249 2510 2611 27112 28113 129 14 30 15 16 1 172 18 3 19 4 20 5 2116 22 7
8. 7 24 Waste toner agitator motor assembly en 7 24 Sensor waste toner cartridge full e 7 24 Developer interlock plate assembly nto 7 25 CMY erase lamp assembly 7 25 K erase lamp assembly nn 7 25 Left transfer belt lift assembly 2 7 26 L Printer Service Manual 40X3722 40X3723 40X3727 40X3729 40X3730 40X3731 40X3732 40X3733 40X3734 40X3735 40X3736 40X3737 40X3738 40X3739 40X3740 40X3741 40X3742 40X3743 40X3744 40X3745 40X3746 40X3747 40X3748 40X3749 40X3750 40X3751 40X3752 40X3753 40X3754 40X3755 40X3756 40X3757 40X3758 40X3759 40X3760 40X3761 40X3762 40X3763 40X3764 40X3765 40X3766 40X3768 40X3769 40X3770 40X3771 40X3772 40X3773 40X3774 40X3775 40X3776 40X3777 40X3778 40X3779 40X3780 40X3781 40X3782 40X3783 40X3785 40X3786 5057 XXX Right transfer belt lift assembly ee 7 26 Transfer belt lift latch assembly with label 502 0025002 no 7 26 Transfer belt lift handle assembly 2200 r rr rrr rrr r rrr rere 7 26 Transfer belt auger front gear 14T e 7 27 Transfer belt auger rear gear 18T 7 20 rrr rrr rrr rrr rrr rrr eee 7 27 Transfer belt auger assembly e 7 27 Transfer belt unit assembly e 7 27 Transfer belt cleaner assembly 7 27 Transfer belt lift recoil spring
9. assembly 2nd transfer roll assembly CO MPF Registration roll assembly O MPF pick roll O A 5 Media transport roll assembly Tray 1 Y O O D Tray 2 Booklet maker bit Qo optional Tray module transport Tray 3 roll assembly O Finisher Tray 4 optional O O O Pick roll O Feed roll Tray 2 3TM optional Separation roll v D 1TM optional O 2 O Tray module transport roll assembly Tray 2 TTM ae Tray4 ad Tray 3 y Tray 4 transport roll assembly O O General information 1 5 5057 XXX SFP sensors Sensor diverter gate Sensor finisher Sensor bridge unit Sensor bridge media entrance media bin exit unit media exit Sensor upper media exit a Sensor upper LFA media bin full Sensor lower media exit E E D Osx Sensor buffer path Sensor duplex wait Sensor compiler media in ul Freen HN Sensor booklet media entrance o lt S Tray 1 NE O ao Booklet maker unit Sensor booklet ra i i Sensor tray 2 feed out Ea y optional media exit Tray 3 Sensor tray 3 feed out ES o y Finisher JA Tray 4 q optional Sensor standard bin media full Sensor fuser exit Sensor media on belt Sensor bridge unit media entrance Sensor tray 4 feed out O O e O O K Tray 2 Sensor tray 2 feed out 3TM optional vi
10. Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Are the media transfer route and the media path free of Go to step 3 Remove debris contamination or debris or contamination 3 Check the 2nd transfer roll assembly for contamination Go to step 4 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd transfer roll assembly removal on page 4 35 4 Check the four PC cartridges for proper installation Go to step 5 Correct and clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 5 Replace the transfer belt unit assembly Go to Transfer Go to step 6 Problem solved belt unit assembly removal on page 4 16 Does the problem remain 6 Check the heat roll and pressure roll Replace the Go to step 8 fuser unit Remove the fuser unit assembly assembly CAUTION Allow the fuser unit assembly to Go to Fuser cool down unit assembly removal on page 4 15 Is there contamination or cracks on the heat roll and or pressure roll Diagnostic information 2 121 5057 XXX Step Check Yes No Check the upper printer engine card assembly Replace t
11. E Fa g EX IN Ge FJERNERE HA Dante HERB EE BT HE THe P DR EFE AARE BA MLE Die SBAS RAES m DUE ES JE RHEI MD MA Safety information Xxiii 5057 XXX Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment as well as general environmental and safety instructions are discussed 2 Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples Conventions Note A note provides additional information Warning A warning identifi
12. Sensor tray 2 feed out Sensor tray 3 feed out QU q SE 4 A TTM left door assembly sl Switch media size O O Connector locations 5 13 5057 XXX 5 14 Printer Service Manual 5057 XXX 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance AN Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the on off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments LEXMARK C930 C935 SERVICE EVERY EVERY wem CALL MEDIA TRAY ALL Media Side Guides Inspect Inspect Check for correct positioning Media End Guide Inspect Inspect Check for correct positioning Separation Pad Inspect Clean Damp cloth Tray Lift Gear assembly In
13. 2 7 9 Sensor tray 1 feed out 5 02 lt ege e e eee EES 7 9 Magnetic catch nn rere 7 9 Media feed lift motor rr erence rere creer eee 7 11 7 44 7 53 Media tray lift one way clutch 7 11 7 44 7 53 Media tray lift one way gear 7 11 7 44 7 53 Media out actuator ee eeee ee 7 11 7 44 7 53 Sensor 2nd transfer roll retract HP 7 18 Sensor MPF media out m mn emme gt 7 13 Sensor printer left lower door interlock 7 9 Sensor standard bin full gt 7 22 Sensor tray 1 media level 7 11 7 44 7 53 Sensor tray 1 media out 7 11 7 44 7 53 Feed unit roll kit non 7 11 7 44 7 53 Feed roll one way clutch 7 11 7 44 7 53 Feed roll one way gear 22T mmmmmmmmemm 7 11 7 44 7 53 Registration transport roll assembly 7 15 Registration clutch ee 7 15 Sensor registration nn 7 15 Sensor tray 4 feed out
14. Go to AC drive card bracket Step Check Yes No 5 Perform a POR Replace the AC Problem solved Does the error occur when the power is turned off on ler See assembly removal on page 4 95 920 07 Sub lamp on time error Step Check Yes No 1 Check the fuser unit assembly for a media jam Remove the Go to step 2 Is there a media jam in the fuser unit assembly eel 2 Check the fuser unit assembly for proper installation Go to step 3 Install the fuser Is the fuser unit assembly installed properly unit assembly properly 3 Check the fuser unit assembly for proper connection Go to step 4 Repair the Is the above component properly connected connection 4 Perform a print test Replace the fuser Problem solved Does the error continue unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 5 5 Perform a POR Replace the AC Problem solved drive card bracket Does the error occur when the power is turned off on assembly Go to AC drive card bracket assembly removal on page 4 95 924 00 Yellow toner RFID communication error Step Check Yes No 1 Check the Y toner cartridge Go to step 2 Reinstall the Y Is the Y toner cartridge properly installed toner cartridge 2 Check the sensor Y toner RFID for proper connection Replace the Replace the Is the above component properly connected EE connection Go to CMYK toner add motor assembl
15. 7 40 7 49 7 58 Tray module left cover 2 2 2 rrr rrr rrr rrr rrr ee 7 40 7 49 7 58 Tray module rear cover 7 40 7 49 7 58 TTM media tray 3 assembly kit rrr eee 7 60 TTM media tray 4 assembly kit nn 7 60 Switch TTM media size nono 7 60 TTM tray support roll 7 60 TTM tray 3 front cover EE 7 62 TIM tr y 3 slide strip s csos cees so cee reper o A eS Ge ee e E 7 62 TTM tray 3 slide button 7 62 TTM tray A front cover 7 63 TTM tray 4 media transport assembly 7 64 TTM tray 4 upper media guide 22222 rrr rrr rrr rrr rrr rrr eee 7 64 TTM tray 4 lower media guide 7 64 Tray 3 feed out sensor assembly e 7 65 TTM vertical turn guide e 7 65 TTM left door assembly 22 eee eee eee eee ee 7 66 TTM tray 3 lift gear assembly gt 7 67 TTM tray 4 lift gear assembly rrr creer rrr rere errr eee 7 67 TIM tray lift gear 17T 55 creer cere ncn se eset nse entrees ence 7 67 TTM tray lift coupling assembly gt 7 67 TTM tray 4 transport drive motor assembly
16. 7 69 TTM controller card assembly ee 7 69 100K printer maintenance kit 110V 22 rrr rrr rrr rrr rrr rrr ree 7 70 600K printer maintenance kit eee e 7 70 Tray module retainer screw 7 47 7 57 7 69 Tray 3 4 teed out sensor cable assembly 7 55 l 8 Printer Service Manual 5057 XXX 40X4068 Tray module left retaining bracket 7 47 7 57 7 69 40X4069 Tray module right retaining bracket 7 47 7 57 7 69 40X4078 Printer left door assembly 7 16 7 17 7 18 40X4079 MPF feed unit assembly errr rere eee ee 7 12 7 13 7 14 40X4080 Standard output bin paper weight 7 22 40X4081 Upper printer engine card cable assembly 7 39 40X4084 TTM tray 3 lift cable 7 62 40X4085 TTM tray 4 lift cable 7 63 40X4086 Separation roll friction clutch 7 11 7 44 7 53 40X4088 Banner media tray assembly 7 70 40X4089 Operato
17. Lower view Repair information 4 23 5057 XXX Sensor media level removal 1 Remove the printer left lower door assembly See Printer left lower door assembly removal on page 4 8 2 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 21 3 Disconnect the connector from the sensor media level A 4 Release the hooks securing the sensor media level A to the media feed unit 5 Remove the sensor media level A ee Harness 4 24 Printer Service Manual 5057 XXX Sensor fuser exit removal Open the printer left door assembly Remove the E clip securing the fuser exit roll assembly A to the machine Remove the bushing B Remove the fuser exit roll assembly A Remove the two screws securing the sensor fuser exit C to the machine Remove the sensor fuser exit C Release the harness from the clamps Disconnect the connector from the sensor fuser exit C 02 A 01 2 601000 Repair information 4 25 5057 XXX Printer left door assembly removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 3 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 4 Remove the screw securing the connector access cover A to the machine 5 Remove t
18. 4 76 Printer Service Manual 5057 XXX Lower printer engine card assembly removal 1 2 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 Remove the three screws securing the lower printer engine card assembly A to the lower printer engine card bracket assembly B Release the two plastic retainers with needle nose pliers securing the lower printer engine card assembly A to the lower printer engine card bracket assembly B Remove the lower printer engine card assembly A Clamps Repair information 4 77 5057 XXX Transfer belt drive motor cooling fan removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 3 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Disconnect the connector from the transfer belt drive motor cooling fan A Remove the harness clamp from the transfer belt drive motor coo
19. Repair information 4 203 5057 XXX Step Check Yes No Check the image density sensor assembly connection Is the above component properly connected Replace the image density sensor assembly See Image density sensor assembly removal on page 4 44 Replace the connection Re perform the Measurement cycle test again Does the above test pass Perform the Control sensor check Go to Control sensor check on page 4 205 Contact next level of support 4 204 Printer Service Manual Control sensor check 5057 XXX Step Check Yes No 1 Perform the Control sensor check test Perform the Go to step 2 1 Enter the Diagnostics Menu Kg sensor 2 Select ENGINE ADJUST de 3 Select RegCon adjust ote brie h 4 Select Control Sensor Check page 4 205 Does the above test pass 2 Check the transfer belt unit assembly for damage Replace the Go to step 3 transfer belt unit Does above component show signs of damage on the frame or on the belt assembly See Transfer belt unit assembly removal on page 4 16 3 Re perform the Control sensor check test again Perform the Contact next level Control sensor of support Does the above test pass cycle See Control sensor cycle on page 4 205 Control sensor cycle Step Check Yes No 1 Perform the Control sensor cycle test Perform the Belt Go to s
20. removal on page 4 77 202 00 Sensor fuser exit lag jam Step Check Yes No 1 Check the media position Remove the Go to step 2 Does the media touch the sensor fuser exit megia 2 Check the sensor fuser exit for proper operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Fuser exit Caution The area around the actuator is very hot Allow the fuser area to cool before proceeding Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check the sensor fuser exit for proper connection Replace the Replace the Is the above component properly connected sensor fuserexit Connection Go to Sensor fuser exit removal on page 4 25 4 Check the duplex diverter gate solenoid for proper Go to step 6 Go to step 5 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly 5 Check the duplex diverter gate solenoid for proper Replace duplex Replace the connection media inverter connection Is the above component properly connected assembly Go to Duplex media inverter assembly removal on page 4 9 Diagnostic information 2
21. 7 64 Sensor transparency detect gt 7 15 Printer left door damper idler gear 7 16 Printer left door damper assembly e 7 16 2nd transfer roll assembly eee rere eee eee 7 17 Sensor fus r xit ge 5 See ee Re ee eee See eee ne Meee ek seder 7 17 Printer left door duplex exit guide gt 7 17 2nd transfer roll retract cam assembly 7 18 2nd transfer retract motor assembly 7 18 Sensor media on belt gt maces een rte e tees 7 18 Printer left door damper sector gear 2 2 7 18 Standard media exit shift assembly 7 22 Standard exit top cover m gt 7 22 Standard bin full actuator gt 7 22 MPF media out actuator nn gt 7 13 MPF pick roll kit 7 14 Printhead assembly e 7 23 Waste toner cartridge cover 2 2 r rrr rrr rrr rrr rrr rrr 7 24 Waste toner cartridge sensor assembly 00 rrr rrr rrr rrr rrr rrr ree 7 24 Switch waste toner cartridge interlock
22. Drum Surface Drum Surface Image Voltage Laser Beam i ja Beam bei Discharge Level Invisible Latent Image Development The toner contained within the PC Cartridge has a magnetic property that causes it to adhere to the Magnetic Roll The Metering Blade spreads the toner into a very thin layer on the Magnetic Roll Friction between the Magnetic Roll and the CM Blade generates a small electrical charge that is transferred to the toner The surface of the Magnetic Roll is made up of a thin sheet of conductive material The HVPS supplies the Magnetic Roll with two voltages a DC voltage and an AC voltage The DC voltage is used to transfer toner from the Magnetic Roll to the surface of the drum The AC voltage agitates the toner on the Magnetic Roll making toner transfer easier The Magnetic Roll maintains a negative DC electrical potential Negative charged areas of the drum have a lower electrical potential or higher relative negative value than the Magnetic Roll Discharged areas of the drum have a higher electrical potential or lower relative negative value than the Magnetic Roll A discharged point on the surface of the drum now appears less negative in relation to the negative charge on the Magnetic Roll General information 1 29 5057 XXX The toner adhering to the Magnet Roll is always in contact with the drum surface When a less negative point on the drum a discharged area comes in contact with the more negative ch
23. Step Check Yes No 5 Check the sensor registration for proper operation Go to step 7 Go to step 6 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Registration Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor registration for proper connection Replace the Replace the connection sensor connection Is the above component properly connected registration Go to Sensor registration removal on page 4 37 7 Check the MPF pick solenoid for proper operation Go to step 9 Go to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select MPF pick solenoid Does the above component operate properly 8 Check the MPF pick solenoid for proper connection Replace the MPF Replace the connection feed unit connection Is the above component properly connected assembly Go to MPF feed unit assembly removal on page 4 8 9 Check the MPF transport drive motor for proper operation Go to step 11 Skip to step 10 Caution When performing motor tests ensure that all cover and door interlock switches are overridden A 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select MPF transport drive
24. Siron Code or Error contents Description Action message Close door A Printer left door open The printer left door assembly is open or the printer left door closed actuator is damaged Go to Printer left door open on page 2 100 Close door B Duplex left door assembly The Duplex left door assembly is open Open Go to Duplex left door assembly open on page 2 94 Close door C Printer left lower door The printer lower left door assembly is open assembly open Go to Printer left lower door assembly open on page 2 101 Close door D 1TM 3TM or TTM left door The 1TM 3TM or TTM tray left door assembly is assembly open open Go to 1TM 3TM or TTM left door assembly open on page 2 93 Close door E Printer front door assembly Printer front door assembly is open open Go to Printer front door assembly open on page 2 99 Close door G Finisher front door open The finisher front door is open Refer to the Finisher Service Manual Close door J Transfer belt access door The transfer belt access door is open open Go to Printer front door assembly open on page 2 99 Close Eject cover open The finisher eject cover is open surface H Refer to the Finisher Service Manual Empty hole Punch waste box full The punch waste box is full punch box Refer to the Finisher Service Manual Insert hole Punch waste box missing No punch waste box punch box Refer to the Finisher Service Manual Load staples Staple cartridge empty
25. 2 136 Printer Service Manual Color misregistration Leading edge Picken ae A 5057 XXX Trailing edge Step Check Yes No 1 Replace the transfer belt unit assembly Go to Go to step 2 Problem solved Transfer belt unit assembly removal on page 4 16 Does the error remain 2 Replace the transfer belt steering motor Go to Go to step 3 Problem solved Transfer belt unit assembly removal on page 4 16 Does the error remain 3 Adjust the color registration Regcon Go to Color Go to step 4 Problem solved registration RegCon on page 4 203 Does the error remain 4 Replace the printhead Go to Printhead assembly Go to step 5 Problem solved removal on page 4 90 5 Re adjust the color registration Regcon for the new Go to step 6 Problem solved printhead Go to Color registration RegCon on page 4 203 Does the error remain 6 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue card assembly Go to RIP card assembly removal on page 4 71 Diagnostic information 2 137 5057 XXX Deletions Leading edge Replace the upper printer engine card assembly Go to Upper printer engine card assembly remov
26. 4 14 Printer Service Manual 5057 XXX Fuser unit assembly removal CAUTION The fuser unit assembly can be extremely hot handle with care to avoid getting burned 1 Open the printer left door assembly 2 Loosen the two thumb screws to release the fuser unit assembly A from the machine 3 Pull the two handles on the fuser unit assembly A away from the machine 4 Remove the fuser unit assembly A from the machine Handles Thumb Screws Repair information 4 15 5057 XXX Transfer belt unit assembly removal Warning When removing the transfer belt unit assembly do not touch the belt surface or damage will occur Note Detach the finisher if equipped Refer to the MFP or the Printer Finisher Service Manual Open the printer front door assembly Open the transfer belt access cover Press the button on the transfer belt lift latch A Raise the transfer belt lift latch A to its upper most position Lower the transfer belt lift handle B to its lower most position Lift the safety latch C while pulling the transfer belt unit assembly D out of the machine Remove the transfer belt unit assembly D NOOB OD A Button Replacement warning When reinstalling the transfer belt unit assembly do not touch the belt surface or damage will occur 4 16 Printer Service Manual 5057 XXX Transfer belt cleaning assembly removal 1 2 3 Warning When removing the transf
27. Repair information 4 161 5057 XXX 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 Remove the media tray 2 assembly Open the 3TM left door assembly Remove the two screws securing the two support straps A to the machine Release the harness from the clamp Disconnect the connector from the media feed unit assembly B Remove the two screws securing the media feed unit assembly B to the machine Remove the media feed unit assembly B NOOB OD Clamps Connector 4 162 Printer Service Manual 5057 XXX Clamps Connector 3X 500 sheet drawer 3TM sensor tray 3 feed out removal 1 Open the 3TM left door assembly 2 Remove the two screws securing the two support straps A to the machine 3 Disconnect the connector from the sensor tray 3 feed out B 4 Remove the two screws securing bracket C to the machine 5 Remove the bracket C 6 Release the hooks securing the sensor tray 3 feed out B to the bracket C Repair information 4 163 5057 XXX 7 Remove the sensor tray 3 feed out B 3X 500 sheet drawer 3TM media feed lift motor removal 1 Remove the media feed unit assembly See 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 on page 4 162 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 160 or 3X 500 sheet drawer 3TM media out actuator removal o
28. i a Ne a L2 TT ES A oe SS es Front Repair information 4 141 5057 XXX 2000 sheet dual input TTM one way 22 tooth removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 140 3 Remove the feed roll one way clutch See 2000 sheet dual input TTM feed roll one way clutch removal on page 4 141 4 Remove the feed roll one way gear 22 tooth A Front 4 142 Printer Service Manual 5057 XXX 2000 sheet dual input TTM separation roll one way friction clutch removal 1 Remove the media tray assembly 2 Remove the separation roll See 2000 sheet dual input TTM separation roll removal on page 4 144 3 Remove the separation roll spacer A 4 Remove the separation roll one way friction clutch B Repair information 4 143 5057 XXX 2000 sheet dual input TTM separation roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the separation roll B to the shaft C 4 144 Printer Service Manual 5057 XXX 4 Remove the separation roll B Note Do not touch the rubber surface of the feed roll B Replacement note Before re installing
29. Diagnostic information 2 107 5057 XXX Does the error remain when the power is turned off on again printer engine card assembly Go to Upper printer engine card assembly Step Check Yes No 2 Replace the CMY PC cartridges Go to step 3 Problem solved Does the error remain 3 Perform a POR Replace the upper Problem solved removal on page 4 74 K PC cartridge nearly exhausted Step Check Yes No 1 Check the K PC cartridge Go to step 2 Reinstall the K PC Is the above component properly installed cartridge Go to PC cartridge unit removal on page 4 43 2 Replace the K PC cartridge Go to step 3 Problem solved Does the error remain 3 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on again printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 K PC cartridge exhausted Step Check Yes No 1 Check the K PC cartridge Go to step 2 Reinstall the K PC Is the above component properly installed cartridge Go to PC cartridge unit removal on page 4 43 2 Replace the K PC cartridge Go to step 3 Problem solved Does the error remain 3 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on again printer engine card assembly Go to Upper printer engine card assembl
30. Step Check Yes No 1 Check printer installation placement Go to step 2 Correct the A installation Check the installation surface for irregularities placement Check for missing printer foot Is the setup surface normal 2 Check the media feed Go to step 3 Problem solved Remove the media tray assembly Properly load media in the media tray assembly Properly install the media tray assembly in the printer Re print the defective image Does the error continue 3 Check the media condition Go to step 4 Problem solved Load new dry recommended media Re print the defective image Does the error continue 4 Check the 2nd transfer roll assembly for contamination Go to step 5 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear assembly and contamination Go to 2nd transfer roll assembly removal on page 4 35 5 Check the registration transport roll assembly Go to step 6 Replace Are all drive rolls on the registration transport roll Sad assembly free of contamination wear and damage assembly Go to Registration transport roll assembly removal on page 4 36 2 134 Printer Service Manual 5057 XXX Step Check Yes No 6 Check the heat roll and pressure roll Replace the Inspect the fuser unit machine for Remove the fuser unit assembly assembly obstructions in CAUTION Allow the fuser unit assembly to Go to Fuser the media path cool down unit
31. Step Check Yes No 2 Check the sensor C ATC for proper connection Replace the C Replace the is the ab d Developer unit connection s the above component properly connected assembly Go to Developer unit assembly removal on page 4 53 3 Perform a very large print test Replace the upper Problem solved Does the error continue Re card Go to Upper printer engine card assembly removal on page 4 74 925 03 Sensor K ATC Step Check Yes No 1 Reset the K ATC failure lock out condition Go to step 2 Problem solved 1 Enter diagnostic mode 2 Select Dev unit reset 2 Select K channel Perform a very large print test Does the error continue 2 Check the sensor K ATC for proper connection Replace the K Replace the Is the ab t ted Developer unit connection s the above component properly connected assembly Go to Developer unit assembly removal on page 4 53 3 Perform a very large print test Replace the upper Problem solved i printer engine card Does the error continue assembly Go to Upper printer engine card assembly removal on page 4 74 940 00 MPF tray 5 size sensing error Step Check Yes No 1 Perform a POR Go to step 2 Problem solved Does the error occur when the power is turned off on 2 82 Printer Service Manual 5057 XXX Does the error continue when the power is turned off on Step Check Yes No 2 Check the MPF feed unit assembly
32. 7 28 Transfer belt lift rear plunger assembly 0 2200 naaa rrr terre eee 7 28 Transfer belt lift front plunger assembly 2 002 r rrr creer rere rrr 7 28 Y toner dispense assembly ee 7 29 M toner dispense assembly 72 20 r rrr rrr rrr rrr ree 7 29 C toner dispense assembly e 7 29 K toner dispense assembly 7 272 rrr rrr rrr rrr ttre 7 29 CMYK toner add motor assembly 20 00 errr rrr rrr rrr rrr rte 7 29 Developer unit assembly 7 020 r rrr rrr rr rrr rrr rte 7 30 K developer carrier e 7 30 Y developer carrier lt gt 222 s etree e eee eee oe eee eee 7 30 M developer carrier e 7 30 CG developer Carrier ue SEET ee SG ce ee ia a lee 7 30 Fuser assembly 110 V sms see ds ee a Hoa mei Hin a H ee erie 7 31 Fuser assembly 220 V lt ss 9smessnmen ae oer sm me Sn ee e pie ges mms e 7 31 Printhead shutter motor assembly 7 27 00 c rrr rrr rrr ttre 7 32 Fuser cooling fan eer sess es snaps tes wane ee aksene se 7 32 Transfer belt drive motor cooling fan e 7 32 Rear lower cooling fan assembly e 7 32 Developer transfer roll HVPS card assembly 7 7 2000 0 rrr rrr rrr rrr ee 7 34 Charge roll HVPS card assembly 0 2 2 0 rrr rrr rrr rrr tree 7 34 5 VLVPS card assembly 110 V e 7 34 5 V LVPS card assembly 220 V 20 rrr rrr rr rrr rrr rrr rere 7 34 Lower print
33. Replace the 1TM controller card assembly or the 3TM controller card assembly or the TTM controller card assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 12 Problem solved 12 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 Problem solved 244 01 Sensor tray 3 feed out on jam feeding from tray 4 Step Check Check the media position Does the media touch the sensor tray 3 feed out Yes Replace the damaged media with new Remove the media No Check the media condition Go to step 2 Is the media in the tray crumpled or damaged Go to step 5 Check the sensor tray 3 feed out for proper operation 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 3 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 5 Go to step 4 Check the sensor tray 3 feed out for proper connection Is the above component properly connected Repl
34. Replace the transfer belt unit assembly Go to Transfer belt unit assembly removal on page 4 16 Does the error remain Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved removal on page 4 77 905 00 NVM read write cannot be executed error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Replace the Problem solved Does the error occur when the power is turned off on again Me i ae Go to Upper printer engine card assembly removal on page 4 74 Go to step 3 3 Perform a POR Replace the RIP Problem solved Does the error occur when the power is turned off on card assembly Go to RIP card assembly removal on page 4 71 905 01 Marking device video error Step Check Yes No 1 Perform a POR Replace the upper Problem solved Does the error occur when the power is turned off on printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 67 5057 XXX 905 02 Marking device Xerographics error Step Check Yes No Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assemb
35. 0 Y 0 Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the inner cover See Inner cover removal on page 4 42 Remove the three CMY toner add assemblies See CMY toner add assembly removal on page 4 46 Remove the K toner add assembly See K toner add assembly removal on page 4 48 Remove the main power switch actuator See Main power switch actuator removal on page 4 88 10 11 12 13 14 15 16 Remove the two screws securing the CMYK toner add motor assembly A to the machine Lift the CMYK toner add motor assembly A slightly and pull it towards the front of the machine Release the harnesses from the clamps Disconnect the connector from the CMYK toner add motor assembly A Release the tabs securing the four sensors toner RFID to the assembly Remove the four sensors toner RFID Remove the CMYK toner add motor assembly A Clamps Connectors Repair information 4 89 5057 XXX CMYK transfer HVPS card assembly removal S OO
36. 1TM optional O N gt O Tray module transport roll assembly Tray 2 TTM 3440 Tray Ai ag Tray 3 Tray 4 transport roll assembly O O Functions of main components When the 1TM is installed under the printer additional trays are available Media tray assembly It is necessary to adjust the rear and the end guide in the media tray assembly to match the media size Rear media guide The rear media guide can be adjusted to different media sizes by moving it to the front or rear The guide comes into contact with the rear edge of the media and holds it in position General information 1 51 5057 XXX Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly The bottom plate is pushed up by the rotation of the lift up shaft which causes the supplied media to come in contact with the pick roll Tray 2 media tray assembly Rear media guide Bottom plate End guide 1TM media feed units Media feed unit assembly The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll assemblies to feed media When the pick roll picks up sheets of media and the remaining media decreases the media level actuator of the sensor media level lowers accordingly Media feed lift motor The media feed lift
37. 3X 500 sheet drawer 3TM separation roll one way friction clutch removal 1 Remove the media tray assembly 2 Remove the separation roll See 2000 sheet dual input TTM separation roll removal on page 4 144 3 Remove the separation roll spacer A 4 Remove the separation roll one way friction clutch B 4 172 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM separation roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the separation roll B to the shaft C gt Repair information 4 173 5057 XXX 4 Remove the separation roll B Note Do not touch the rubber surface of the feed roll B Replacement note Before re installing do not touch the rubber surface of the separation roll B 4 174 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM pick roll removal 1 Remove the media tray assembly 2 Move the front guide A toward the front in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before re installing do not touch the rubber surface
38. 982 01 Service finisher error Sensor front tamper HP lag error The sensing area of the sensor front tamper HP remains interrupted within the specified time after the front tamper starts moving from the home position Refer to the Finisher Service Manual 983 00 Service finisher error Sensor rear tamper HP late error The sensing area of the sensor rear tamper HP is not interrupted when the rear tamper starts moving to the home position Refer to the Finisher Service Manual 983 01 Service finisher error Sensor rear tamper HP lag error The sensing area of the sensor rear tamper HP remains interrupted within the specified time after the rear tamper starts moving from the home position Refer to the Finisher Service Manual 984 00 Service finisher error Sensor punch unit HP late error The sensing area of the sensor punch unit HP is not interrupted during the specified time after the punch unit starts moving to the home position Refer to the Finisher Service Manual 984 01 Service finisher error Sensor punch unit HP lag error The sensing area of the sensor punch unit HP remains interrupted within the specified time after the punch unit starts moving from the home position Refer to the Finisher Service Manual 985 00 Service finisher error Sensor punch carriage shift HP late error The sensing are of the sensor punch carriage shift
39. Communication error with the K sensor RFID toner cartridge has occurred Go to 924 03 Black toner RFID communication error on page 2 80 5057 XXX Error code or Error contents Description Action message 925 00 Sensor Y ATC Outputs of the sensor Y ATC are not in the Service PC specified range cartridge This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur Go to 925 00 Sensor Y ATC on page 2 80 925 01 Sensor M ATC Outputs of the sensor M ATC are not in the Service PC specified range cartridge This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur Go to 925 01 Sensor M ATC on page 2 81 925 02 Sensor C ATC Outputs of the sensor C ATC are not in the Service PC specified range cartridge This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur Go to 925 02 Sensor C ATC on page 2 81 925 03 Sensor K ATC Outputs of the sensor K ATC are not in the Service PC specified range cartridge This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur Go to 925 03 Sensor K ATC on page 2 82 940 00 MPF Tray 5 size sensing The MPF size width sensor has failed Service MPF SCH Go to 940 00 MPF tray 5 size sensing error on failure page 2 82 941 00 Switch media size size Th
40. Parts catalog 7 41 5057 XXX Assembly 35 1TM feed unit assembly Asm Part FRUs Units Description index number mach FRU p 1 40X3677 3 1 Switch media size 2 40X3676 6 1 Media tray slide 3 40X3675 3 1 Media tray catch 4 40X3678 3 6 Media tray assembly kit e Media tray assembly e 1 label e 2 label e 3 label e 4 label e Instruction label 5 40X3679 1 1 Media feed unit assembly 7 42 MFP Service Manual 5057 XXX Assembly 36 1TM media feed unit Parts catalog 7 43 5057 XXX Assembly 36 1TM media feed unit Asm Part FRUs Units Description index number mach FRU 1 40X3679 4 1 Media feed unit assembly 2 40X3687 4 1 Media out actuator 3 40X3688 30 1 Sensor tray media out 4 40X3688 30 1 Sensor tray media level 5 40X3684 4 1 Media feed lift motor 6 40X0888 6 1 Bushing 6 mm 7 40X3686 4 1 Media tray lift one way gear 8 40X3685 4 1 Media tray lift one way clutch 9 40X4086 4 2 Separation roll friction clutch 10 40X3689 2 1 Feed unit roll kit e Feed roll 2 e Pick roll 2 e Separation roll 2 11 40X3690 4 1 Feed roll one way clutch 12 40X3691 4 1 Feed roll one way gear 22T 13 40X0952 6 1 Bushing 6 mm 7 44 MFP Service Manual Assembly 37 1TM left door 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3818 1 1 Tray 2 feed out sensor cable assembly 2 40X3817 1 1 Sensor tray
41. Replace the connection Check the media feed lift motor in media tray 4 for proper operation Caution When performing motor tests ensure that all cover and door interlock 1 Enter the Diagnostics Menu switches are overridden 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select Tray 4 media feed lift motor Does the above component operate properly Go to step 9 Skip to step 8 Check the media feed lift motor for proper connection Is the above component properly connected Replace the media feed lift motor Go to Media feed lift motor removal on page 4 109 Replace the connection Check the TTM tray 4 transport motor for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select TTM tray 4 media transport motor Does the above component operate properly Go to step 9 Skip to step 8 10 Check the TTM tray 4 transport motor for proper connection Is the above component properly connected Replace the TTM tray 4 transport motor Go to 2000 sheet dual input TTM TTM tray 4 transport motor removal on page 4 152 Replace the connection Diagnostic information 2 43 5057 XXX Step Check Yes No 11 Perform a print test Does the error continue
42. feed out ee 3 5V RTN 1 12 or i lar 2 eed out 12 2 del am Elger 2 1 ATM ONLY SWITCH g E SIn SVRIN 4 9 vam o g GE 1 ae Je 7 am a 7 e BV RTN P548 P546 6 SWITCH media size 2 P546 6 5VDC5V RTN 3 Z 5V RTN SHORTING WIRE SENSOR tray3 o 8 5 5 feed out 1 8VDC Te 4 4 SWITCH SV RTN 3 3 TTM media 2 S E 2 SV RTN SHORTING WIRE gt size 3 TG vam 2 4 SV RTN SHORTING WIRE 1 T g SV RIN SHORTING WIRE g SV RTN SHORTING WIRE Media feed lift P549 e mm a y 5 5V RTN SHORTING WIRE E motor 4 7 AB AB a z H 11 129000 1 112 P557 P557 5V RTN SHORTING WIRE 2 oh 2 SENSOR media 211 3 5V RTN SHORTING WIRE 3 3 24VDC 3 40 SV RIN 3 level 3 3110 1 4 SV RTN SHORTING WIRE 4 24VDC 4 9 5VDC 1 419 5 518 2 I LI SENSOR media out 3 578 m 6 6 7 L SVRIN 3 617 1 d _ 3 SVRIN I7 g 716 P549 2 e6 SENSOR I 193 SE 6 P541 L TO PRINTER ASM media out 44 13 vam fgg 24vDO GE ue gt 3 SVATN Jun 3 24VDC 103 6 t pte 112 112 714 mn SE 8VDC ai IER gt 8 7 ES AB Media feed lift motor AB ae A A SENSOR 2 3 ss al L U Ta svoo media level 2 Lu OD a M M n 11 20 5 Ww 10 5V RTN 3 CH E gt g am i SENSOR or 8 Ss 2 sed media out 2 7 3 P547 R 6 5 EN O 3 24VDC i 2 1 24vde S A i Media feed lift motor Switch tray module amp 3 E pasa O left door interlock Sie 24vde J E 2 gt P555 3 gt TO PRINTER ASM 4 gt AAA 5 gt 6 gt 7 gt 8
43. page 4 82 Remove the CMYK transfer HVPS card assembly See CMYK transfer HVPS card assembly removal on page 4 90 Disconnect the connector from the MPF transport drive motor assembly A Remove the three screws securing the MPF transport drive motor assembly A to the machine Remove the MPF transport drive motor assembly A Connector Repair information 4 101 5057 XXX Feed roll removal 1 Remove the media tray 2 Move the feed unit front guide A in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the rubber surface of the feed roll B Front 4 102 Printer Service Manual 5057 XXX Pick roll removal 1 Remove the media tray 2 Move the media feed unit front guide A in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before reinstalling do not touch the rubber surface of the pick roll B Repair information 4 103 5057 XXX Separation roll removal 1 Remove the media tray 2 Move the feed unit front guide A in the direction of the arrow 3 Release the hook securing the separation roll B to the shaft C 4 Remove the separation roll B Note Do not to
44. 287 05 Sensor upper media exit Media remains on the sensor upper media exit Paper jam static jam Refer to the Finisher Service Manual 288 00 Sensor diverter gate late The media is late reaching the sensor diverter gate Bapori m jam within the specified time after reaching the sensor per bridge unit media exit Refer to the Finisher Service Manual 288 01 Sensor diverter gate static The media reached the sensor diverter gate but Paper jam jam A to top bin did not clear it within the specified time Refer to the Finisher Service Manual 288 04 Sensor diverter gate static The media reached the sensor diverter gate but Paper jam jam B to stacker bin did not clear it within the specified time Refer to the Finisher Service Manual 289 00 Sensor booklet media The media is late reaching the sensor booklet Paper iam entrance late jam media entrance within the specified time after per reaching the sensor bridge unit media exit Refer to the Finisher Service Manual 289 01 Sensor booklet media The media reached the sensor booklet media Paper jam entrance lag jam entrance but did not clear it within the specified time Refer to the Finisher Service Manual 289 02 Sensor booklet media Media remains on the sensor diverter gate Paper jam Me Refer to the Finisher Service Manual 289 03 Sensor booklet compiler in Media remains on the sensor booklet compiler in Paper jam static jam Refer to the Finisher Service Manual 2
45. Go to Developer unit assembly removal on page 4 53 2 80 Printer Service Manual 5057 XXX Step Check Yes No Perform a very large print test Does the error continue Replace the upper printer engine card assembly Go to Upper printer engine card assembly Problem solved removal on page 4 74 925 01 Sensor M ATC Step Check Yes No 1 Reset the M ATC failure lock out condition Go to step 2 Problem solved 1 Enter diagnostic mode 2 Select Dev unit reset 2 Select M channel Perform a very large print test Does the error continue 2 Check the sensor M ATG for proper connection Replace the M Replace the Is the ab t ted Developer unit connection s the above component properly connected assembly Go to Developer unit assembly removal on page 4 53 3 Perform a very large print test Replace the upper Problem solved a printer engine card Does the error continue assembly Go to Upper printer engine card assembly removal on page 4 74 925 02 Sensor C ATC Step Check Yes No 1 Reset the C ATC failure lock out condition Go to step 2 Problem solved 1 Enter diagnostic mode 2 Select Dev unit reset 2 Select C channel Perform a very large print test Does the error continue Diagnostic information 2 81 5057 XXX
46. I I d Standard media 1 exit roll assembly 1 d d I I I I Standard media exit Duplex media transport roll ASM Duplex media Center transport roll ASM PRINT EXIT j 1 50 Printer Service Manual Media transport path 5057 XXX The following is a cross section of the printer and the 1TM showing the main components directly associated with the media path and transport Upper media Finisher media entrance transport tell assembly Bridge unit assembly roll assembly U p x KG pper media exit included with finisher Standard media exit roll assembly roll assembly Bridge unit bin exit j roll assembly o og Gei SEET Buffer roll assembly i op Fuser exit 3 A Media eject DEER A roll assembly ne O O CO v Fuser Duplex media yy Q lt Lower media exit transport roll roll assembly assembly 2nd transfer roll assembly e Booklet media MEP A Registration roll assembly transport roll assembly MPF pick roll eG 2 e 3 Booklet medi Media transport roll assembly Tray 1 O O poke entrance roll assembly O Booklet maker Got O Tray 2 optional Booklet media Q exit roll assembly Tray module transport Tray 3 ia roll assembly O Finisher Booklet folding Tray 4 x optional roll assembly O O O Pick roll O S Feed roll Tray 2 3TM optional Separation roll
47. K Channel 925 03 Dev Unit Reset See Dev Unit Reset on page 3 19 Y Channel M Channel C Channel K Channel ENGINE ADJUST See ENGINE ADJUST on page 3 20 PH Adjust registration PRO CON RegCon Adjust Booklet Fold Adj Finisher Config Booklet Fold Adjust See Booklet Fold Adjust on page 3 23 Booklet Tamper Shift Adj Booklet Compile Position Booklet 2 sheet Booklet 15 sheet Booklet Fold Pos Fine Adj Booklet Staple Pos Fine Adj Finisher Config See Finisher Config on page 3 23 Exit Diagnostics Menu See Exiting Diagnostics on page 3 23 MOTOR TESTS The tests in this group allow you to test specific motors and on some motors run them forward or reverse To run the MOTOR TESTS 1 Select MOTOR TESTS from the Diagnostics Menu 2 Select the test to run The following Finisher Motor Tests are available e Motor entrance paddle e Motor buffer transport e Motor exit e Fin diverter solenoid e Sub paddle solenoid e Media eject clutch e Media eject clamp motor e Media eject motor e Fin Buffer solenoid e Punch carriage shift motor e Punch unit motor e Front tamper motor e Rear tamper motor e Stapler carriage motor e Stapler unit motor Stacker bin lift motor Booklet end guide drive motor Booklet paddle drive motor Booklet front tamper motor Booklet rear tamper motor Book
48. Loosen the screw securing the ground wire A Remove the ground wire A Disconnect the connector B and rotate it 90 Remove the connector B Remove the four screws securing the controller box assembly C to the machine Note When lifting the controller box assembly C the bridge card assembly D and the upper printer engine card assembly E will become detached Lift the controller box assembly C 4 68 Printer Service Manual 5057 XXX Switch main power removal 0 JO Om P Co b i Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4 4 Detach the metal rod A from the switch main power B Release the two hooks securing the switch main power B to the machine Remove the switch main power B Disconnect the connector from the switch main power B Disconnect the two large connectors from the switch main power Connector Large connectors Repair information 4 69 5057 XXX Bridge card assembly removal ON E es SOON om Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4
49. Patch B in Patch B out Is the value for both of the above settings a 4 Go to step 4 Go to step 6 Perform the skew rough setup 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Skew rough setup Does the above test pass Go to step 5 Go to step 6 4 208 Printer Service Manual 5057 XXX Step Check Yes No 5 Perform the skew rough setup printhead adjustment Re perform step 1 Go to step 6 e If the test fails then 1 Enter the Diagnostics Menu replace the 2 Select ENGINE ADJUST printhead 3 Select RegCon adjust See Printhead 4 Select Control setup cycles assembly 5 Select Cycle result values removal on page 4 90 Locate the following new values for the following settings Once the i printhead is Y Skew adjustment replaced then re M Skew adjustment perform the entire RegCon C Skew adjustment procedure K Skew adjustment See Color registration RegCon on Turn the appropriate printhead adjustment screws located page 4 203 behind the waste toner cartridge the number of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG Y Skew adjustment 10 Turn the screw CW 10 clicks EG Y Skew adjustment 10 Turn the screw CCW 10 clicks Print
50. Sensor media out If there is no media in the media tray assembly the media out actuator lowers and the flag of the media out actuator that has stayed in the sensor media out sensing area leaves there Thus the light of the sensor is transmitted When the sensing area is blocked media is present the signal turns off Sensor media level General information 1 45 5057 XXX This sensor detects by the actuator position whether media in the media tray assembly is lifted When the flag of the actuator leaves the sensor media level sensing area the sensor detects that the media has been lifted Media feed lift motor Switch media size Main components Switch tray module left door interlock The switch tray module left door interlock detects open close of the tray module left door assembly Sensor tray 2 feed out The sensor tray 2 feed out detects media fed from trays 2 3 or 4 Sensor tray 3 feed out The sensor tray 3 feed out detects media fed from the tray 3 or tray 4 Sensor tray 4 feed out The sensor tray 4 feed out detects media fed from the tray 4 1 46 Printer Service Manual 5057 XXX Tray module media transport roll assembly The tray module transport roll assembly feeds media from the tray 3 or tray 4 to the printer Tray module drive motor This motor is used to drive the media transport mechanism in the tray module 3TM controller card assembly The 3TM controller card assembl
51. Switch printer left door interlock removal on page 4 19 4 Perform a print test Replace the upper Problem solved Does the error continue when the power is turned off on GE card Go to Upper printer engine card assembly removal on page 4 74 100K maintenance required Step Check Yes No 1 Install the 100K maintenance kit Reset the 100K Problem solved Does the message still occur maintenance counter Go to Scheduled maintenance on page 6 2 600K maintenance required Step Check Yes No Install the 600K maintenance kit Does the message still occur Reset the 600K maintenance counter Go to Scheduled maintenance on page 6 2 Problem solved 2 102 Printer Service Manual ADF maintenance required 5057 XXX Step Check Yes No 1 Install the ADF maintenance kit Reset the ADF Problem solved a 9 maintenance Does the message still occur counter Go to Scheduled maintenance on page 6 2 Standard media bin full Step Check Yes No 1 Check the actuator for movement Go to step 2 Reinstall the ae standard media Ge ie mae media bin full actuator move up and bin full actuator 2 Check the sensor standard bin full exit 1 for operation Go to step 5 Go to step 3 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Exit level 4 Select Standard
52. Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Is the media transfer route and the media path clear of Go to step 3 Remove debris or debris contamination 3 Check the laser beam route Go to step 4 Remove debris or Check for debris between the printhead assembly and the Ge PC drum assembly window Check the four printhead assembly windows for contamination Is the laser beam route free of debris and the glass window in the printhead assembly free of contamination 4 Check the four PC cartridges for proper installation Go to step 5 Correct and clean g contaminated Check the PC cartridge connections pins or replace Are the PC cartridge connections free of excess wear and the appropriate contamination PC cartridge or connector 5 Check the 2nd transfer roll assembly for contamination and Go to step 6 Replace the 2nd wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd transfer roll assembly removal on page 4 35 6 Replace the transfer belt unit assembly Go to Transfer Go to step 7 Problem solved belt unit assembly removal on page 4 16 Does the problem remain 7 Check the printhead assembly Go to step 8 Problem solved Replace the printhead assembly Go to Printhead assembly removal on page 4 90 Does the error
53. 3 When the printer is not in Diagnostics mode Check Config ID appears on the LCD Note Each of the above conditions will remain until a valid value is entered for Configuration ID 1 and Configuration ID 2 The Configuration ID setting allows you to set both Configuration IDs simultaneously To set one or both Configuration IDs 1 From the PRINTER SETUP menu select the icon to the right of the Configuration ID menu item The screen displays the value of both Configuration IDs By default the cursor appears on the Configuration ID 1 line 2 To change the value of Configuration ID 1 press the Backspace key to erase any of the existing characters Then enter the correct ID using the number and letter keys that appear on the screen 3 To edit the value of Configuration ID 2 select a section of the display screen that appears inside of the text box containing the current value of Configuration ID 2 The cursor appears in the text box containing the current value of Configuration ID 2 4 To change the value of Configuration ID 2 press the Backspace key to erase any of the existing characters Then enter the correct ID using the number and letter keys that appear on the screen Note To exit the Configuration ID screen and return to the PRINTER SETUP menu press Back Note Although it is recommended that all unused and reserved bits be set to zero the code will not validate or enforce this condition 5 To save the values of both Configu
54. 4 Remove the two screws securing the two brackets B to the printer front door assembly C 5 Remove the two brackets B 6 Remove the printer front door assembly a Repair information 4 3 5057 XXX Right cover assembly removal Note Detach the finisher if equipped Refer to the MFP or Printer Finisher Service Manual 1 Open the transfer belt unit access door A 2 Remove the three screws securing the right cover assembly B to the machine 3 Move the right cover assembly B down and pull out 4 Remove the right cover assembly B Top cover assembly removal Open the printer front door assembly Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the three screws securing the top cover assembly A to the machine Gently detach the top cover assembly A Disconnect the operator panel cable assembly B from under the top cover assembly A Remove the top cover assembly A NOOR OD 4 4 Printer Service Manual 5057 XXX Rear cover assembly removal Note Remove the blind cover A if the printer is equipped with a 1TM 3TM or a TTM 1 Remove all connectors and power cords from the rear of the machine 2 Remove the four screws securing the rear cover assembly B to the machine 3 Remove the rear cover assembly B Connectors
55. B Connector 2000 sheet dual input TTM media feed lift motor removal Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 4 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 121 5 Remove the media feed unit assembly See 2000 sheet dual input TTM media feed unit assembly 2 removal on page 4 130 or 2000 sheet dual input TTM media feed unit assembly removal tray 4 on page 4 125 6 Disconnect the harness from the media feed lift motor A 7 Remove the two screws securing the media feed lift motor to the media feed unit assembly B D ao Repair information 4 133 5057 XXX 8 Remove the media feed lift motor B Rea Connector 4 134 Printer Service Manual 5057 XXX 2000 sheet dual input TTM one way clutch gear assembly removal D w Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM T
56. Class I laser products are not considered to be hazardous The printer contains internally a Class ID 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse I 1 In anderen Landern gilt der Drucker als Laserprodukt der Klasse I der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de C
57. Developer unit assemblies Asm Part FRUs Units Description index number mach FRU 1 40X3742 4 1 Developer unit assembly 2 40X3744 1 1 Y developer carrier 3 40X3745 1 1 M developer carrier 4 40X3746 1 1 C developer carrier 5 40X3743 1 1 K developer carrier 7 30 MFP Service Manual 5057 XXX Assembly 28 Fuser assembly Asm Part FRUs Units D escribti n index number mach FRU p 1 40X3747 1 1 Fuser assembly 110 V 1 40X3748 1 1 Fuser assembly 220 V Parts catalog 7 31 5057 XXX Assembly 29 Cooling fans 7 32 MFP Service Manual geg gt Gg Gm Description 1 40X3750 1 1 Fuser cooling fan 2 40X3749 1 1 Printhead shutter motor assembly 3 40X3752 1 1 Rear lower cooling fan assembly this comes assembled 4 40X3751 1 1 Transfer belt drive motor cooling fan 5057 XXX Assembly 30 Electrical 1 Parts catalog 7 33 5057 XXX Assembly 30 Electrical 1 Asm Part FRUs Units Description index number mach FRU 1 40X3762 1 1 Laser diode power card assembly 2 40X3757 1 1 Lower printer engine card assembly 3 40X3758 1 1 24 V LVPS card assembly 4 40X3763 1 1 Rear upper cooling fan 5 40X3759 1 1 24 V LVPS cooling fan 6 40X3760 1 1 CMYK transfer roll HVPS card assembly 7 40X3755 3 1 5 V LVPS card assembly 110 V 7 40X3756 3 1 5 V LVPS card assembly 220 V 8 40X376
58. Repair information 4 5 5057 XXX Rear left middle cover removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Open the printer left door assembly 3 Remove the screw securing the rear left middle cover A to the machine 4 Remove the rear left middle cover 4 6 Printer Service Manual 5057 XXX Rear left upper cover removal 1 ROD Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Warning Ensure that the rear left middle cover is removed before removing the rear left upper cover or damage will occur Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove one screw securing the rear left upper cover A to the machine Release the hook securing the rear left upper cover A to the machine Remove the rear left upper cover A Repair information 4 7 5057 XXX Printer left lower door assembly removal Remove the media tray 1 Open the printer left lower door assembly Disconnect the connector from the printer left lower door assembly A Release the harness from the clamp Pull the cap of the hinge pin B out with a prying tool to remove the hinge pin B from the machine Remove the hinge pin B Remove the printer left lower door assembly A NOOB OD Connector B Clamp MPF feed unit assembly removal Remove the rear cover a
59. a G G G r 349 SEEEEEEEEEEEEEEEEEEEEEERE 35110 aja oa aa 93 2 2 El 36 11 2 37 12 3 3813 J3 3914 40115 nnnnnnannanannnanananananannnl 141116 4 X Si gg j 142 17 aa J lad jag Hd ag II Jug eu Interconnect Card ASM RS RR ERRERRERRERREEEEEEER BEEEEEEEEEEEEEEEEEEEEEEERE SEREEEEEEEEEEEEEERRKKKKRE 14419 La CR a al al aj ol a i al oj al ol a o a al 1 S 2 145 20 Tajo soon o AS NERREFRPREANRE amp R 16 21 147 22 148 23 49 24 50 25 1 2 314 RIP card assembly 4 5 50 1 49 2 148 3 474 146 5 145 6 FUSER ASM 447 43 8 42 9 141110 140 11 g 39112 3813 J8 o H 37 14 D 36 15 NS Bridge card 35116 ASM au 33 18 3211 Psa sai A E EE ICT JLeleleeloil e 3021 J12 0 b 3 4 a 129122 S 24 ze ga g H Ey gt p823 E 3 g d al al 127 24 0 E gt 3 FJ gt 26 25 5 3 i E al ei a p USB 1 J16 g 3 0 E EN TO AG drive card ASM El El E FS46 FS 47 FS 48 z3 0 ETH J13 0 R use J15 TO AG drive card ASM P590 0 Ten 87 rajo us 3 S 22 jae S _ 3 Se E SEEEEER de i A ee A a 7 a a a 230 8 D lt 4 Z S z E S gl el lt S 2 4 2 9 S SEKEEEEER d 0 5V RTN 8 2 e El 2 z 25 g F FAIL RIP card SEEEEER 3 5 SLP VOC cooling fan E 2 o 3 o 9 dr z 5 EE FEE ds 8 a E SEEEEEEEEEEEEEEEEER E s3223835523355432950 E Ad A A AREA ASES oo no e ola a P411
60. e PP Parts Packet in the parts description column indicates the part is contained in a parts packet Model name Configuration Machine type Maximum speed Lexmark X940e Network 7510 030 35 PPM Lexmark X945e Network 7510 230 45 PPM Lexmark C930 Network 5057 030 35 PPM Lexmark C935 Network 5057 230 45 PPM Parts catalog 7 1 5057 XXX Assembly 1 Covers 1 Asm Part FRUs Units index number mach FRU Description 1 40X0553 3 Switch printer front door interlock 1 2 40X0553 3 1 Switch transfer access door interlock 3 40X3780 1 1 Right cover assembly 4 40X3778 1 1 Printer front door assembly this comes assembled 5 40X3779 1 1 Printhead slit glass cleaner assembly 7 2 MFP Service Manual 5057 XXX Covers 2 Assembly 2 Parts catalog 7 3 5057 XXX Assembly 2 Covers See mer Ajer FRU Description 1 40X3782 1 1 RIP card access cover 2 40X3781 1 1 Top cover assembly 3 40X3787 1 1 Switch main power 4 40X3786 1 1 Main power switch actuator 5 40X3783 1 1 Main switch cable assembly 6 40X3785 1 1 Inner cover 7 40X4111 1 1 Front left cover 8 40X4089 1 1 SFP operator panel assembly 9 TBD SFP operator cable assembly Warning In the event of replacement of any one of the following components e Operator panel assembly universal e Operator panel controller card assembly e RIP
61. foot cover removal 00 eee cece eee eee eee 4 154 3X 500 sheet drawer 3TM right cover removal 00 eee cece eee eee eee 4 154 3X 500 sheet drawer 3TM tray module left cover removal eee eeeees 4 155 3X 500 sheet drawer 3TM rear cover removal 0020 ce cece eee eee eee eens 4 155 3X 500 sheet drawer 3TM caster removal 000 eee e eee eee eee eee eee 4 156 3X 500 sheet 3TM media feed unit assembly removal tray A 4 156 3X 500 sheet drawer 3TM sensor tray 4 feed out removal oooooooomoomo o 4 157 3X 500 sheet drawer 3TM sensor tray 2 feed out removal ooooooooooomo o 4 158 3X 500 sheet drawer 3TM switch media size removal ooooooomommmmmo 4 159 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 4 160 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 4 162 3X 500 sheet drawer 3TM sensor tray 3 feed out removal ooooooooooomo o 4 163 3X 500 sheet drawer 3TM media feed lift motor removal sence eee 4 164 3X 500 sheet drawer 3TM one way clutch gear assembly removal 4 165 3X 500 sheet drawer 3TM media out actuator removal oooooooommommomoo 4 166 3X 500 sheet drawer 3TM sensor media level removal 4 167 Xii Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM sensor media out removal 00 eee c
62. ofoo N Jo io lee vt A A A A A A A A a ada aaa ee sl sl sis si s SEEEIEEEFER AB 33333323333 20 ik lt lt lt lt lt lt lt lt i HEHE HEGE RE 19 2 i 8 8 8 8 8 8 8 8 i gl gl g g g g gl gl g 1831 j S S S i Z Z Z Z Z LEA I 3 3 3 3 3 3 3 3 1615 i DERG ERE gel i 8 amp amp 5 amp amp amp 58 E E E 147 i Sl S 5 S S 8 3 3 i 8333333 3 13 8 i S 2 eres H 8 3 8 8 8 8 12901 i i HAr seede nei PR 21 8 3 38 8 gh I x x 3 o a 5 i 1 3 3 8 S la 8 13 i Bs ER 714 i 8 6j15 i Upper printer engine card assembly Sta Al i i 3118 i i 2hg i 1 20 i AB i d i i I i i i i i i i i i i i i i To lower printer engine card ASM J410 SWITCH printer left door i st I interlock At P410 To J410 lower printer engine card ASM i VC fe i 5VDC 3 5 i LD NSOS K 2 LJ i 5V RTN 3 D LD VDATA C 7 7 i LD VDATA C 6 i LD PCONT C 5 INTLK 1 T LD ENB C d 8 Al 24V RTN LS KE y LD PWR C Es SWITCH printer Ae 6 EI AB 3 front door interlock Bole ne Je pen Y 1 Lo roont gg 2 Bi 24V RTN 4 a 20 1 5 INTLK C 1 lt TO lower printer engine card ASM P531 3 24V SQ OUT 3 lt ajo 19 0o N ele SIE NLF Rl Q L LD ENB C q 19 2 p2 PCONT ic 5VDC 1 GND 8 HENNENMAN a a LD ENB 0 Jha 3 p2 PEONT A LD NSOS C
63. remains interrupted within the specified time after the booklet end guide starts moving from the home position Refer to the Finisher Service Manual 991 06 Service finisher error Sensor booklet unit interlock error The sensor booklet unit interlock detected that the booklet maker was not completely inserted when the finisher front door assembly was closed Refer to the Finisher Service Manual 991 07 Service finisher error Sensor booklet compiler no media no media detected The sensing area of the sensor booklet compiler no media did not detect any media when the booklet stapler motor was activated Refer to the Finisher Service Manual 991 08 Service finisher error Sensor booklet knife HP late error The sensing area of the sensor booklet knife HP is not interrupted within the specified time after the booklet knife started moving to home position Refer to the Finisher Service Manual 991 09 Service finisher error Sensor booklet knife HP lag error The sensing area of the sensor booklet knife HP remains interrupted within the specified time after the booklet knife started moving from home position Refer to the Finisher Service Manual 991 10 Service finisher error Sensor booklet knife folding late error The sensing area of the sensor booklet knife folding is not interrupted within the specified time after the booklet knife solenoid was activate
64. removal on page 4 15 Diagnostic information 2 21 5057 XXX Step Check Yes No 4 Check the sensor registration for proper operation Go to step 6 Go to step 5 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Registration Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 5 Check the sensor registration for proper connection Replace the Replace the sensor connection Is the above component properly connected registration Go to Sensor registration removal on page 4 37 6 Check the sensor fuser exit for proper operation Go to step 8 Go to step 7 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Fuser exit Caution The area around the actuator is very hot Allow the fuser area to cool before proceeding Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 7 Check the sensor fuser exit for proper connection Replace the Replace the Is the above component properly connected sensor User EX Connection Go to Sensor fuser exit removal on page 4 25 8 Check the registration clutch for proper operation Go to step 10 Go to step 9 Caution When performing motor tests ensure that all cover and door interlock switches are overridde
65. switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Tests 4 Select K developer transport drive motor Does the above component operate properly 3 Check the K developer transport drive motor assembly for Replace the K Replace the proper connection developer connection transport drive Is the above component properly connected motorassembly Go to K developer transport drive motor assembly removal on page 4 92 4 Perform a POR Replace the lower Problem solved printer engine card Does the error occur when the power is turned off on assembly Go to Lower printer engine card assembly removal on page 4 77 2 58 Printer Service Manual 903 01 K PC drive motor error 5057 XXX Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on panties If the problem remains go to step 2 2 Check the CMYK PC cartridge drive motor assembly for Go to step 4 Go to step 3 proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Tests 4 Select K PC cartridge drive motor Does the above component operate properly 3 Check the CMYK PC cartridge drive motor assembly for Replace the Replace the proper connection CMYK PC conn
66. transfer belt access door interlock A Release the hooks securing the switch transfer belt access door interlock A to the machine Repair information 4 79 5057 XXX 7 Remove the switch transfer belt access door interlock A Connector 4 80 Printer Service Manual 5057 XXX Laser diode power card assembly removal 1 2 as Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 Disconnect the connector from the laser diode power card assembly A Release the four plastic supports with needle nose pliers Remove the laser diode power card assembly A Repair information 4 81 5057 XXX 24V LVPS card bracket assembly removal n Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Disconnect the four connectors from the 24V LVPS card bracket assembly A Remove the harnesses from the clamps Remove t
67. 1 Select Print Quality Pages from the Configuration Menu Printing Quality Test Pages appears on the LCD 2 Select Back to return to the Configuration Menu Note When this report is printed from the Configuration Menu the device enforces the toner cartridge lockout mechanism that is the Machine Class ID of its cartridge must match the Machine Class ID stored in the printer s NVRAM SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source equipped with size sensing hardware Size sensing Input source Length Width Multipurpose feeder integrated MPF Y Tray 1 integrated 500 sheet drawer Y Tray 2 integrated 500 sheet drawer Y Tray 3 integrated HCF 850 sheet drawer Tray 4 integrated HCF 1150 sheet drawer Tray 3 optional 2TM 500 sheet drawer Y Tray 4 optional 2TM 500 sheet drawer Y SY Sal Sal Pl Sal e Diagnostic aids 3 25 5057 XXX To change the value of this setting 1 Select SIZE SENSING from the Configuration Menu The screen displays each size sensing equipped input source and its current Size Sensing value 2 Select Back to cancel and return to the Configuration Menu 3 Select V to save the change By turning this setting to Auto every input option equipped with size sensing hardware automatically registers what size paper it contains When this setting is turned Off the printer ign
68. 1TM optional O O Sensor tray 2 feed out ge Tray 2 TTM optional Sensor tray 3 feed ou IN z O 2 A Tray 4 Tray 3 Sensor tray 4 feed out O O Functions of main components e Media tray assembly Media feed unit assembly es MPF e Xerographics e Transfer e Fuser e Drive e Electrical components and rolls Media tray assembly It is necessary to adjust the media tray rear guide and media tray end guide of the media tray assembly to match the media size 1 6 Printer Service Manual 5057 XXX Rear media guide The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear The rear guide come into contact with the media and hold it in position End guide The media tray assembly is designed so it can adapt to the media length in the media feed direction by moving the end guide to the left or right Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly The bottom plate is pushed up by the rotation of the lift up shaft which causes the supplied media to come in contact with the pick roll Media tray assembly Rear media guide Bottom plate End guide Detection of media size The media size set for the media tray assembly is transmitted to the switch media size by moving these guides The media size is detected by the on off
69. 2 feed out 3 40X3821 1 1 Switch tray module left door interlock 4 40X4141 1 1 1TM left door assembly this comes assembled 5 40X4119 1 1 Tray module media transport roll assembly Parts catalog 7 45 5057 XXX Assembly 38 1TM drive and electrical 7 46 MFP Service Manual Assembly 38 1TM drive and electrical 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X4152 1 1 1TM controller card assembly 2 40X3812 1 1 Tray module drive motor assembly 3 40X4068 1 1 Tray module left retaining bracket 4 40X4034 2 1 Tray module retainer screw 5 40X3815 3 1 Media transport gear 33T 6 40X3813 1 1 Media transport gear 23 46T 7 40X4117 4 1 Front locking caster 8 40X4143 4 1 Rear non locking caster 9 40X4069 2 1 Tray module right retaining bracket 10 40X4109 1 1 1TM main cable assembly Parts catalog 7 47 5057 XXX Assembly 39 3TM covers 7 48 MFP Service Manual Assembly 39 3TM covers 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3825 1 1 Tray module right cover 2 40X3824 1 1 Tray module foot cover 3 40X3826 2 1 Tray module left cover 4 40X3827 1 1 Tray module rear cover 5 40X3823 1 1 Tray module top cover Parts catalog 7 49 5057 XXX Assembly 40 3TM feed unit assembly J 7
70. 27 5057 XXX Step Check Yes No 6 Check the Replace the K developer transport drive motor Go to step 8 Go to step 7 assembly for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select K developer transport drive motor Does the above component operate properly 7 Check the K developer transport drive motor assembly for Replace the K Replace the proper connection developer connection transport drive Is the above component properly connected motor sssembiik Go to K developer transport drive motor assembly removal on page 4 92 8 Perform a print test Replace the lower Problem solved printer engine card Does the error continue assembly Go to Lower printer engine card assembly removal on page 4 77 230 00 Sensor duplex wait late jam duplex media feed Step Check Yes No 1 Check the media position Remove the media Go to step 2 Does the media remain in standard media exit 2 Check the duplex unit assembly rolls Go to step 3 Clean or replace the a duplex unit Are the duplex unit assembly rolls free of excess wear and contamination assembly Go to Duplex unit assembly removal on page 4 10 3 Check the sensor duplex wait for proper operation Go to step 5 Go to step 4 1 Enter the Diag
71. 3 feed out The sensor tray 3 feed out detects media fed from the tray 3 or tray 4 Sensor tray 4 feed out The sensor tray 4 feed out detects media fed from the tray 4 Tray module media transport roll assembly The tray module transport roll assembly feeds media from the tray 3 or tray 4 to the printer General information 1 39 5057 XXX Tray module drive motor This motor is used to drive the media transport mechanism in the tray module TTM tray 4 media transport motor This motor is used in the TTM to transport media from the tray 4 towards the tray module left door assembly TTM controller card assembly The TTM controller card assembly which contains a CPU controls media feed in the tandem tray module upon receiving a command from the upper printer engine card assembly and sensor switch information Tray module TTM tray 4 media drive motor transport drive motor Switch tray module interlock TTM controller card assembly Sensor tray 2 feed out Sensor tray 3 feed out Switch media size Switch TTM media size Sensor tray 4 feed out 1 40 Printer Service Manual 5057 XXX Switch TTM media size The following table gives on off states of the switches on the switch TTM media size corresponding to the media sizes of the media tray assembly Note The switches TTM media size are denoted by S W1 and S W3 respectively from the left side Analog switch Media S
72. 5 2 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 3 Disconnect the connector from the rear upper cooling fan A 4 Remove the rear upper cooling fan A from the rear upper cooling fan bracket Connector 4 98 Printer Service Manual 5057 XXX Developer transfer roll HVPS card assembly removal po ro oun 7 8 9 10 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Loosen the screw securing the ground wire A to the machine Remove the ground wire A Warning The connector P572 and P502 are permanently attached to the developer transfer roll HVPS card assembly B do not attempt to remove these connectors or damage will occur Disconnect the five connectors from the developer transfer roll HVPS card assembly B Remove the three screws securing the developer transfer roll HVPS card assembly B to the machine Note The developer transfer roll HVPS card assembly B can be supported by the plastic support C by attaching it to the hook on the machine Lower the developer transfer roll HVPS card assembly B Remove the connector from the developer transfer roll HVPS card assembly B Release the harnesses from the clamps Lift the right side
73. 50 MFP Service Manual Assembly 40 3TM feed unit assembly 5057 XXX Asm Part FRUs Units Des ribtion index number mach FRU p 1 40X3677 3 1 Switch media size 2 40X3676 6 1 Media tray slide 3 40X3675 3 1 Media tray catch 4 40X3678 3 6 Media tray assembly kit e Media tray assembly e 1 label e 2 label e 8 label e 4 label e Instruction label 5 40X3679 1 1 Media feed unit assembly Parts catalog 7 51 Assembly 41 3TM media feed unit 5057 XXX X y y y AN kA SN JN d N i RN Ca 7 52 MFP Service Manual 5057 XXX Assembly 41 3TM Media feed unit Asm Part FRUs Units Description index number mach FRU 1 40X3679 4 1 Media feed unit assembly 2 40X3687 4 1 Media out actuator 3 40X3688 30 1 Sensor tray media out 4 40X3688 30 1 Sensor tray media level 5 40X3684 4 1 Media feed lift motor 6 40X0888 6 1 Bushing 6 mm 7 40X3686 4 1 Media tray lift one way gear 8 40X3685 4 1 Media tray lift one way clutch 9 40X4086 4 2 Separation roll friction clutch 10 40X3689 2 1 Feed unit roll kit e Feed roll 2 e Pick roll 2 e Separation roll 2 11 40X3690 4 1 Feed roll one way clutch 12 40X3691 4 1 Feed roll one way gear 22T 13 40X0952 6 1 Bushing 6 mm Parts catalog 7 53 5057 XXX Assembly 42 3TM left door i 7 54 MFP Service Manual 5057 XXX Assembly 42 3TM left door Asm
74. 5057 XXX 40X3668 40X3669 40X3670 40X3671 40X3672 40X3673 40X3674 40X3675 40X3676 40X3676 40X3677 40X3678 40X3679 40X3679 40X3680 40X3681 40X3682 40X3684 40X3685 40X3686 40X3687 40X3688 40X3688 40X3688 40X3688 40X3688 40X3688 40X3689 40X3690 40X3691 40X3692 40X3693 40X3694 40X3694 40X3695 40X3696 40X3697 40X3698 40X3699 40X3700 40X3701 40X3702 40X3703 40X3704 40X3705 40X3706 40X3707 40X3709 40X3711 40X3712 40X3713 40X3714 40X3715 40X3716 40X3717 40X3718 40X3719 40X3720 40X3721 Transfer belt drive motor assembly e 7 6 CMY developer drive motor assembly 7 6 Developer and transport drive motor assembly 7 6 Developer idler gear assembly e 7 6 MPF transport drive motor assembly 2 7 6 Transfer belt steering motor rrr eee 7 7 Image density sensor assembly ee 7 7 Media tray catch nn rrr enero 7 8 7 42 7 51 7 60 Media tray side ae a Se a eee Bee See 7 8 Media tray slide een 7 42 7 51 7 60 Switch media size 7 8 7 42 7 51 7 60 Media tray assembly 0050 r rrr rrr rrr rrr eee 7 8 7 42 7 51 7 60 Media feed assembly e 7 9 Media feed unit assembly 7 11 7 42 7 44 7 51 7 53 7 64 7 65 Printer left lower door assembly
75. 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse Illb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse I laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p b lgel ngdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse el
76. A 4 10 Printer Service Manual 5057 XXX Sensor duplex wait removal 1 Remove the duplex unit assembly See Duplex unit assembly removal on page 4 10 2 Remove the screw securing the bracket A to the duplex unit assembly B 3 Release the hooks securing the sensor duplex wait C to the bracket A 4 Remove the sensor duplex wait C 5 Disconnect the connector from the sensor duplex wait C Switch duplex left door interlock removal 1 Remove the duplex unit assembly See Duplex unit assembly removal on page 4 10 2 Release the hooks securing the switch duplex left door interlock A 3 Remove the switch duplex left door interlock A 4 Disconnect the connector from the switch duplex left door interlock A Repair information 4 11 5057 XXX Duplex media exit turn guide removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 3 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 4 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 5 Lay the printer left door assembly on a flat surface 6 Move the duplex media exit turn guide A toward the rear and release the hook from the front hinge 7 Remove the duplex media exit turn guide A A ef GS Repla
77. ABIES E ALT REE A PRE fh I DELER EN xviii Printer Service Manual 5057 XXX BLAS 1838 41014 ASSO CHE DHHS 21 CFR Subchapter 39 FNS Atos ges UZAN ISten 32 9 ejod IEC 825 732 EFE 158 MOA BORA 2138 Giele 184 AOA ASSES HNE HOS ZS CI E HERES 5 22jeje AS falo alo HZA 770 795 LE Ol E S TFHA SSste Class ill 3b HOME yo Aa MSc E Hoa AAMT zae HA 35 Boll FA ET 3 EE FHE MEA AEH 7 2 Class I FE HoH Bol Ago SO 3428 913 MASON VE Notices and safety information XIX 5057 XXX XX Printer Service Manual 5057 XXX Safety information The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the A product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit e La s curit de ce produit repose sur des tests et des agr atio
78. AC drive card assembly is turned on after a preset time period has passed from power on If a failure occurs the heater lamps are turned off the fuser ready is turned off and then the fuser temperature control is stopped Main sub heater lamps on off control The front and rear thermistors detect the heat roll surface temperature fuser temperature to regulate the temperature at the target control temperature by turning on or off the main sub heater lamps Fuser warm up The fuser warm up starts at the time of power on interlock open or close jam reset or return from the low power mode and ends when the ready temperature is attained when a failure occurs or when executing diagnosis 1 26 Printer Service Manual 5057 XXX Xerographic process during a print cycle K toner C toner M toner Y toner Fuser OO Transfer belt ON A A A Cleaning roll Transfer belt KC lt K transfer roll e roll M ao roll Y transfer roll cleaning _ assembly 2nd transfer roll assembly Bee Y Registration roll Printhead Erase i Cleaning blade Photo conductor drum eo am ald SEN Sensor ATC General information 1 27 5057 XXX Charge The Charge Roll places a uniform negative electrostatic charge on the surface of the drum The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness Light striking
79. Assembly 36 1TM media feed unt 7 43 Assembly 37 11M left door EEN EELER EE re NEEN EE 7 45 Assembly 38 1TM drive and electrical 0 cece tees 7 46 Assembly 39 SIM COVEIS 2 cscccs cc ddr iS 7 48 Assembly 40 3TM feed unit assembly 2 0 2 eee tees 7 50 Assembly 41 3TM media feed unt 7 52 Assembly 42 STM leh GOOF iis coc Aere Frere TEN di eee ed eee RS 7 54 Assembly 43 3TM drive and electrical 0 cece tee 7 56 Assembly 44 TTMcovers 0 0 00 cece eee ene ranerne 7 58 Assembly 45 TTM media trays oocococcccoco etna 7 59 Assembly 46 T TMmedatay 3 ett eens 7 61 Assembly 47 TTM media tray 4 oococccccococ ttt eee 7 63 Assembly 48 TTM media tray 4 transport 7 64 Assembly 49 TTM media transport coccccccoc teens 7 65 Assembly 50 TIM lem door csccccacceck dase rra aa 7 66 Assembly 51 TIM Way I EE 7 67 Assembly 52 TTM drive and electtcal tee 7 68 Assembly 53 MIScellaneGus EE 7 70 FEE PE PL DE NE EE Li Part number IR icv ie ieee eee ed ee usus irn Nae Seah ewe l 5 XIV Printer Service Manual 5057 XXX Notices and safety information The following laser notice labels may be affixed to this printer Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825 1
80. E clips securing the tray support rolls B to the two brackets A using a prying tool Remove the two E clips securing the tray support rolls B to the main frame C 4 114 Printer Service Manual 5057 XXX 8 Remove the shafts D 9 Remove the tray support rolls B Repair information 4 115 5057 XXX 2000 sheet dual input TTM TTM media tray 4 assembly removal a Pull out the TTM media tray 4 assembly Remove the two screws securing the TTM tray 4 media transport assembly A to the TTM media tray 4 assembly B Push the TTM tray 4 media transport assembly A into the machine in the direction of the arrow Remove the two screws securing the TTM tray 4 stopper C to the lower part of TTM media tray 4 assembly B Remove the TTM tray 4 stopper C Remove the TTM tray 4 assembly B M ou Ww 4 116 Printer Service Manual 5057 XXX 2000 sheet dual input TTM TTM media tray 3 assembly removal Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Open the TTM left door assembly Loosen the screw securing the TTM tray 3 stopper A Move the TTM tray 3 stopper A out in the direction of the arrow while pulling out the TTM media tray 3 assembly B Remove the TTM media tray 3 assembly B RON al 2000 sheet dual input TTM tray 3 front cover removal 1 Pull out the media t
81. HP is not interrupted within the specified time after the punch carriage starts moving to the home position Refer to the Finisher Service Manual 985 01 Service finisher error Sensor punch carriage shift HP lag error The sensor punch carriage shift HP remains interrupted within the specified time after the punch carriage starts moving from the home position Refer to the Finisher Service Manual 986 00 Service finisher error Sensor media eject clamp HP late error The sensing area of the sensor media eject clamp HP is not interrupted within the specified time after the eject clamp starts moving to the home position Refer to the Finisher Service Manual 986 01 Service finisher error Sensor media eject clamp HP lag error The sensing area of the sensor media eject clamp HP remains interrupted within the specified time after the eject clamp starts moving from the home position Refer to the Finisher Service Manual 987 00 Service finisher error Sensor media eject shaft HP late error The sensing area of the sensor media eject shaft HP is not interrupted within the specified time after the media eject shaft starts moving to the home position Refer to the Finisher Service Manual Diagnostic information 2 15 5057 XXX EE Error contents Description Action message 987 01 Sensor media eject shaft The sensin
82. It also contains the fuser relay to feed cut off AC power to the heater lamps of the fuser unit assembly 5V LVPS card assembly The LVPS card assembly generates low voltages 5V for logic circuits 5 V for laser diodes from AC power 24V LVPS card assembly The LVPS card assembly generates 24 V for motors clutches from AC power CMYK transfer roll HVPS card assembly The CMYK transfer roll HVPS card assembly generates AC power and feeds it to the CMYK transfer rolls inside the transfer belt unit assembly Developer roll HVPS card assembly The HVPS card assembly generates AC power and feeds it to the four developer rolls the transfer belt unit assembly and the 2nd transfer roll assembly Charge roll HVPS card assembly The HVPS card assembly generates AC power and feeds it to the four charge rolls Charge roll HVPS card assembly CMYK transfer roll HVPS card assembly Developer roll HVPS card assembly General information 1 23 5057 XXX Upper printer engine card assembly The upper printer engine card assembly controls printing operation based on the communication with the RIP card assembly and optional peripherals It also controls toner dispense erase lamps and fuser control Lower printer engine card assembly The lower printer engine card assembly controls printing operation based on the communication with the RIP card assembly and on sensor switch information It also controls many of the drive motors clutches
83. OO Y DU Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 82 Disconnect the two connectors from the CMYK transfer HVPS card assembly A Disconnect the four faston connectors from the CMYK transter HVPS card assembly A Remove the two screws securing the CMYK transter HVPS card assembly A to the machine Remove the CMYK transfer HVPS card assembly A Connectors Faston connectors Printhead assembly removal 0 JO Om P Co b i Warning When removing the printhead assembly be careful not to drop it or damage will occur Warning Always perform color registration adjustment when reinstalling the printhead NVM initialization or developer interlock plate assembly Detach the finisher if equipped Refer to the MFP or the Printer Finisher Service Manual Remove the base machine from the scanner ADF stand assembly Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remo
84. Part FRUs Units Description index number mach FRU 1 40X3818 1 1 Tray 2 feed out sensor cable assembly 2 40X3817 1 1 Sensor tray 2 feed out 3 40X3821 1 1 Switch tray module left door interlock 4 40X3819 1 1 Tray 3 4 feed out sensor actuator 5 40X3820 2 1 Sensor tray 3 feed out 6 40X3820 2 1 Sensor tray 4 feed out 7 40X3816 1 1 3TM left door assembly this comes assembled 8 40X4035 2 1 Tray 3 4 feed out sensor cable assembly 9 40X4119 3 1 Tray module media transport roll assembly Parts catalog 7 55 5057 XXX 3TM drive and electrical Assembly 43 7 56 MFP Service Manual Assembly 43 3TM drive and electrical 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3811 1 1 3TM controller card assembly 2 40X3812 1 1 Tray module drive motor assembly 3 40X4068 1 1 Tray module left retaining bracket 4 40X4034 2 1 Tray module retainer screw 5 40X3815 3 2 Media transport gear 33T 6 40X3814 2 2 Media transport gear 46T 7 40X3813 1 1 Media transport gear 23 46T 8 40X4117 4 4 Front locking caster 9 40X4143 4 4 Rear non locking caster 10 40X4069 2 1 Tray module right retaining bracket 11 40X4108 1 1 3TM main cable assembly Parts catalog 7 57 5057 XXX Assembly 44 TTM covers Asm Part FRUs Units Description index number mach FRU 1 40X3825 1 1 Tray module right cover 2 40X3824 1 1 Tray module foot c
85. Printer Service Manual 5057 XXX Step Check Yes No 7 Check the media feed lift motor in media tray 2 for proper Go to step 9 Skip to step 8 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select Tray 2 media feed lift motor Does the above component operate properly 8 Check the media feed lift motor for proper connection Replace the media Replace the Is the above component properly connected feed lift motor connection Go to Media feed lift motor removal on page 4 109 9 Perform a print test Replace the lower Problem solved Does the error continue Seana SR Go to Lower printer engine card assembly removal on page 4 77 242 01 Sensor tray 1 feed out late jam feeding from tray 2 Step Check Yes No 1 Check the media condition Replace the Go to step 2 Is the media in the tray crumpled or damaged ple media 2 Check the media position Remove the Go to step 5 Does the media touch the sensor tray 1 feed out media 3 Check the sensor tray 1 feed out for proper operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 1 5 Select Feed out Does the display on the operator panel change every time the sensing
86. Problem solved removal on page 4 74 Toner cartridge set error Step Check Yes No 1 Checking the toner cartridge for correct installation Go to step 2 Reinstall the toner Open the printer front door assembly Is the toner cartridge cartridge properly installed properly 2 Checking the toner cartridge Is the toner cartridge Replace the toner Go to step 3 damaged cartridge 3 Checking the toner cartridge guide assembly Remove the Replace the toner Go to step 4 top cover assembly Is the toner cartridge guide assembly cartridge damaged 4 Checking the appropriate color sensor RFID toner Replace the Go to step 5 cartridge appropriate sensor RFID toner Is the above sensor attached and connected properly cartridge Go to Sensor RFID toner cartridge removal on page 4 105 5 Perform a print test Replace the Problem solved Does the error remain et card Go to Upper printer engine card assembly removal on page 4 74 Waste toner cartridge full Step Check Yes No 1 Check the waste toner cartridge Go to step 2 Reinstall the waste Is the above component properly installed 2 104 Printer Service Manual toner cartridge 5057 XXX Step Check Yes No 2 Check the sensor waste toner cartridge full for proper Go to step 5 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSO
87. Remove the two screws securing the upper guide D to the media feed unit assembly A 15 Remove the upper guide D 16 Remove the two screws securing the rear bracket E to the media feed unit assembly A 17 Remove the rear bracket E 4 126 Printer Service Manual 5057 XXX 2000 sheet dual input TTM sensor tray 4 feed out removal k ao oun N Remove the media tray 2 assembly Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Disconnect the connector from the sensor tray 4 feed out A Release the hooks securing the sensor tray 4 feed out A to the upper guide B Remove the sensor tray 4 feed out A Repair information 4 127 5057 XXX 2000 sheet dual input TTM switch media size removal Note This procedure can be applied to tray 1 or tray 2 switch media size 1 Remove media Tray 1 and media Tray 2 2 Remove one screw securing the switch media size A to the bracket inside the machine 3 Remove the connector from switch media size A 4 Remove the switch media size A Connector 4 128 Printer Service Manual 5057 XXX 2000 sh
88. Replace the MPF Replace the feed unit connection Is the above component properly connected assembly Go to MPF feed unit assembly removal on page 4 8 3 Perform a POR Replace the upper Problem solved printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 941 00 Switch media size size sensing error tray 1 Step Check Yes No 1 Check the media Go to step 2 Load media Is media loaded in tray 1properly properly 2 Check the media tray Replace the media Go to step 3 Are the size sensing mechanisms on the back and the tray assembly bottom of the media tray damaged 3 Check the tray 1 switch media size for proper operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 1 5 Select Tray 1 present Does the display on the operator panel change every time the media tray is opened and closed 4 Check the tray 1 switch media size for proper connection Replace the switch Replace the Is the above component properly connected meala size connection Go to Switch media size removal on page 4 110 5 Perform a POR Replace the upper Problem solved Does the error continue when the power is turned off on ee Ge Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 83 5057 XXX 941 01 Sen
89. Reports 3 Select Network Setup Page The following report prints Standard Network Card Status Connected 100 Mbps Half Duplex Auto Disabled 2007 05 21 10 43 00040091E1E1 000000000000 NC NPS N125 04 May 07 09 37 mls bld Not Set Integrated Network Option Settings Printer Type Lexmark X940e Integrated Network Option Settings ve 84 168 1 ET0004009 I ELE1 dhep Jexmark com d 157 184 147 17 157 184 202 202 Unknown On ET00040091E1E1 dhep lexmark com Yes ET00040091E1E1 Lexmark X940e LaserWriter H 101 225 Yes ET00040091E1E1 PSERVER 00000000 AppleTalk is a trademark of Apple Computer Inc Using a fine incremental ruler measure from the black line border to the edge of the media Ideally the borders should be centered on the page To perform the ENGINE ADJUST settings 1 Select ENGINE ADJUST from the Diagnostics Menu The following tests appear on the LCD Select tne Then select Appears on the LCD following PH Adjust Adj Side Reg ALL appears on LCD Registration values appear on the Media tray rae LCD If required reset the values registration Adj side reg all trays and Select y to submit the changes Adj Side Reg MSI appears on LCD Adj side reg MPF Adj Side Reg DUP appears on LCD Adj side reg duplex 3 20 Printer Service Manual Registration values appear on the LCD If required reset the values and Select y to submit the changes Registr
90. Sensor media level late The sensing area of the sensor media level in the TE error tray 3 media tray 3 is not interrupted within the specified failure y time after the lift tray has risen to operating level Go to 943 01 Sensor media level late error tray 3 on page 2 87 944 00 Switch media size size The tray 4 switch media size detected an invalid Service tray 4 sensing error tray 4 size setting failure Go to 944 00 Switch media size size sensing error tray 4 on page 2 88 944 01 Sensor media level late The sensing area of the sensor media level in the Service wave error tray 4 media tray 4 is not interrupted within the specified failure y time after the lift tray has risen to operating level Go to 944 01 Sensor media level late error tray 4 on page 2 89 980 00 Communication error with A communication error has occurred with the Service tray 2 1TM 3TM or TTM assembly 1TM 3TM or TTM controller card assembly and the comm y upper printer engine card assembly Go to 980 00 Communication error with 1TM 3TM or TTM assembly on page 2 90 980 01 HVPS controller A communication error has occurred with the communication error developer roll HVPS card assembly and the upper pek device printer engine card assembly Go to 980 01 HVPS controller communication error on page 2 91 980 02 Communication error A communication error has occurred with the RIP i between printer and RIP card card asse
91. Sensor printer left lower door interlock Sensor tray 1 feed out GE a I I Printer left lower door assembly 5 8 Printer Service Manual 5057 XXX RIP card cooling fan Tray module drive motor Connector locations 5 9 5057 XXX Feed lift motor Sensor media out Sensor media level Switch tray module left door interlock Media feed J unit assembly Sensor tray 2 feed out assembly media size 5 10 Printer Service Manual 5057 XXX 3TM controller card assembly Tray module drive motor Switch tray module left door interlock Sensor tray 2 feed out Sensor tray 3 feed out 3TM left door assembly Sensor tray 4 feed out Connector locations 5 11 5057 XXX TTM controller card assembly AF Switches media size AF Tray module S drive motor TTM tray 4 transport 2 drive motor 5 12 Printer Service Manual 5057 XXX Feed lift motor Sensor media out Sensor media level d unit assembly SS SS vi Switch tray module left door interlock Media feed
92. Staple cartridge empty Refer to the Finisher Service Manual Load tray x with No media in the selected Media is not loaded in the tray smeda media tray Go to No media in the selected media tray on page 2 96 Remove paper Finisher upper media bin full Stacker set over count from Bin The upper media bin has reached maximum capacity Refer to the Finisher Service Manual Remove paper Stacker media bin full no The stacker media bin has reached maximum from bin 2 mix capacity no mix Refer to the Finisher Service Manual Remove paper Stacker media bin full mix The stacker media bin has reached maximum from bin 2 size capacity mix size Refer to the Finisher Service Manual 2 18 Printer Service Manual 5057 XXX Error code or message Error contents Description Action Remove paper from standard Standard bin 1 full Media in standard bin 1 is at maximum capacity Go to Standard media bin full on page 2 103 output bin Toner Toner cartridge RFID error A toner cartridge of a different specification is unsupported installed Go to Toner cartridge set error on page 2 104 Diagnostic information 2 19 5057 XXX Service checks 200 00 Sensor registration late jam 2 20 Printer Service Manual Step Check Yes No 1 Check the media position Remove the Go to step 2 Does the media touch the sensor registration med a 2 Check the regi
93. The force pushing up the bottom plate of tray 4 is transmitted to the tray lift shaft assembly through the tray lift gear assembly 4 The bottom plate is lifted up via the front tray cables and rear tray cables by the rotation of the tray lift shaft assembly which causes the supplied media to contact the pick roll Tray 2 media tray assembly Rear media guide Bottom plate End guide 1 36 Printer Service Manual 5057 XXX Tray 3 or 4 media tray assembly Rear lift cables Rear media guide Bottom plate F R lift cable F L lift cable General information 1 37 5057 XXX TTM media feed units Media feed unit assembly Since the tray 3 and tray 4 are functionally equivalent in terms of the switch TTM media size sensor media out sensor media level and sensor pre feed only the components of one tray are described here The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll assemblies to feed media When the pick roll picks up sheets of media and the remaining media decreases the media level actuator of the sensor media level lowers accordingly Media feed lift motor The media feed lift motor is activated to feed media and to lift the bottom plate While feeding media it rotates forward to drive the pick roll When lift
94. and solenoids RIP card assembly The RIP card assembly connected to the printer engine card assembly controls the entire system as well as the printhead operations RIP card cooling fan RIP card Assembly Fuser Laser diode cooling fan card assembly Rear upper cooling fan Upper printer engine card Ee assembly cooling fan AC drive card Assembly Transfer belt drive motor cooling fan Rear lower i cooling fan Lower printer S engine card assembly 1 24 Printer Service Manual Control Media size control Media tray assembly feeding 5057 XXX The following table gives the states on off of the switches on the switch media size corresponding to the media sizes of the media tray assembly Note The switches on the switch media size are denoted by S W2 S W4 S W3 S W5 and S W1 respectively from the left side Analog switch Digital Media size switch S W1 S W2 S W3 S W4 S W5 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 LE
95. assembly 4 40X4092 1 1 SFP RIP card assembly 5 40X3808 1 1 Upper printer engine card chassis assembly 6 40X4081 1 1 Upper printer engine card cable assembly WARNING In the event of replacement of any one of the following components e Operator panel assembly e Operator panel controller card assembly e RIP card assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable WARNING Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer Parts catalog 7 39 5057 XXX Assembly 34 1TM covers Asm Part FRUs Units Description index number mach FRU 1 40X3825 1 1 Tray module right cover 2 40X3824 1 1 Tray module foot cover 3 40X4142 1 1 1TM front door assembly 4 40X3826 2 1 Tray module left cover 5 40X3827 1 1 Tray module rear cover 6 40X3823 1 1 Tray module top cover 7 40 MFP Service Manual 5057 XXX Assembly 35 1TM feed unit assembly
96. assembly removal on page 4 15 Is there contamination or cracks on the heat roll and or pressure roll Diagnostic information 2 135 5057 XXX No fuse Leading edge Trailing edge Step Check Yes No 1 Check the fuser unit assembly installation Go to step 2 Problem solved Check that the levers on both sides of the fuser unit assembly are pushed down Re print the defective image Does the error continue 2 Check the media condition Go to step 3 Problem solved Load new dry recommended media Re print the defective image Does the problem remain 3 Check the heat roll and pressure roll Replace the Go to step 4 f fuser unit Remove the fuser unit assembly assembly CAUTION Allow the fuser unit assembly to Go to Fuser cool down unit assembly removal on page 4 15 Is there contamination or cracks on the heat roll and or pressure roll 4 Check the connections on the AC drive card assembly Go to step 5 Problem solved Replace the AC drive card assembly Go to AC drive card bracket assembly removal on page 4 95 Does the error continue 5 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue card assembly Go to RIP card assembly removal on page 4 71
97. card assembly Go to RIP card assembly removal on page 4 71 2 126 Printer Service Manual Spots i Leading edge 5057 XXX Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the media transfer route Go to step 3 Remove debris eo as e or Is the media route free of contamination or debris contamination 3 Check the four PC cartridges for spots or other damage Go to step 4 Replace the on the drum surfaces appropriate PC cartridge or Are the PC cartridges free of excess wear and contamination connector 4 Check the 2nd transfer roll assembly for contamination Go to step 5 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd transfer roll assembly removal on page 4 35 5 Check the heat roll and pressure roll Replace the Go to step 6 fuser unit Remove the fuser unit assembly assembly CAUTION Allow the fuser unit assembly to Go to Fuser cool down unit assembly removal on page 4 15 Is there contamination or cracks on the heat roll and or pressure roll 6 Replace the transfer belt unit assembly Go to Transfer Go to step 7 Problem solved belt unit assembly removal on page 4 16 Does the problem remain Diagnostic informat
98. card assembly e Interconnect card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer 7 4 MFP Service Manual Assembly 3 Covers 3 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3796 1 1 Rear left upper cover 2 40X3793 1 1 Rear left middle cover 3 40X3795 1 1 Left front cover 4 40X3794 1 1 Rear left lower cover 5 40X3788 1 1 Rear blind cover 6 40X3791 1 1 Rear cover assembly 110 V 6 40X3792 1 1 Rear cover assembly 220 V Parts catalog 7 5 5057 XXX Assembly 4 PC cartridge and developer drive Asm index ona E Ww PY Part number 40X3671 40X3669 40X3670 40X3672 40X3667 40X3668 FRUs mach i A sch sch Units FRU A A sch sch sch ld Description Developer idler gear assembly CMY developer drive motor assembl
99. damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 5057 XXX Removal procedures Before starting service work CAUTION A Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly CAUTION DA While performing service around the fuser assembly ensure the fuser area has cooled down Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Note A wide variety of screws are used make note of their positions during service 4 2 Printer Service Manual 5057 XXX Printer front door assembly removal 1 Open the printer front door assembly 2 Press the tab and rotate the two flexible supports A 90 and pull from the machine 3 Remove the two flexible supports A
100. dens SENSING EE 1 32 TUMITACON ERE EE PE EE EE PR EN 1 33 Menla tans TN TN at la ud aa ad 1 34 Media tansport EE EEE EE ER ARA 1 34 MESTRE TE SG EEE SEE EE EE ERE 1 35 Functions of main Components sacd cnsoseescrdednteoiminseesateraauocaweenan 1 35 IV Printer Service Manual 5057 XXX Media tray assembly sca ii das id a Ses ORE RS ROR RE ews 1 35 Hear ET QUIN EE WEE as ari 1 35 BON PE espia edge woah Mate Haase eS aent 1 36 Thay 2 EEE SET EEE EEE AAA 1 36 Heer EEE NE ENE ad EE 1 37 TIM Media teen NS cosas csi ie dis asas 1 38 IO EIER gn VE 1 38 HEER ios vedas 1 38 Se DEE REE EE EE EE eee 1 38 SEE media EEE EEE EE EEE ANN 1 38 Sensor EEE ee 1 38 Sensor media BA EE 1 38 Manege EIERE EES sew RER e EE ERNEIEREN SE 1 39 Switch tray module left door interlock 0 00 cee tenes 1 39 RE e Ee EE EE 1 39 Sensor tray S feed OUN ses tics soared ek o A a Ae 1 39 VSHSO ay 0 EE FEE EE sede eect SE EEE 1 39 Tray module media transport roll assembly e ak cose ease kane p eee arabe sne 1 39 Tray modus ANE MOTOS ccnciseacrceecs weet SE UKERS Aa 1 40 TIM tray 4 media transport Motor AS EENS NEEN edes parer bakke EE Genk Ede 1 40 TIM contoller card assembly sce ccgulsectrtegigee ddgheddedd sae bi 1 40 SEE EEE EE 1 41 EE 1 42 Media transport cc nkra Ane a raaa 1 43 Medid tanpon Pall sacs cates EE EE EE SE 1 43 Modia SEL d EEE AAA AAA ASE 1 44 PUACIONS NAN COMPONENTS 4 65255 ps rare sed eae oe eRe eee ER 1 44 Media thay ASSembi T
101. developer transport drive motor is a DC motor that drives the K developer unit assembly registration roll 2nd transfer roll fuser and standard media exit rolls MPF transport drive motor General information 1 19 5057 XXX The MPF transport drive motor is a stepper motor that drives the MPF unit assembly and media transport roll K developer transport drive motor assembly MPF transport drive motor CMYK PC cartridge drive motor assembly The CMYK PC cartridge drive motor assembly uses dual DC brushless motors that drive the four drums in the four PC cartridges K drive motor CMY drive motor 1 20 Printer Service Manual 5057 XXX CMY developer drive motor assembly The CMY developer drive motor assembly uses a DC brushless motor to drive the three color developer unit assemblies K developer clutch This clutch is used to engage the K developer unit assembly and is driven by the K developer transfer drive motor assembly K developer clutch CMY developer drive motor assembly CMYK toner add motor assembly Y toner add motor M toner add motor C toner add motor est K toner add motor Y toner add assembly M toner add assembly C toner add assembly K toner add assembly General information 1 21 5057 XXX The CMYK toner add motor assembly consists of 4 separate DC motors Each color of toner has its own motor that is used to rotate the toner auger inside th
102. do not touch the rubber surface of the separation roll B Repair information 4 145 5057 XXX 2000 sheet dual input TTM pick roll removal 1 Remove the media tray assembly 2 Move the front guide A toward the front in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before re installing do not touch the rubber surface of the pick roll B 4 146 Printer Service Manual 5057 XXX 2000 sheet dual input TTM left door assembly removal e SERGE page 4 112 Open the TTM left door assembly Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on Remove the two screws securing the two support straps A to the machine Remove one screw securing the bracket B Remove the bracket B Move the TTM left door assembly C to the front and out in the direction of the arrow Remove the TTM left door assembly C AO Ee E a EE AH La WEEE Sc UT ART t LC SC Repair information 4 147 5057 XXX 2000 sheet dual input TTM switch TTM left door interlock removal Open the TTM left door assembly Remove the screw securing the support strap A to the machine Remove the screw sec
103. drive motor assembly A 10 Release the hook securing the access cover B to the machine 11 Remove the access cover B 12 Remove the two screws securing the socket C to the machine 13 Detach the socket C from the machine Note The lower left screw can be accessed through the hole in the frame where the socket B was detached in step 7 14 Remove the eight screws securing the CMY PC cartridge drive motor assembly A to the machine 15 When removing the CMYK PC cartridge drive motor assembly A ensure none of the harnesses become damaged 16 Remove the CMYK PC cartridge drive motor assembly A O ST Connector Connector Screwdriver Sl access hole 7 Fuser cooling fan removal 1 Remove the top cover assembly See Top cover assembly removal on page 4 4 2 Disconnect the connector from the fuser cooling fan A 3 Remove the harness from the clamps 4 Lift the fuser cooling fan A Repair information 4 87 5057 XXX 5 Remove the fuser cooling fan Connector Main power switch actuator removal 1 Remove the top cover assembly See Top cover assembly removal on page 4 4 2 Remove the screw securing the main power switch actuator A to the machine 3 Release the hook securing the main power switch actuator A to the machine 4 Remove the main power switch actuator A 4 88 Printer Service Manual 5057 XXX CMYK toner add motor assembly removal OO PS Go b
104. e SV INTLCK K SV INTLK M d i 1 VATN 2011 ee Q 24V LVPS j ol ola ojojo g E a 219 SE a ANSETT gt LD VDATA M Ute Sr eE rene i a a SOR A ER EE Se 5 i 53 alk u his his tie 1 i 3 31183 ing fan fr Ceres op SIS on AB vd GR 8 118 1 8 118 i ds ma 174 peN GE 2 TE xE ji E E E E SENSOR 5 la IMAGE DENSITY SNR2A d 16 5 p SV TN gt i Qs fem E Dx Fu 5VDG n wean else D 3 Ilhste Panama e ae 183 68 8 EN ven y y le le Ns i ATG 5V PWR KATO i n ze ne 25 RIN ev ea VE NE NE NE Th 4 471 gt gt ps S nu e ne pe e Ble IMAGE DENSITY SNR28__q 13 G p gt SV RIN gt eee de fasten i 2 an 5 i Eu IMAGE DENSITY LED 2AON 12 g p gt SNR CATO gt See i 10 IMAGE DENSITY LED 28 ON 441 pp ATC SV PWR ee y d 3 e E Uy y Th 8VDC ag HOL p gt 5VATN gt AB P800A B 5 aj De SVATN d 9 42 b gt SNRMATO it eee MCUTOTRAY ag 4 14 EW HA gt 3 le 4 813 AT0 Sv PWR ad MG TRAY TO MOU_q 15 438 pp MACS DL STARTIOUTPUT SIG DA 3 Tale ha gt SVRTN e TRAY CLK og 3112 p SVATN gt 3A 3 e SENSOR 5 le IMAGE DENSITY SNR 1A ag G 15 gt SNB Y ATC p SENSOR TRAY o q A 44 p MACSDLACK SA 2 mage 1 Ge 15 16 p Are sv own pl Dao OPTION DET q 5 140 pv ATN SA 2 TO P668 PIN 1 TRAY 5VDC MACS SCLK1 x KW 417 2 gt PKS GR 6 9 gt t o 6A 8Ble MAGE DENSITY SNR1B q 3 yg po FNEL N Fuser e DEBUG q 7 p OUTPUTTOMCU HB
105. error Step Check Yes No 1 Reinstall the waste toner cartridge Replace the waste Problem solved Does the error remain toner cartridge Go to step 2 2 Check the sensor waste toner full for proper operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Devices 4 Select Waste toner cartridge full Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check the sensor waste toner full for proper connection Replace the Replace the sensor waste connection Is the above component properly connected toner full 4 Perform a POR Replace the lower Problem solved Does the error occur when the power is turned off on Bee S card Go to Lower printer engine card assembly removal on page 4 77 Diagnostic information 2 71 5057 XXX 911 00 24V LVPS cooling fan error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Check the 24V LVPS cooling fan assembly for proper Replace the 24V Replace the connection LVPS cooling fan connection Is the above component properly connected assembly Go to 24V LVPS cooling fan removal on page 4 84 3 Perform a POR Replace the lower Problem solved Does the error occur when the powe
106. fail HP Does the transfer belt appear damaged or torn in half 2 Check the transfer belt cleaning assembly for proper Go to step 3 Reinstall the installation transfer belt i cleanin Is the above component installed properly Semi 3 Perform a POR Go to step 4 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 4 4 Replace the transfer belt unit assembly To to Transfer Replace the lower Problem solved belt unit assembly removal on page 4 16 printer engine card Does the error remain assembly Go to Lower printer engine card assembly removal on page 4 77 904 01 Transfer belt position failure Step Check Yes No 1 Check the transfer belt unit assembly for proper installation Go to step 2 Re install the transfer belt unit Is the above component properly installed dg um Diagnostic information 2 61 5057 XXX Step Check Yes No 2 Check the transfer belt cleaning assembly for proper Go to step 3 Reinstall the installation transfer belt i cleaning Is the above component installed properly assembly 3 Check the transfer belt unit assembly for damage Go to step 4 Replace the transfer belt unit ee component free of damage to the frame and assembly 4 Check the transfer belt steering motor assembly for proper Go to step 6 Go to step 5 operation Caution When performing motor tests ensure
107. fan assembly 1 2 0 JO Om P Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 Remove the 5V LVPS card bracket assembly See 5V LVPS card bracket assembly removal on page 4 83 Disconnect the connector from the rear lower cooling fan assembly A Release the harnesses from the clamp Remove the two screws securing the rear lower cooling fan assembly A to the machine Remove the rear lower cooling fan assembly A Connector AY ee QI s fh J i A b I Repair information 4 85 5057 XXX CMY developer drive motor assembly 1 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 2 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 3 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 Remove the 5V LVPS card bracket assembly See 5V LVPS card bracket assembly removal on page 4 83 Disconnect the connector fro
108. gt IIR Sy o 7 Lower view 4 168 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM feed roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before re installing do not touch the rubber surface of the feed roll B Repair information 4 169 5057 XXX 3X 500 sheet drawer 3TM feed roll one way clutch removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 140 3 Remove the feed roll one way clutch A from the shaft B a Oy d T iT Front 4 170 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM one way 22 tooth removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 140 3 Remove the feed roll one way clutch See 2000 sheet dual input TTM feed roll one way clutch removal on page 4 141 4 Remove the feed roll one way gear 22 tooth A Repair information 4 171 5057 XXX
109. hae roll assembly O Finisher Booklet folding Tray 4 e optional roll assembly O O O Pick roll O Feed roll Tray 2 3TM optional Separation roll Da Z 1TM optional O a O Tray module transport AR roll assembly Tray 2 TTM ao Tray 4 Tray 3 Tray 4 transport roll assembly O O Functions of main components When the TTM is installed under the printer additional trays are available Media tray assembly It is necessary to adjust the rear side guides in the media tray assembly to match the media size Rear media guide The rear media guide can be adjusted to different media sizes by moving it to the front or rear The guide comes into contact with the rear edge of the media and holds it in position General information 1 35 5057 XXX Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly The bottom plate is pushed up by the rotation of the lift up shaft which causes the supplied media to come in contact with the pick roll The force pushing up the bottom plate of tray 3 is transmitted by the driving force of the media feed lift motor on the media feed unit assembly to the media lift shaft assembly through the tray lift gear assembly 3 The bottom plate is lifted up via the rear tray cables front right cable and front left cable by the rotation of the tray lift shaft assembly which causes the supplied media to come into contact with the pick roll
110. holding the four developer unit assemblies firmly inside the machine gently remove the developer interlock plate assembly A Small plastic clamp 15 Remove the developer interlock plate assembly A and allow it to gently hang down by the harness if removing the developer units If removing the developer interlock plate assembly A from the machine goes to step 15 16 Remove the screw securing the harness cover B to the machine 17 Remove the harness cover B 18 Disconnect the connector from the developer interlock plate assembly A 4 50 Printer Service Manual 5057 XXX Replacement note When replacing the developer interlock plate assembly A install the bottom edge first and ensure that all four developer unit assemblies are properly aligned when replacing the developer interlock plate assembly A j Connectors g Repair information 4 51 5057 XXX Replacement warning Ensure that the erase lamp harnesses and developer unit assembly harnesses are correctly installed in the clamps or they may become detached Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle up and down several times before reinstalling the inner cover Erase lamp amp developer unit assembly harnesses 4 52 Printer Service Manual 5057 XXX Developer unit assembly removal arWND oO ON OD Note The following procedure can be applied to the
111. home position Go to 904 04 Sensor 2nd transfer roll retract HP lag error on page 2 64 904 05 Service transfer belt Sensor CMY transfer roll retract HP late error The sensing area of the sensor CMY transfer roll retract HP is not interrupted within the specified time when the CMY transfer rolls is moving to the home position Go to 904 05 Sensor CMY transfer roll retract HP late error on page 2 66 904 06 Service transfer belt Sensor CMY transfer roll retract HP lag The sensing area of the sensor CMY transfer roll retract HP remains interrupted within the specified time when the 2nd transfer roll is moving from the home position Go to 904 06 Sensor CMY transfer roll retract HP lag error on page 2 66 904 07 Service transfer belt CMY transfer roll retract motor time out The CMY transfer roll retract motor has failed Go to 904 07 CMY transfer roll retract motor time out on page 2 66 Printhead error motor error 905 00 NVM read write cannot be Engine NVM read write has failed Service engine ecuted error Go to 905 00 NVM read write cannot be error executed error on page 2 67 905 01 Marking device video error Internal processing error occurred in printer engine Service engine Go to 905 01 Marking device video error on error page 2 67 905 02 Marking device Xerographic Internal processing error occurre
112. information of these switches Media feed unit assembly Since tray 1 and tray 2 are functionally equivalent in terms of the switch media size sensor media out sensor media level and sensor pre feed only the components of one tray are described here The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three media feed rolls to feed media When the pick roll picks up media the remaining media decreases and the actuator of the sensor media level lowers accordingly When the sensor media level detects the lowering the media feed lift motor is activated to lift the lift up shaft and the bottom plate accordingly Thus the remaining media is ready to be fed General information 1 7 5057 XXX Media feed lift motor This motor is activated to feed media and to lift the bottom plate When feeding media it rotates forward to drive the pick roll When lifting the bottom plate it rotates reversely to drive the tray module gears to lift the lift up shaft Switch media size This switch media size sets the size of media supplied from each media tray assembly A signal indicating the media size is transmitted as a voltage to the printer engine card assembly Sensor media out If media runs out in a media tray assembly the actuator lowers and the actuator flag un
113. left door assembly C to the front and out in the direction of the arrow 6 Remove the tray module left door assembly C 4 196 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM switch tray module left door interlock removal NOoRWD Open the 1TM left door assembly Remove the screw securing the support strap A to the machine Remove the screw securing the bracket B to the machine Remove the bracket B Disconnect the two connectors from the switch tray module left door interlock C Remove the two screws securing the switch tray module left door interlock C to the bracket B Remove the switch tray module left door interlock C Repair information 4 197 5057 XXX 1X 500 sheet drawer 1TM tray module drive motor assembly removal 1 Remove the rear cover See 1X 500 sheet drawer 1TM rear cover removal on page 4 181 2 Disconnect the connector from the tray module drive motor A 3 Remove the two screws securing the tray module drive motor A to the machine 4 Remove the tray module drive motor A 1X 500 sheet drawer 1TM 1TM controller card assembly removal 1 Remove the rear cover See 1X 500 sheet drawer 1TM rear cover removal on page 4 181 2 Disconnect the seven connectors from the 1TM controller card assembly A 3 Remove the four screws securing the 1TM controller card assembly A to the machi
114. lt lt aT we Fe s i MOT K SPEED 1 A sl E 5 2 pas 2 6 K PC cartridge 2 2 3 lo to io 8 i 6 moron 5 O i Bl 5 E a a E 7 sve 3 drive motor e lt TOIFUSER ASM E Sl QO st un co Noo SNIE ajmee 2 8 SV RIN 3 TTT yyy yyy rm E eos 2 E pe D 24V INTLK AC drive card assembl 888 gee 23 8 5 3EY g 8 SS c El 10 1 R aaa dls Biggaza ag ge a 9 Stater 2 blip HE 9 9 Si FAN FAIL 5 ag g oda zz aa zz 2 AA MM ad od ba nt ne td bad hud md add dd ne nd sl dE E ELE rr Se aaa 131 ga EFE HEI E 3 Sem 3583 2838 EE BEER 8 8 EE g i 3358 333 33 vile NC E i HA aa Sl 29 1333 zz a a ala OO e 4 z CONN CHK3 i 533 Kb 222 a 22 SIS o i i aaa 33 Ge z EP al al a 3 SS z i 335 GE as 33 35 EE i i 38338 333 Ha ce 33 53 33 A gs raser 855 5858 p 223 E 22 SE 3 5 3 3 3 5 333 333 q yee EE a a HR i y Z 8 Q a a gt 93 2233 aaa 3 353 232 SS H 1 7 a 1 1 1 i ag 55333335 gee BEE g EEE EJE BIE 33 aadddaqaq i 31330 P541 2 g 2 3 a 3 8 Bee BEE Ha 585 EE de 35 z 2 As geal fzdzed 22333 g g i g g Ap witch alin Mo PEE 2 NE P E P ER DP EE e e BN 4 Bi ay gl ee Jaa az a 9 2972 Level 1 TLI ITa MEDIA LEVEL 1 SNR yg 2 24VDC UNTLK E E x El fr Si Si Gl i power SEEEEEE E ua a Jaia ida 684 4843853 E til svam EEN ewan TO MCU P412 El AR go kl ei I U i lt ds E LL ro CONTROLER GARD ASM ss 2 8 5 el E E E S E lt El El S S 3 ssvo
115. media Go to step 2 Does the media remain in standard media exit 2 Check the duplex unit assembly rolls Go to step 3 Clean or replace the Are the duplex unit assembly rolls free of excess wear and contamination duplex unit assembly Go to Duplex unit assembly removal on page 4 10 2 30 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the sensor registration for proper operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media Path 4 Select Registration Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor registration for proper connection Replace the sensor Replace the Is the above component properly connected registration PER Go to Sensor registration removal on page 4 37 5 Check the duplex diverter gate solenoid for proper Go to step 7 Go to step 6 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly 6 Check the duplex diverter gate solenoid for proper Replace duplex Replace the connection media inverter connection Is the above component properly connected asse
116. media tray 4 assembly removal on page 4 116 4 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 121 5 Remove the media feed unit assembly See 2000 sheet dual input TTM media feed unit assembly 2 removal on page 4 130 2000 sheet dual input TTM media feed unit assembly removal tray 3 on page 4 130 or 2000 sheet dual input TTM media feed unit assembly removal tray 4 on page 4 125 6 Disconnect the connector from the sensor media level A Release the hooks securing the sensor media level A to the media feed unit assembly 8 Remove the sensor media level A N X E P WEG a uten 4 138 Printer Service Manual 5057 XXX 2000 sheet dual input TTM sensor media out removal N w P a o co ON Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 121 Remove the media feed unit assembly See 2000 s
117. menus 3 1 diagnostic information confirm the installation status 2 2 Power on Reset sequence 2 2 Diagnostic Menus entering diagnostic menus 3 2 diagnostics error code table 2 3 Diagnostics Menus available tests 3 2 BASE SENSOR TEST 3 14 DUPLEX TESTS 3 8 3 9 Quick Test 3 8 EVENT LOG 3 17 Clear the Event Log 3 18 5057 XXX Display the Event Log 3 17 Print the Event Log 3 18 FINISHER TESTS Feed Tests 3 12 Hole Punch Test 3 12 Sensor Test 3 12 Staple Test 3 11 HARDWARE TESTS 3 7 Button Test 3 7 CACHE Test 3 8 DRAM Test 3 8 Panel Test 3 7 INPUT TRAY TESTS Feed Tests 3 9 Sensor Test 3 10 MOTOR TESTS 3 5 OUTPUT TRAY TESTS Feed Tests 3 10 Feed To All Bins 3 11 Sensor Test 3 11 PRINT TESTS 3 6 PRINTER SETUP 3 16 Configuration ID 3 16 Defaults 3 16 Engine Setting 1 to 4 3 16 Model Name 3 16 Printed Page Count 3 16 Serial Number 3 16 Duplex 1 56 E environment 1 1 error codes 200 00 sensor registration late jam 2 20 200 01 sensor registration lag jam 2 21 200 01 sensor registration late jam 2 24 200 01 sensor registration static jam 2 23 201 00 sensor fuser exit late jam 2 25 202 00 sensor fuser exit lag jam 2 27 230 00 sensor duplex wait late jam duplex media feed 2 28 231 00 sensor registration late jam duplex feed 2 30 231 01 sensor registration late jam duplex media feed 2 32 241 00 sensor tray 1 feed out late jam 2 34 242 00 sensor tray 2 feed out late jam 2 36 242 01 senso
118. motor Does the above component operate properly Diagnostic information 2 47 5057 XXX Step Check Yes No 10 Check the MPF transport drive motor for proper connection Is the above component properly connected Replace the MPF transport drive motor Go to MPF transport drive motor assembly removal on page 4 101 Replace the connection 11 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved removal on page 4 77 Black toner cartridge detection error Step Check Yes No 1 Check the black toner cartridge for proper installation Go to step 3 Reinstall the black Is the above component properly installed toner cartridge 2 Replace the black toner cartridge Got to step 3 Problem solved Does the error continue 3 Check the sensor RFID toner cartridge for the black toner Replace the Replace the cartridge for proper connection sensor RFID connection Is the above component properly connected toner cartridge Go to Sensor RFID toner cartridge removal on page 4 105 4 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on Re cara Go to Upper printer engine card assembly removal on page 4 74 5 Perform a POR Replace the RIP Problem solved Does the error remai
119. motor is activated to feed media and to lift the bottom plate While feeding media it rotates forward to drive the pick roll When lifting the bottom plate it rotates in reverse to drive the tray module gears to turn the lift up shaft 1 52 Printer Service Manual 5057 XXX Switch media size The switch media size switches the setting of the size of media supplied from each media tray assembly A signal indicating the set size is transmitted as a voltage to the printer engine card assembly Sensor media out If there is no media in the media tray assembly the media out actuator lowers and the flag of the media out actuator that has stayed in the sensor media out sensing area leaves there Thus the light of the sensor is transmitted When the sensing area is blocked media is present the signal turns off Sensor media level This sensor detects by the actuator position whether media in the media tray assembly is lifted When the flag of the actuator leaves the sensor media level sensing area the sensor detects that the media has been lifted Media feed lift motor Switch media size Front Main components Switch tray module left door interlock The switch tray module left door interlock detects open close of the tray module left door assembly General information 1 53 5057 XXX Sensor tray 2 feed out The sensor tray 2 feed out detects media fed from the tray 2 Tray module medi
120. oes 3 2 Entering Diagnostics Menus 3 2 TE LE an ini 22506 28540864 dar 3 2 MOTOR TESTO 2224 1 2smatukes por whet ees siden ende eee eddik 3 5 PRINT TESTS ac dees SERIES ds dra ER sade cee eee 3 6 Mpu SOUS PNAC ISS AAA erea a eae aeS aaaea 3 7 Print Guallly Test EE 3 7 viii Printer Service Manual 5057 XXX HARDWARE EEN 3 7 Panel Testa ri sii di VE 3 7 B ROM TEST cas ei AAA A A EE det e dE gg 3 7 DRAM RE EE 3 8 CACHE EE 3 8 KT e EE 3 8 QUIK TEST erger E a cee mes eee See E be Se 3 8 SENSo LESK OUDIO arosi dosed Renee adie Se un ewe AE 3 9 INPUT TRAY TESTS EE 3 9 Feed TESIS egene amine Ledelse s FERGE AA 3 9 Sensor Test Unputkap ssesenasseadsaedpareesrda este che debe 3 10 OUTPUT BIN TESTS sssccashsdnce rims ii order EE 3 10 Feed Tests OUIDUEDINS eer deet EE EE bse bee EE 3 10 Feed To All BINS ida REET te eRe ROSS PES Sake ekke m 3 11 SEE gt NEE EE 3 11 FINISHER TESTS coo a a AEG LESES bk DE kn det ka 3 11 SE EEE EE TE FE EE EE we 3 11 eler SM Test EEE EEE PE EEE 3 12 Feed Tests FINISHER Age AAA EE EE 3 12 Sensor Tesi Finishers trari sere dE Peep Pees bee SSG 3 12 BASE SENSOR TEST oscars RS wees besette 3 14 PRINTER SETUP soso eel aeeebuwess 3 16 DEIS od FER EEE HEEN NE EP dades 3 16 PAGE GOUNTS Eed dE chee eee E de 3 16 Se l OG 1 RE ER SETE aa PENE TEN TR DEE Se 2 3 16 See EE ecs ose EER 3 16 Model Name EE EE E EE ET 3 16 Renee Mr Wl EE 3 16 EVENT LOG gg BEE ceed sae rad a 3 17 Display Event lOG 22
121. of the developer transfer roll HVPS card assembly up B 11 Remove the developer transfer roll HVPS card assembly B Connectors Repair information 4 99 5057 XXX Charge roll HVPS card assembly removal a Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 3 Remove the developer transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 4 Remove the two screws securing the charge roll HVPS card assembly A to the assembly Release the hooks securing the charge roll HVPS card assembly A to the assembly 6 Remove the charge roll HVPS card assembly A al 4 100 Printer Service Manual 5057 XXX MPF transport drive motor assembly removal k Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on
122. of the pick roll B Repair information 4 175 5057 XXX 3X 500 sheet drawer 3TM 3TM left door assembly removal 1 Open the 3TM left door assembly 2 Remove the two screws securing the two supports straps A to the machine 3 Remove the screw securing the bracket B to the machine 4 Remove the bracket B 5 Move the tray module left door assembly C to the front and out in the direction of the arrow 6 Remove the tray module left door assembly C VER SS Ag tg IT 3X 500 sheet drawer 3TM switch tray module left door interlock removal 1 Open the 3TM left door assembly 2 Remove the screw securing the support strap A to the machine 3 Remove the screw securing the bracket B to the machine 4 Remove the bracket B 5 Disconnect the two connectors from the switch tray module left door interlock C 6 Remove the two screws securing the switch tray module left door interlock C to the bracket B 4 176 Printer Service Manual 5057 XXX 7 Remove the switch tray module left door interlock C Connector Exe es 3X 500 sheet drawer 3TM tray module drive motor assembly removal 1 Remove the rear cover See 3X 500 sheet drawer 3TM rear cover removal on page 4 155 2 Disconnect the connector from the tray module drive motor A 3 Remove the two screws securing the tray module drive motor A to the machine 4 Remove the tray modul
123. page 4 90 Does the problem remain 4 Re adjust the color registration Regcon for the new Go to step 3 Problem solved printhead Go to Color registration RegCon on page 4 203 Does the problem remain 5 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the problem continue card assembly Go to RIP card assembly removal on page 4 71 Diagnostic information 2 139 5057 XXX Select a menu or menu item for more details Color Menu Color Adjust Color Balance Color Correction Color Samples Color Saver Manual Color Print Mode Print Resolution Toner Darkness Job Menu Cancel Job Reset Printer Print Buffer Confidential Job Held Jobs Reset Active Bin Finishing Menu Duplex Duplex Bind Copies Blank Pages Collation Separator Sheets Separator Source Hole Punch Offset Pages Staple Job Staple Prime Src Multipage Print Multipage Order Multipage View Multipage Border Network Menu PCL SmartSwitch PS SmartSwitch MAC Binary PS NPA Mode Network Buffer Job Buffering Network lt x gt Setup Std Net Setup PCL Emul Menu Font Source Serial Menu PCL SmartSwitch Help Menu Print All Help Guide Printing Guide Supplies Guide Print Quality Color Quality
124. pass 4 206 Printer Service Manual 5057 XXX Step Check Yes No 2 Perform the Skew fine setup printhead adjustment Perform the In Out Adjust the setup printhead 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Cycle result values Locate the following new values for the following settings Y Skew adjustment M Skew adjustment C Skew adjustment K Skew adjustment Turn the appropriate printhead adjustment screws located behind the waste toner cartridge the number of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG Y Skew adjustment 10 Turn the screw CW 10 clicks EG Y Skew adjustment 10 Turn the screw CCW 10 clicks Printhead adjusting screw Have the appropriate printhead adjustment screws been adjusted See In out setup on page 4 211 adjustment screws then perform the In Out setup See In out setup on page 4 211 Repair information 4 207 5057 XXX Step Check Yes No Analyze the fine skew setup 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Cycle result values Locate the following new values for the following settings
125. print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved removal on page 4 77 242 00 Sensor tray 2 feed out late jam Step Check Yes No 1 Check the media condition Replace the Go to step 2 Is the media in the tray crumpled or damaged Se media 2 Check the media size setup Go to step 3 Replace the Does the media size in use match the size set for tray 2 NA eee setup 3 Check the feed roll separation roll and pick roll for media Go to step 4 Clean or replace tray 2 the feed roll Are the above components free of excess wear and separating roll or eier pick roll contamination Go to Feed roll removal on page 4 102 Separation roll removal on page 4 104 and Pick roll removal on page 4 103 4 Check the media position Remove the Go to step 5 Does the media touch the sensor tray 2 feed out media 5 Check the sensor tray 2 feed out for proper operation Go to step 7 Go to step 6 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 2 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor tray 2 feed out for proper connection Replace the Replace the Is the above component properly connected A 2 Senne chon 2 36
126. proper Go to step 7 Go to step 6 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly 6 Check the duplex diverter gate solenoid for proper Replace duplex Replace the connection media inverter connection Is the above component properly connected assembly Go to Duplex media inverter assembly removal on page 4 9 7 Check the duplex drive motor for proper operation Go to step 9 Go to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex drive motor Does the above component operate properly 8 Check the duplex drive motor for proper connection Replace duplex Replace the drive motor connection Is the above component properly connected Go to Duplex drive motor removal on page 4 13 Diagnostic information 2 33 5057 XXX Step Check Yes No 9 Check the duplex media inverter clutch for proper Go to step 11 Go to step 10 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TEST
127. re installing It is recommended that all four cables be replaced Ensure tray 4 front cables C are not twisted or kinked Route the cables properly as shown in the figure Replace the cables by setting the frame assembly B on its side as shown in the figure 2000 sheet dual input TTM media feed unit assembly removal tray 4 Remove the media tray 2 assembly 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 3 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 4 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 5 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 121 6 Disconnect the two connectors from the media feed unit assembly A Repair information 4 125 5057 XXX 7 Remove the two screws securing the media feed unit assembly A Connectors 8 Remove one screw securing the front bracket B to the machine 9 Remove the front bracket B 10 Move the media feed unit assembly A to the left and up in the direction of the arrow 11 Remove the media feed unit assembly A 12 Remove the two screws securing the lower guide C to the media feed unit assembly A 13 Remove the lower guide C 14
128. remains go to step 2 2 Turn the printer off for 60 seconds Replace the RIP Problem solved Does the error occur when the power is turned off on again card assembly Go to RIP card assembly removal on page 4 71 Go to step 3 901 xx RIP card assembly software error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Replace the RIP Problem solved Does the error occur when the power is turned off on again card assembly Go to RIP card assembly removal on page 4 71 Go to step 3 Diagnostic information 2 57 5057 XXX Step Check Yes No Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved 903 00 K developer transport drive assembly motor error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Check the K developer transport drive motor assembly for Go to step 4 Go to step 3 proper operation Caution When performing motor tests ensure that all cover and door interlock
129. roll assembly removal on page 4 35 4 Check the sensor media on belt for proper operation Go to step 6 Go to step 5 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Media on belt Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 5 Check the sensor media on belt for proper connection Replace fe Replace the Is the above component properly connected belt WEE connection Go to Sensor media on belt removal on page 4 30 6 Perform a print test Replace the lower Problem solved e printer engine card Does the error continue assembly Go to Lower printer engine card assembly removal on page 4 77 2 24 Printer Service Manual 201 00 Sensor fuser exit late jam 5057 XXX Step Check Yes No 1 Check the media position Remove the Go to step 2 Does the media touch the sensor fuser exit media 2 Check the fuser exit actuator Replace the Go to step 3 Does the fuser exit actuator attached to the sensor fuser sensor fuser exit exit appear to be binding or sticking in its normal resting Go to Sensor position and not allowing media to pass fuser exit removal on page 4 25 3 Check the 2nd transfer roll assembly Go to step 4 Clean or replace Is the 2nd transfer roll assembly free of excess wear and Es ano rd contamination TA G
130. screws securing the two support straps A to the machine Remove the three screws securing the media feed unit assembly B to the machine Release the harness from the clamp Disconnect the connector from the media feed unit assembly B Remove the media feed unit assembly B Remove the two screws securing the bracket C to the assembly Remove the bracket C 4 130 Printer Service Manual 5057 XXX y EN N PN Ico a Wl po NIT ES 0 A A Y Repair information 4 131 5057 XXX 2000 sheet dual input TTM sensor tray 3 feed out removal Open the TTM left door assembly Remove the two screws securing the two support straps A to the machine Disconnect the connector to the bracket B Remove the two screws securing the bracket B to the machine Remove the bracket B Release the hooks securing the sensor tray 3 feed out C to the bracket B Remove the sensor tray 3 feed out C NORWOOD Connector 4 132 Printer Service Manual 5057 XXX 2000 sheet dual input TTM sensor tray 2 feed out removal 1 Open the TTM left door assembly 2 Remove the two screws securing bracket A to the machine 3 Remove the bracket A 4 Disconnect the connector from the sensor tray 2 feed out B 5 Release the hooks securing the sensor tray 2 feed out B to the bracket A 6 Remove the sensor tray 2 feed out
131. securing the bracket B to the machine Slide the bracket B to remove it from the machine Move the bracket B toward the front of the machine Detach the bracket B Disconnect the connector from the sensor transfer roll retract HP C Release the hooks securing the sensor transfer roll retract HP C to the bracket B Remove the sensor transfer roll retract HP SOMNOaARWOND gt 4 34 Printer Service Manual 5057 XXX 2nd transfer roll retract motor assembly removal 1 Remove the 2nd transfer roll assembly See 2nd transfer roll assembly removal on page 4 35 2 Remove the 2nd transfer roll retract cam assembly See 2nd transfer roll retract cam assembly removal on page 4 31 3 Remove the screw securing the 2nd transfer roll retract motor assembly A to the 2nd transfer roll retract cam assembly B 4 Remove the 2nd transfer roll retract motor assembly A 2nd transfer roll assembly removal 1 Open the printer left door assembly 2 Remove the two screws securing the registration pinch guide assembly A to the machine 3 Remove the registration pinch guide assembly A 4 Remove the four screws securing the transfer roll assembly B to the machine 5 Gently remove the transfer roll assembly B Repair information 4 35 5057 XXX Warning When removing the main transfer roll assembly B do not touch the roll surface Replacement warning When r
132. solenoid Transfer belt drive motor C toner add motor M toner add motor Y toner add motor K toner add motor CMY developer drive motor K developer clutch Fuser cooling fan Image density sensor shutter solenoid K erase lamp CMY erase lamps Tray module drive motor TTM tray 4 media transport motor Tray 2 media feed lift motor Tray 3 media feed lift motor Tray 4 media feed lift motor Waste toner auger motor Printhead shutter motor Standard exit shift motor PRINT TESTS See PRINT TESTS on page 3 6 Tray 1 Tray 2 Tray 3 Tray 4 MP Feeder Prt Quality Pgs See Print Quality Test Pages on page 3 7 HARDWARE TESTS Diagnostic aids 3 3 5057 XXX Panel Test See Panel Test on page 3 7 Button Test See Button Test on page 3 7 DRAM Test See DRAM Test on page 3 8 CACHE Test See CACHE Test on page 3 8 DUPLEX TESTS Quick Test See Quick Test on page 3 8 Sensor Test See Sensor Test duplex on page 3 9 INPUT TRAY TESTS Feed Tests See Feed Tests on page 3 9 Sensor Test See Sensor Test input tray on page 3 10 OUTPUT BIN TESTS Feed to All Bins See Feed Tests output bins on page 3 10 Feed Tests See Feed To All Bins on page 3 11 Sensor Tests See Sen
133. the appropriate CMY erase lamp assembly B Release the harness from the clamp Remove the screw securing the appropriate bracket C to the machine Lower the transfer belt lift handle A to its lower most position Note Access to the rear mounting hook on the CMY erase lamp B can be gained by reaching into the transfer belt unit opening from the right side of the machine Repair information 4 61 5057 XXX 12 13 Gently raise the rear of the appropriate CMY erase lamp assembly B to detach the mounting hook from the machine Remove the appropriate CMY erase lamp assembly B K erase lamp assembly removal k ON 0 0 Warning Ensure the transfer belt assembly unit is removed or damage will occur Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 Remove the inner cover See Inner cover removal on page 4 42 Raise the transfer belt lift handle A to its upper most positio
134. the error continue when the power is turned off on EE Gel Go to Upper printer engine card assembly removal on page 4 74 944 00 Switch media size size sensing error tray 4 Step Check Yes No 1 Check the media Go to step 2 Load media Is media loaded in tray 4 properly properly 2 Check the media tray Replace the media Go to step 3 Are the size sensing mechanisms on the back and the tray assembly bottom of the media tray damaged 2 88 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the tray 4 switch media size for proper Go to step 5 Go to step 4 operation 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 4 5 Select Tray 4 present Does the display on the operator panel change every time the media tray is opened and closed 4 3TM equipped machines check the tray 4 switch media Replace the switch Replace the size for proper connection media size for connection TTM equipped machines check the tray 4 Switch TTM STM media size for proper connection Go to 3X 500 Is the above component properly connected Aich media size removal on page 4 159 Replace the switch TTM media size for TTM 2000 sheet dual input TTM switch TTM media size removal on page 4 129 5 Perform a POR Replace the upper Problem solved e printer engine card the error continue when the
135. the printhead is not engaged during this test These tests can use any media size or envelope supported by the printer To run the Feed Tests for the output bins 1 Select OUTPUT BIN TESTS from the Diagnostics Menu 2 Select Feed Tests 3 Select the output bin you want the paper to exit into The standard bin as well as any output option bin installed on the printer is shown on the menu e Standard Bin e Output Bin 1 4 Select either Single or Continuous e Single Feeds one sheet of media from the selected source e Continuous Media continues feeding from the selected source until Stop Ni is pressed 3 10 Printer Service Manual 5057 XXX Press Stop to return to the Selected Output Bin While this test runs Selected Output Bin Feeding appears on the LCD During Single tests no buttons are active However during Continuous tests you can press Stop to cancel the test Feed To All Bins This test can be used to verify that the printer can feed media to the standard bin or any installed output options No information will be printed on the test pages as the printhead is not engaged during the feed test The media feeds from the default paper source To run the Feed To All Bins Test 1 Select OUTPUT BIN TESTS from the Diagnostics Menu 2 Select Feed To All Bins The printer feeds media from the default source to each installed bin After the test is selected the printer feeds a separate piece of media to the
136. to verify the printer processor cache To run the CACHE Test 1 Select HARDWARE TESTS from the Diagnostics Menu 2 Select CACHE Test CACHE Test Testing appears on the LCD and then Resetting the Printer appears The printer automatically performs a POR The following type of message appears CACHE Test x100 P HHHHHF F 7HHHF s 6 P represents the number of times the cache has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 es F represents the number of times the cache has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 Initially only four digits appear but additional digits appear as needed Each time a test is completed the number of passes and failures is incremented If the test fails the message Failure appears for approximately three seconds and the failure count increases by one The test continues until all of the printer processor s cache has been tested Once the maximum pass count or fail count is reached the test is stopped and the final results display To stop this test before completion turn the printer off DUPLEX TESTS Quick Test This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page You can run one duplexed page Single or continue printing duplexed pages Continuous unti
137. toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the inner cover See Inner cover removal on page 4 42 Disconnect the connector from the waste toner agitator motor assembly A Remove the two screws securing the waste toner agitator motor assembly A to the machine Remove the waste toner agitator motor assembly A Connector PC cartridge unit removal 1 2 3 4 Note The following procedure applies to the C M Y and K PC cartridge units Warning When removing or installing the PC cartridge units do not touch the drum surfaces or damage will occur Warning When removing the PC cartridge units ensure that the drum surfaces are not exposed to any sources of light or damage will occur Open the printer front door Press the button and raise the transfer belt lift latch assembly A to its upper most position Lower the transfer belt lift handle B to its lower most position Gently pull the appropriate PC cartridge assembly B out of the machine Warning When placing the PC cartridge units on a level surface ensure that no part of the OPC drum or any roller comes into contact with the resting surface Repair information 4 43 5057 XXX Replacement warning Ensure that all PC cartridge units are properly seated and aligned before raising the transfer belt lift handle to its upper most position or damage will occur Never for
138. tray 3 feed out late jam feeding from tray 4 The media is late reaching the sensor tray 3 feed out within the specified time after reaching the sensor tray 4 feed out TTM equipped machines go to 244 01 Sensor tray 3 feed out on jam feeding from tray 4 on page 2 44 3TM equipped machines refer to the Options Service Manual 250 00 Paper jam Sensor registration late jam feeding from the MPF The media is late reaching the sensor registration within the specified time after the MPF pick solenoid is turned on Go to 250 00 Sensor registration late jam feeding from the MPF on page 2 46 280 00 Paper jam 280 01 Paper jam 2 4 Printer Service Manual Sensor bridge unit media entrance late jam Sensor bridge unit media entrance static jam The media is late reaching the sensor bridge unit media entrance within the specified time after reaching the sensor fuser exit Refer to the Finisher Service Manual Media remains on the sensor bridge unit media entrance Refer to the Finisher Service Manual 5057 XXX Error code or Error contents Description Action message 281 00 Sensor bridge unit media The media is late reaching the sensor bridge unit Paporiam exit late jam media exit within the specified time after reaching aper ja the sensor bridge unit media entrance Refer to the Finisher Service Ma
139. unit assembly removal on page 4 16 Does the error remain printer engine card assembly Go to Lower printer engine card assembly Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Replace the transfer belt unit assembly Go to Transfer Replace the lower Problem solved removal on page 4 77 904 06 Sensor CMY transfer roll retract HP lag error Step Check Yes No 1 Check the transfer belt unit assembly To to step 2 Properly reinstall S the transfer belt Is the above component properly installed unit assembly 2 Perform a POR Go to step 3 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 3 3 Replace the transfer belt unit assembly Go to Transfer Replace the lower Problem solved belt unit assembly removal on page 4 16 Does the error remain printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 904 07 CMY transfer roll retract motor time out Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 66 Printer Service Manual 5057 XXX Step Check Yes No
140. unsupported Go to Incorrect lt color gt toner cartridge error a on page 2 49 cartridge 34 Tray 1 media size mismatch The media tray assembly 1 side guide or end guide Check tray 1 error is not properly set guides Go to Tray 1 media size mismatch error on page 2 50 34 Tray 2 media size mismatch The media tray assembly 2 side guide or end guide Check tray 2 error is not properly set guides Go to Tray 2 media size mismatch error on page 2 50 34 Tray 3 media size mismatch The media tray assembly 3 side guide or end guide Check tray 3 error is not properly set guides Go to Tray 3 media size mismatch error on page 2 51 34 Tray 4 media size mismatch The media tray assembly 4 side guide or end guide Check tray 4 error is not properly set guides Go to Tray 4 media size mismatch error on page 2 52 34 Tray 1 media type mismatch The sensor transparency detect did not detect Incorrect paper error transparency media type check Go to Tray 1 media type mismatch error on tray 1 page 2 52 34 Tray 2 media type mismatch The sensor transparency detect did not detect Incorrect paper error transparency media type check Go to Tray 2 media type mismatch error on tray 2 page 2 53 34 Tray 3 media type mismatch The sensor transparency detect did not detect Incorrect paper error transparency media type check Go to Tray 3 media type mismatch error on tray 3 page 2 54 34 Tra
141. upper printer engine card assembly B ensure that the NVM board D is installed on the new upper printer engine card assembly B or the machine may not function properly Replacement warning Ensure that the bridge card assembly C and the lower printer engine card D are connected Note Perform color registration adjustment Repair information 4 75 5057 XXX Lower printer engine card bracket assembly removal 1 NR No Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the fifteen connectors from the lower printer engine card bracket assembly A Remove the harnesses from the clamps Remove the two screws securing the lower printer engine card bracket assembly A to the machine Note When removing the lower printer engine card bracket assembly A the lower printer engine card assembly B and the upper printer engine card assembly C will become detached Move the lower printer engine card bracket assembly A down Remove the lower printer engine card bracket assembly A Connectors Connectors ww Connectors S O Connector
142. 1 5057 XXX To run the Staple Test 1 Select FINISHER TESTS from the Diagnostics Menu 2 Select Staple Test The printer feeds eight pieces of media from the default input source to the output bin that supports stapling After all eight pieces of media are deposited the device staples the packet While this test runs Staple Test Running appears on the LCD Press Stop to cancel the test Hole Punch Test This test is used to verify that media can be fed to a finisher output bin and then hole punched No information is printed on the feed test pages To run the Hole Punch Test 1 Select FINISHER TESTS from the Diagnostics Menu 2 Select Hole Punch Test 3 Select 3 Punch Test Eight sheets of paper are fed and then the pages are hole punched with a 2 hole or 3 hole pattern depending on the selected punch test Media is initially requested from the default input source and then output to the Finisher output bin The Hole Punch Test cannot be canceled No buttons are active during this test During the test Hole Punch Test Running appears on the LCD After completion of the test the display returns to the Hole Punch Test screen Feed Tests Finisher This test is used to verify that media can be fed to a finisher output bin This test feeds one sheet of media from the printer s default input source to a finisher output bin The device can perform this test using any paper size that is supported by the finisher N
143. 1 1 1 Noise filter assembly 9 40X3753 1 1 Developer transfer roll HVPS card assembly 10 40X3754 1 1 Charge roll HVPS card assembly 7 34 MFP Service Manual Assembly 31 Electrical 2 5057 XXX ae ake di au Description 1 40X3764 1 1 AC drive card bracket assembly 110 V this comes assembled 1 40X3765 1 1 AC drive card bracket assembly 220 V this comes assembled 2 40X3766 1 1 Outlet power panel cable assembly Parts catalog 7 35 5057 XXX Assembly 32 Electrical 3 7 36 MFP Service Manual Assembly 32 Electrical 3 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3775 1 1 DC main cable assembly 2 40X3776 1 1 DC rear right cable assembly 3 40X3774 1 1 2nd transfer charge roll cable 4 40X3771 1 1 CK transfer roll cable assembly 5 40X3770 1 1 YM transfer roll cable assembly 6 40X3772 1 1 Transfer belt charge cable 7 40X3769 1 1 Charge roll block cable assembly 8 40X3768 1 1 Developer block cable assembly 9 40X3773 1 1 2nd transfer roll charge connector 10 40X3777 1 1 DC rear left cable assembly Parts catalog 7 37 5057 XXX Assembly 33 Electrical 4 7 38 MFP Service Manual 5057 XXX Assembly 33 Electrical 4 der ge ders PRU Description 1 40X3804 1 1 RIP card cooling fan cover assembly this comes assembled 2 40X3807 1 1 RIP bridge card assembly 3 40X2359 1 1 Interconnect card
144. 104 and Pick roll removal on page 4 103 4 Check the media position Remove the Go to step 5 Does the media touch the sensor tray 1 feed out Ede 5 Check the sensor tray 1 feed out for proper operation Go to step 7 Go to step 6 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 1 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor tray 1 feed out for proper connection Replace the Replace the sensor tray 1 connection Is the above component properly connected feed out 7 Check the media feed lift motor in media tray 1 for proper Go to step 9 Skip to step 8 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select Tray 1 media feed lift motor Does the above component operate properly 8 Check the media feed lift motor for proper connection Replace the media Replace the feed lift motor connection Is the above component properly connected Go to Media feed lift motor removal on page 4 109 Diagnostic information 2 35 5057 XXX Step Check Yes No Perform a
145. 2cccs tense cease sde SI 3 17 PIM Ne BET L0G e0nhoe Sane bende teens eho oi di 3 18 Clear ite Event log 2 chaos pce esa ree iwGe dida cia 3 18 Trans Belt HP Fall Clear Lososssoaseasreketsnset A la ce 3 18 Dev Unit Reset seo rra EES STEEN EEN Ek A 3 19 Fuser Temp Fall Cleat cir sterke weirs seeks se save EES 3 19 ATG SENSOR FAILURE CLEAR gege EELER ar 3 19 ENGINE ADJUST 22 criado il a 3 20 Booklet Fold AQUSE iria Lande a A A A 3 23 Finisher GOMA icchs tees susta onto TT 3 23 Exiting DIAGROSUES ss varas das eRe ED CREE Ree Ra eee AAA SA 3 23 Entering Configuration MeN ccacideacikesinawsrthbond Et aba 3 24 Available MENUS acsnirvr cea aida lakes a ia te bakk diker 3 24 Maintenance Counter Valle 2 ue EES EE BIER NK RUN has e eens Aba need amme kle d 3 24 Reset Maintenance Counter 00 eee c eee eee eee eens 3 25 Black Only Mode sra a ENER Ree GRE ke sed He ees 3 25 Print Quality Pages Configuration Menu 3 25 EE PRE 3 25 PEEL SE EEE EE EE NE NE 3 26 Se PE EET PE 3 26 A tees EE 3 26 PPDS Emulatlonaacassasaes enes ars kares EE EE EE AER kva me ak bakke au 3 26 Factory Deg aa A 3 27 Energy Gonserve ceso RIES TEE san ab adr ee eee ieee desea EEE ek ie se 3 27 EVENT LOG Contiguration Men i ur car rai aaa Eer 3 27 Paper Prompts sra ctas id 00646080 cea ERR EERE ORE AERTS RRS A 3 28 ee TET 3 28 Font Sharpening der SE A SSES 3 28 Require Standby 823 bank ge keener AA SERRE RRR 3 28 Short Edge Pri
146. 3 Select Sensor test 4 Select Tray 1 5 Select Media out 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 2 5 Select Media out 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 3 5 Select Media out 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 4 5 Select Media out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check the sensor media out connection for proper Replace the Replace the connection on the appropriate media tray appropriate sensor connection Is the above component connected properly media out Go to 1X 500 sheet drawer 1TM sensor media out removal on page 4 189 3X 500 sheet drawer 3TM sensor media out removal on page 4 168 or 2000 sheet dual input TTM sensor media out removal on page 4 139 4 Perform a POR Replace the upper Problem solved Does the error continue when the power is turned off on printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 97 5057 XXX Paper is installed short edge in the media paper tray Step Check Yes No Is the media installed short edge orientation in the media tray assembly as oppos
147. 4 Remove the RIP card assembly See RIP card assembly removal on page 4 71 Remove the controller box top cover assembly See RIP card cooling fan cover assembly removal on page 4 67 Remove the controller box assembly See Controller box assembly removal on page 4 68 Remove the three screws securing the bracket A to the controller box assembly B Remove the bracket A Remove the four screws securing the bridge card assembly C to the bracket A Remove the bridge card assembly C Connector Replacement warning Ensure that the bridge card assembly C and the lower printer engine card D are connected 4 70 Printer Service Manual 5057 XXX RIP card access cover removal 1 Using your finger lift the RIP card access cover A by the notch 2 Remove the RIP card access cover A RIP card assembly removal 1 Remove the two screws securing the RIP card assembly A to the machine 2 Pull the two knurled thumb screws to remove the RIP card assembly A from the machine 3 Remove the RIP card assembly A from the machine Knurled thumb screws Hard drive removal 1 Remove the RIP card assembly See RIP card assembly removal on page 4 71 Warning Do not drop the RIP card assembly or damage will occur 2 Remove the two connectors from the hard drive A 3 Remove the four screws securing the hard drive B to the side of the RIP card assembly A 4 Remove
148. 4 201 00 Sensor fuser exit late jam 2 25 202 00 Sensor fuser exit lagjam 2 27 230 00 Sensor duplex wait late jam duplex media feed ooooooooomommomoo 2 28 231 00 Sensor registration late jam duplex feed 00 e eee eee eee 2 30 231 01 Sensor registration late jam duplex media feed 2 32 241 00 Sensor tray 1 feed out late jam 2 34 242 00 Sensor tray 2 feed out late jam 2 36 242 01 Sensor tray 1 feed out late jam feeding from tray 2 oooooocooommmmmm o 2 37 243 00 Sensor tray 3 feed out late jam 2 38 243 01 Sensor tray 2 feed out late jam feeding from tray 3 000 cece eee eee 2 40 244 00 Sensor tray 4 feed out late jam 1 6 0 eee eee 2 42 244 01 Sensor tray 3 feed out on jam feeding from tray AN 2 44 250 00 Sensor registration late jam feeding from the MPF 2 20 cece eee ee eee 2 46 Black toner cartridge detection GITOl a see aia di h wind aa 2 48 lt Color gt toner cartridge detection error 2 49 Incorrect black toner Cartridge error A e acces EE cnet hae sek LEET sede kal bk ee oo 2 49 Incorrect lt color gt toner cartridge error 2 cee eee 2 49 Tray 1 media size mismatch BEE 0053 RARA 2 50 Tray 2 media size mismatch error 0 cece eee eee eee eee eee 2 50 Tray 3 media size mismatch error o oocococccncco eee eee eee 2 51 Tray 4 media size mismatch error 00 0 e eee eee eee 2 52 Tray 1 media type m
149. 45 5057 XXX 12 Remove the image density sensor assembly A Replacement note Requires color calibration adjustments Replacement warning When replacing the harness access cover ensure that the harnesses are not pinched or damage will occur CMY toner add assembly removal 1 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 2 Remove the front left cover See Front left cover removal on page 4 9 3 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 4 Remove the waste toner cartridge sensor assembly See Wasie toner cartridge sensor assembly removal on page 4 39 5 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 D Remove the inner cover See Inner cover removal on page 4 42 7 Remove the screw securing the appropriate CMY toner add assembly A to the machine Warning Pull the appropriate shutters to reduce toner spillage into the machine Warning The C M and Y toner add assemblies must be removed in this order Y M C or damage will occur 4 46 Printer Service Manual 5057 XXX 5057 XXX K toner add assembly removal RON Warning Ensure the three CMY toner add assemblies are removed before removing the K toner add assembly or damage will occur Remove the printer front door assembly See Print
150. 5 Fuser exit roll assembly removal 00 ee eee e cree eee eect e eee inae sai 4 106 MPF media out actuator removal cocinar a rad a b de 4 106 Sensor MPF media out removal 00 cece eee eee eee eee ee eee eee 4 107 MPF pick roll assembly removal 200 cee eee erence eee eee ence eens 4 107 Media feed lift motor Geiger EELER EELER EELER ER 4 109 Sven media se ut WEE 4 110 2000 sheet dual input TTM removals 4 111 2000 sheet dual input TTM top cover removal 0000c eee e eee eee eee eee 4 111 2000 sheet dual input TTM foot cover removal 02 0 cee cece eee eee eee 4 111 Xi 5057 XXX 2000 sheet dual input TTM right cover removal 00 ee cece eee eee eee 4 112 2000 sheet dual input TTM tray module left cover removal ooooooooo 4 112 2000 sheet dual input TTM rear cover removal 200 cece eee eee o 4 113 2000 sheet dual input TTM caster removal 00 0c eee eee eee 4 113 2000 sheet dual input TTM tray support roll removal 4 114 2000 sheet dual input TTM TTM media tray 4 assembly removal 4 116 2000 sheet dual input TTM TTM media tray 3 assembly removal 4 117 2000 sheet dual input TTM tray 3 front cover removal eee eee eee eee 4 117 2000 sheet dual input TTM tray 3 rear cable assembly removal 4 118 2000 sheet dual input TTM tray 3 front cable assembly remov
151. 7 21 Switch duplex left door interlock 7 21 RIP card cooling fan cover assembly reer rrr rrr rrr rrr 7 39 RIP bridge card assembly nn 7 39 Upper printer engine card assembly 7 39 3TM controller card assembly 7 00 nn 7 57 Tray module drive motor assembly 7 47 7 57 7 69 Media transport gear 23 46T 7 47 7 57 7 69 Media transport gear 46T eeeeeeeee 7 57 7 69 Media transport gear 33T e eeee ee 7 47 7 57 7 69 STM left door assembly en 7 55 Sensor tray 2 feed out 7 45 7 55 7 65 Tray 2 feed out sensor cable assembly 7 45 7 55 7 65 Tray 3 4 feed out sensor actuator gt 7 55 Sensor tray 3 feed out lt Sc eee teeter certo eee eee io a 7 55 Sensor tray 4 feed out senses rete pss ds E EES E 7 55 Switch tray module left door interlock 7 45 7 55 7 66 Tray module top cover 7 40 7 49 7 58 Tray module foot cover rrr rrr rrr rrr rrr re 7 40 7 49 7 58 Tray module right cover
152. 770 40X3667 Description Page Power cord USA Canada Latin America Asia Pacific LV 8ft right angle 7 70 Power cord Japan 15A LV 8ft straight 7 70 Power cord United Kingdom 8ft straight 7 70 Power cord Chile Italy Uruguay HV 8ft straight 7 70 Power cord lsrael HV 8ft straight m e 7 70 Power cord Brazil high amp LV 6ft straight 7 70 Power cord Korea 10A HV 6ft straight 7 70 Power cord Taiwan 13A LV 6ft straight 7 70 Power cord Argentina HV 8ft straight 7 70 Power cord China HV 6ft straight eee eee 7 70 Power cord Australia New Zealand HV 6ft straight 7 70 Switch printer front door interlock mmmmmmmeee 7 2 Switch printer left door interlock 7 22 Switch transfer access door interlock 7 2 Hinge NEE 7 9 Sensor RFID toner cartridge m 7 29 TTM large idler pulley kit
153. 8 Remove the printhead shutter motor assembly A from the machine ROD A N 4 64 Printer Service Manual 5057 XXX Replacement warning When reinstalling the printhead shutter motor assembly A ensure that the plastic arm is inserted into the printhead shutter B Connectors Repair information 4 65 5057 XXX Switch printer front door interlock removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the connector form the switch printer front door interlock A Release the hooks securing the switch printer front door interlock A to the machine Remove the switch printer front door interlock A from the machine OO P Go M 4 66 Printer Service Manual 5057 XXX Sensor printer left lower door interlock removal oarwonNnd Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Release the hooks securing the sensor printer left lower door interlock A to the machine Remove the sensor printer left lower interlock A Disconnect the connector fr
154. 89 04 Sensor booklet media exit The media is late reaching the sensor booklet Paper jam late jam media exit within the specified time after the per J booklet folding solenoid is turned on Refer to the Finisher Service Manual 289 05 Sensor booklet media exit The media reached the sensor booklet media exit Paper jam lag jam but did not clear it within the specified time Refer to the Finisher Service Manual 289 06 Sensor booklet media exit Media remains on the sensor booklet media exit Paper jam Static jam Refer to the Finisher Service Manual 31 Black toner cartridge The Black toner cartridge is defective not installed en a detection error Go to Toner cartridge error on page 2 103 efective blac cartridge 2 6 Printer Service Manual 5057 XXX Error code or Error contents Description Action message 31 lt Color gt toner cartridge The lt Color gt toner cartridge is defective or not Missing or detection error installed defective Go to lt Color gt toner cartridge detection error ae on page 2 49 cartridge 32 Incorrect black toner cartridge A black toner cartridge of an incorrect specification Replace error is installed unsupported Go to Incorrect black toner cartridge error on Black cartridge page 2 49 32 Incorrect lt color gt toner A lt color gt toner cartridge of an incorrect Replace cartridge error specification is installed
155. 9 le IMAGE DENSITY LED 1AON q 9 49 FANFAL p V cooling Q P568 PIN TRAY SVEIN a 8 7 jp OUTPUT TO MCU eB 10 mace oensrmv en 18 08 po para fan 3 le 35V BTN q 9 6 lo MOU TO OUTPUT 3B AB i e 2 D al Dl TSIZE SNR ag 10 5 p MCU TO OUTPUT ap P403 1 3 5VDC 41114 b REGICL SIG 5B SWITCH E E D DET q 123 p gt OUTPUT DET ep meda dre 1 EDHDET q 13 2 pp OUTPUT ENABLE 78 D E D DET 141 p MACS DET 8B TABU 1 P404 P414 AB TO 24v LVPS Psos 1 24 LV ENABLE q 1511 pp APosoLaLs 6 5 i TO 24V LVPS P505 2 4 SV RTN d 142 pt20V00 7 punen Fa Pu LAMP ON K ADCSOL NIP T NN sr Ed on v yy v yy K erase D See 133 EE 8 by 3 oe ala sl oln oa gt ajo to co NJ oo Assemb pe 41124 gt 5 D 3 D ense e LAMP ON C q 1115 ADC LED2 ON SPC 4 H E 536 m st 40 ON oo TIN 09 UO ON oo Assos B E 2av y 106 lp ADG LED1 ON DIF 3 Bs a E Se Ers A 50 M easel y e LAMP ON K q 9 7 po ADCH SNR 2 Si E sE A mg OL sr GE ler 7 3 2 u o ZE LAMP ON Y TMP bd E 3 bp M erase la Va 7 9 gt llo 53 TO SV LVPS P511B 8 5VDC 5 a 2 Assembly 24VDC 5V RTN oa 6 HA AB E je 1610 31 2 SENSOR TO SV LVPS P511B 4 5VDC pu i pi Waste toner lo AGITATOR MOT ON A 5 144 jp HUME 2 hum amp temp OAL GA 15 rn l as na eo ond T P i agitator motor C 24V INTLK SV LE o 4 as NG MOTB n ranster ro te a EE go LE To 20v ives sso jazva y
156. A into the rails of the frame assembly 2000 sheet dual input TTM tray 4 rear cables removal 1 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 2 Remove the media tray 4 front cover See 2000 sheet dual input TTM media tray 4 front cover removal on page 4 121 Place the media tray 4 assembly on its right side as shown in the figure 4 Remove the E clip with a prying tool securing the tray lift cable pulley A to the tray lift shaft assembly B ao Repair information 4 121 5057 XXX 5 Gently move the tray lift shaft assembly B toward the rear of the tray and detach the rear bushing C from the frame Note Do not remove the front lift cable pulley A or the front lift cables will become detached 6 Move the rear portion of the tray lift shaft assembly B away from the frame 7 Move the rear the rear lift cable pulley E toward the rear of the tray to release the two tray 4 rear cables D from the tray lift shaft assembly B 8 Remove the two tray 4 rear cables D from the tray lift shaft assembly B 9 Place the media tray 4 assembly back to its upright position 10 Remove two E clips with a prying tool securing the two small pulleys F on the rear of the frame assembly 11 Remove two small guides G and two small pulleys F 4 122 Printer Service Manual 5057 XXX 12 Remove the tray 4 r
157. C M Y and K developer unit assemblies Warning When removing developer unit assemblies ensure that the area on the floor in front of the machine is protected from toner spillage Warning When replacing the developer unit assemblies ensure that all toner spillage and contamination is removed Warning Always perform the sensor ATC sensor setup and adjustment if required or print quality problems may occur Go to Sensor ATC setup on page 4 199 Warning Always perform color registration adjustment RegCon when removing or reinstalling the printhead developer unit assembly or developer interlock plate assembly or print quality problems may occur Go to Color registration RegCon on page 4 203 Remove the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Note The waste toner cartridge sensor assembly does not need to be removed from the machine It may be allowed to hang by the wires Remove the inner cover See Inner cover removal on page 4 42 Remove the three CMY ton
158. Check the CMYK toner add motor assembly connection ape the Replace the MYK toner add connection Is the above component properly connected motor assembly Go to CMYK toner add motor assembly removal on page 4 89 7 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on printer engine card i assembly again Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 109 5057 XXX Color toner cartridge empty Step Check Yes No 1 Check the appropriate toner cartridge Go to step 2 Replace the toner Does the appropriate toner cartridge contain toner cartridge 2 Check the appropriate toner cartridge for proper installation Go to step 3 Reinstall the Is the appropriate above component properly installed n toner 3 Check the gear rotation in the appropriate toner add Go to step 4 Replace the assembly appropriate toner Does the gear located at the lower part of the above add assembly component rotate smoothly 4 go to s 4 Check the appropriate toner add assembly chute for Go to step 5 Clean any clogging obstructions Is the chute located at the lower part of the above component free of clogs and obstructions 5 Check the appropriate segment of the CMYK toner add Go to step 7 Go to step 6 motor assembly for operation Caution When performing motor tests ensure that all cover and door int
159. Color Alignment Coverage Estimator 3 Diagnostic aids 5057 XXX This chapter explains the tests and procedures to identify printer failures and to verify that repairs have corrected the problem Accessing service menus Access the following menus to identify problems with the printer and run diagnostic tests Diagnostics Menu 1 Turn off the printer 2 Press and hold the w and p buttons simultaneously 3 Turn on the printer 4 Release the buttons after 10 seconds The Diagnostics Menu group consists of menus settings and operations that are used to diagnose various printer problems Note While the Diagnostics Menu Group is active all host interfaces are offline Configuration Menu 1 Turn off the printer 2 Press and hold the Select y and Right Arrow buttons simultaneously 3 Turn on the printer 4 Release the buttons after 10 seconds The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation Diagnostic aids 3 1 5057 XXX Diagnostics Menus Entering Diagnostics Menus Turn off the printer Turn on the printer Release the buttons after 10 seconds Pee Available tests Tests appear on the LCD in the order shown Press and hold the w and p buttons simultaneously
160. Disconnect the connector from the media feed unit assembly A Remove the two screws securing the media feed unit assembly A to the machine Remove the media feed unit assembly A Connector Clamp Repair information 4 21 5057 XXX Sensor media out removal Remove the printer left lower door assembly See Printer left lower door assembly removal on page 4 8 Remove the media feed unit assembly See Media feed unit assembly 1 removal on page 4 21 Remove the media feed unit assembly See Media feed lift motor removal on page 4 109 Remove the media out actuator See Media out actuator removal on page 4 22 Disconnect the connector from the sensor media out A Release the hooks securing the sensor media out A to the media feed unit Remove the sensor media out A NOOR OD ES J OG WEE gt Lower view Media out actuator removal 1 Remove the media feed unit assembly See Media feed unit assembly 1 removal on page 4 21 2 Remove the media feed unit assembly See Media feed lift motor removal on page 4 109 3 Release the two bosses on the media out actuator A from the media feed unit assembly 4 22 Printer Service Manual 5057 XXX 4 Remove the media out actuator A
161. EE 1 44 Meal meda QUITE REE EE SE ie EEE o 1 44 Bortom PAG EE 1 45 Tray 2 3 4 meda Tay assembly asssseseersree anke see tein bakes kake A en 1 45 SIM media teed UNS cesa 1 45 Media feed unit assembly EEN EEN EELER Ea ed 1 45 Media SAT SER EN NE 1 45 Se meda SIZE EE ET es 1 45 DENSON Meda QUO E AER de arre 1 45 Sensor Media level i 44ei eqssegaesdmeeseeeesaneeraedeteaseig we hseeeser dus 1 45 Malin components ciber ara ede AA eRe E 1 46 Switeh tray module left door intenOCk au eisasseraadeerkssadenkesee de ark aan EE 1 46 Sensor 2 1S6G OUt aora he een Dene SAGE COMO GRS ke ENG 1 46 RE MEN 10510 EM EEE ENE ee nd oad ones 1 46 Sensor ray EG cese rr TE ed AA 1 46 Tray module media transport roll assembly 1 47 Tray module MVE MOS EE 1 47 STM Controller Gard assembl cesos enai rro si Ai 1 47 e 1 48 TTM theory EE ir AAA ANA A AAA A 1 49 Medi tansport aci ia sae a ase 1 50 Media iranspo pala EET a REE dica 1 50 MESEN ee EE ETNE eben ee 1 51 Feks EEE did 1 51 Media Kee esparragos aces Seed seer ad Sabre anaes 1 51 Rear Meda EE EE RER dE e 1 51 BONN Hale EE EE Ee 1 52 Thay e media enn mestere Renee RA 1 52 TIM MECN RTE E 1 52 Media feed unit assembly saavitsevreassreaverrn berak o rr rr 1 52 Media LESE EE 1 52 e n 1 53 5057 XXX SENSO Meda OU ERE iene SIRS eRe EEE EN das 1 53 Se da veces e ge E eege EE RER Eeer AS 1 53 M in componens coria atle AAA AS AAA dad nea eee Re ens A 1 53 Switch tray module lettdo
162. ENSOR 2 CMY ROLL RET SNR 617 DUP MOT ON transfer belt HP EI 1 TRANS BELT HP ENR FET g DUP MOT GLK 1 Jl 5V RTN 4 9 DUP MOT CUR_DWN 2 TRANS BELT EDGE SNA 310l GND SENSOR OO 3 SVRIN Fofa Loenion per transfer belt edge detect 4 seve A 12 A B P539 OPTION DET LI ES dE g BIS H Duplex controller pe E 33 des sl sisle s all d bl More z ol 3333 dis gig ze sa ss S 8 S S 8 dq seg Eb card assembly MOT ON SE 353 SE 2 2 2 a 3 z g g 2 2 LEA ls J dd dsdagagaaa ARE EFEEEEEEER DUP WAIT SNR z EE 3 z Zz E E ol z z zl zl z z z H A A lt A lt Aj lt a x SWITCH duplex rer E ani 55833335 2 EE E E EEEE E 5V RTN 4434443343344 Q S el zl Bl Bl left door interlock E OPEN SW 24V RTN f 1 p 2 2 2 E E E Z E 1 7 3 on om CMYK transfer roll HVPS ere 3 F Hae yola Eelke f 2 WAIT SNR 24VDC b HH E E PE E SENSOR ac ape 4 card assembly Eee 8 N duplex wait MOTNE E a 3 32 p d a a l ai SS ern REFERER MOT NGOM Duplex drive g 3 3 3 55 3 2 MOT COM motor oo 0 0 0 oj o MOTB MOTA Developer transfer roll y HVPS card assembly 5057 AND 7510 Tray
163. Edition July 10 2007 e S Lexmark C930 amp C935 Printer Service Manual 5057 XXX e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index LEXMARK 5057 XXX Edition July 10 2007 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countrie
164. Electrical components and controller 2060 eee ee eee eee eee 1 22 SE AE EE EEE PE NTT TEEN 1 22 Ge GAGN EE 1 22 Switch printer front door interlock and switch printer left door interlock 1 22 Swit h printer left lower door interlock cis 42 5cccccc000ecnaen dees edeneesaeeeieeneaus 1 22 ege leet CT EE Mad Sakte conde eee BER eee datt 1 23 AG CVE EE Es anar EA EE Ae 1 23 SV EVES Cae Bassey cs sr breer eV dase ere r 1 23 2 UNS Card as MD EEE EEE AA TT 1 23 CMYK transfer rol AVPS Card assembly micosis cere dates karse SE E Se 1 23 Developer roll HVPS card assembly 1 23 Charge roll HVPS card assembly 2 344 ersang oresar iaire verre Senere ae sea b e ee 1 23 Upper printer engine card assembly 1 24 Lower printer engine card assembly 1 24 PIP PSN EE 1 24 EE RE ERE 1 25 ET Ge re oe RENEE ET 1 25 Prime CONUG arras idad A 1 25 eelerer pinhead MEN asar sr E ar e a 1 25 Determination of printhead ready AEN NEE EELER REENERT E AA 1 26 Printhead TOTS SACO Valie sucesora bee A ii ia ad Fre ordet 1 26 See casitas tail TT 1 26 Fuser control method 2 65 i4 200rcdheoed sete rre es 1 26 Main sub heater lamps Ono control ig re a AA 1 26 FOSer wamp spice E EE TEE EE e ER dE 1 26 Xerographic process during a print cycle 1 27 CHANGE o 6 54 3 00245 5005640546 04545 b 4b EE 1 28 EXDOSUNG EE EE PE pf aed ds 1 29 Kan 1 29 He EE EE rs A 1 30 EL e EE 1 31 BE EEE NE GEES Dees Rew ee EE a aes T 1 31 AUTO
165. F On On On On On Printhead control Rotation of printhead motor The on off control of the printhead motor is performed according to the mode of operation as shown below Operation mode PRINTHEAD motor on off Standby mode Always off Print mode Turns on upon receiving the signal from the controller 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 General information 1 25 5057 XXX Determination of printhead ready The printhead goes into ready state after the specified period passes since the reception of the printhead MPA start signal and the SOS cycle exceeds the reference value Printhead reference value Printhead reference value Description Ready reference value SOS signal interval equivalent to 98 or more of the rated RPM of the printhead motor Fail reference value SOS signal interval less than 98 of the rated rpm of the printhead motor Fuser control Fuser control method The on off control of the main sub heater lamps is performed based on the fuser control temperature The fuser transmits between the five states warm up ready standby print and low power depending on the heat roll surface temperature or printer conditions The fuser temperature control starts when the fuser ready in the
166. Go to 907 03 SOS internal error on page 2 70 907 04 Printhead error SOS internal error The interval of the printhead start of scan K signals exceed the specified value Go to 907 04 SOS internal error on page 2 70 907 05 Printhead error Printhead control error Operation error of the printhead ASIC in the printer engine An error occurred during the read write test Go to 907 05 Printhead control error on page 2 71 908 00 Service engine error Waste toner full error After the sensor waste toner full turned on the pixel count exceed the specified value Go to 908 00 Waste toner full error on page 2 71 911 00 Service engine error 24V LVPS cooling fan error When the 24V LVPS cooling fan was operating fan lock was detected for more than 30 seconds Go to 911 00 24V LVPS cooling fan error on page 2 72 911 01 Service engine error Transfer belt drive motor cooling fan error When the transfer belt drive motor cooling fan was operating fan lock was detected for more than 30 seconds Go to 911 01 Transfer belt drive motor cooling fan error on page 2 72 911 02 Service engine error Fuser cooling fan lock error When the Fuser cooling fan was operating fan lock was detected for more than 30 seconds Go to 911 02 Fuser cooling fan lock error on page 2 73 918 00 Service std bin 1 error Standard media exit s
167. ION CHART Bar code num per Sensitivity gradient default value Standard TC output default value last 2 digits 53 663 168 54 708 164 55 753 160 56 799 156 57 844 152 58 889 148 59 934 144 60 526 181 61 572 178 62 617 174 63 663 170 64 708 166 65 753 162 66 799 158 67 844 154 68 889 150 69 934 146 70 526 183 71 572 180 72 617 176 73 663 172 74 708 168 75 753 164 76 799 160 77 844 156 78 889 152 79 934 148 80 526 185 81 572 182 82 617 178 83 663 174 4 202 Printer Service Manual 5057 XXX ATC VALUE CONVERSION CHART Bar coge je per Sensitivity gradient default value Standard TC output default value last 2 digits 84 708 170 85 753 166 86 799 162 87 844 158 88 889 154 89 934 150 90 526 187 91 572 184 92 617 180 93 663 176 94 708 172 95 753 168 96 799 164 97 844 160 98 889 156 99 934 152 Color registration RegCon Measurement cycle test Step Check Yes No 1 Perform the Measurement cycle test Perform the Go to step 2 1 Enter the Diagnostics Menu a SES 2 Select ENGINE ADJUST ag 3 Select RegCon adjust Ree P s 4 Select Measurement cycle page 4 205 Does the above test pass 2 Check the transfer belt unit assembly for damage Replace the Go to step 3 transfer belt unit Does above component show signs of damage on the frame or on the belt assembly See Transfer belt unit assembly removal on page 4 16
168. IP Problem solved Does the error occur when the power is turned off on card assembly Go to RIP card assembly removal on page 4 71 907 01 SOS internal error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Perform a POR Replace the RIP Problem solved Does the error occur when the power is turned off on card assembly Go to RIP card assembly removal on page 4 71 907 02 SOS internal error Step Check Yes No 1 Perform a POR Go to step 2 Perform several print tests Does the error occur when the power is turned off on If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again Diagnostic information 2 69 5057 XXX Step Check Yes No Perform a POR Does the error occur when the power is turned off on Replace the RIP card assembly Go to RIP card Problem solved assembly removal on page 4 71 907 03 SOS internal error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the
169. Is the above component properly connected Go to Media feed lift motor removal on page 4 109 6 Perform a POR Replace the upper Problem solved Does the error continue when the power is turned off on EE Gel Go to Upper printer engine card assembly removal on page 4 74 980 00 Communication error with 1TM 3TM or TTM assembly connection Is the above component properly connected Step Check Yes No 1 Check the 1TM 2TM or TTM controller card assembly Go to step 2 Replace the and the printer engine card assembly for proper connection 2 90 Printer Service Manual 5057 XXX Step Check Yes No Perform a POR Does the error continue when the power is turned off on Replace the 1TM 3TM or the TTM TTM controller card assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 3 Problem solved Perform a POR pees the error continue when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved 980 01 HVPS controller communication error Step Check Yes No Check the d
170. MOTOR TESTS See MOTOR TESTS on page 3 5 Finisher Motor Tests Motor entrance paddle Motor buffer transport Motor exit Fin diverter solenoid Sub paddle solenoid Media eject clutch Media eject clamp motor Media eject motor Fin Buffer solenoid Punch carriage shift motor Punch unit motor Front tamper motor Rear tamper motor Stapler carriage motor Stapler unit motor Stacker bin lift motor Booklet end guide drive motor Booklet paddle drive motor Booklet front tamper motor Booklet rear tamper motor Booklet folder exit drive motor Booklet media entrance drive motor Booklet knife solenoid Booklet bin media transport motor Bridge unit bin media exit solenoid Bridge unit diverter gate solenoid De curler clutch Bridge unit transport drive motor Booklet diverter gate solenoid 3 2 Printer Service Manual 5057 XXX Booklet stapler motor Bridge unit bin media exit solenoid Printer Motor Tests Transfer belt steering motor CMY PC cartridge drive motor K PC cartridge drive motor Printhead polygon mirror motor Tray 1 media feed lift motor Registration clutch 2nd transfer roll retract motor K developer transport motor MPF pick solenoid MFP transport drive motor Duplex drive motor Inverter clutch Duplex diverter gate
171. Media Guide Connection Guide Moving Guide Print Defects Jam Clearance Parallel Menu PCL SmartSwitch PS SmartSwitch NPA Mode Parallel Buffer Job Buffering Advanced Status Protocol Honor Init Parallel Mode 1 Parallel Mode 2 MAC Binary PS Font Name PS SmartSwitch Point Size NPA Mode Pitch Serial Buffer Symbol Set Job Buffering Orientation Serial Protocol Lines per Page Robust XON A4 Width Baud Auto CR after LF Data Bits Auto LF after CR Parity Tray Renumber Honor DSR Paper Menu Setup Menu Paper Source Printer Language Paper Size Printer Usage Paper Type Power Saver Custom Types Resource Save Output Bin Download Target Configure Bins Print Timeout Overflow Bin Auto Continue Assign Type Bin Substitute Size Configure MP Paper Texture Paper Weight Paper Loading Universal Setup PostScript Menu 2 140 Printer Service Manual Print PS Error Font Priority Image Smoothing Wait Timeout Jam Recovery Page Protect Display Language Alarm Control Hole Punch Alarm Staple Alarm Toner Alarm Job Accounting Print Area Black amp White Lock Supplies Menu lt color gt Toner Oiler Waste Bottle USB Menu PCL SmartSwitch PS SmartSwitch MAC Binary PS NPA Mode USB Buffer Job Buffering Utilities Menu Print Menus Print Net lt x gt Setup Print Fonts Print Directory Factory Defaults Format Flash Defragment Flash Format Disk Job Acct Stat Hex Trace
172. Modules SENSOR tray2
173. No 1 Check the media Go to step 2 Load media Is media loaded in tray 3 properly properly 2 Check the sensor media level tray 3 for proper operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 3 5 Select Media level Does the display on the operator panel change every time the media tray is opened and closed Diagnostic information 2 87 5057 XXX Step Check Yes No 3 Check the sensor media level tray 3 for proper Replace the Replace the connection sensor media connection Is the above component properly connected level Go to Sensor media level removal on page 4 24 4 Check the media feed lift motor tray 3 for proper Go to step 6 Go to step 5 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Tray 3 media feed lift motor Warning The media tray must be opened before performing this test or paper jam may occur Does the above component operate properly 5 Check the media feed lift motor tray 3 for proper Replace the media Replace the connection feed lift motor connection Is the above component properly connected Go to Media feed lift motor removal on page 4 109 6 Perform a POR Replace the upper Problem solved Does
174. Optional parallel and serial Size and weight without finisher e Size Hx W x D 42 x 27 x 25 in 1153 x 660 x 810 mm e Weight 383 Ib 174 kg General information 1 1 5057 XXX Printer overview CAUTION Do not set up this product or make any electrical or cabling connections such as the power cord or options and features during a lightning storm Basic model The following illustration shows a printer with its base features ADE Operator Duplex unit I Multipurpose feeder MPF d Tray 3 and tray 4 850 1150 sheet dual input tray TTM Tray 1 and tray 2 500 sheet trays 1 2 Printer Service Manual 5057 XXX Configured model The following illustration shows a fully configured printer Items denoted with an asterisk are options Operator panel Duplex unit Bridge unit Used in conjunction with finisher Multipurpose feeder ES MPF CC EF Finisher 0 eg Kc Tray 3 and tray 4 850 1150 sheet dual input tray TTM Tray 1 and tray 2 500 sheet trays General information 1 3 5057 XXX Printer theory Media transport Media transport path Media is supplied from the MPF tray 1 2 3 or 4 and is transported to the printer along the media transport path shown below Tray 1 Tray 2 Tray 3 Tray 4 re ie ee Mar a ee FE ae ee ET ee o ds y 1 y i y HI y 1 Pick roll I d Pic
175. P514 FRONT INTLK ESS y me r S o o no o oa ajo wo LD ENB 1 y 17 4 gt PNT q 5V pm S SC ajos jo joo SNA EP ER e A EE J 2 lt rajo loo rojo Saa lt P ane 165 WEE LO VDATA YF rz _ T i SE EI 9 lt 15 6 gt LD VDATA Y TTT yr a 4 5 HE Ege 6 SWITCH transfer GE Al Y I TONNTAK i SKIS SSRIS SS i F El 3 85 El ai A ee 147 we MPA LD PCONT Y 5 belt access i lt a o inonoo ALAS s E Ss ba N A A lt 11398 gt LD ENB Y d Bi a co mono o SN OPS SPR mR gje rana Sloan ol ojal i ajo so noo ST NATA DAR E FE 8 S 3 E Si wennt fg pp tONSOS C ES Vo SZ TEGE Ta A SETTE i ZS ZS LD VDATA Y SVATN EEEEEEER Ade are a SISI dz l i i SIT IT CELE z o ei P E Ed lee d av 2 z a 3 z Z z so zag Fe ge 5 el a e gf ele 2 ee EE i CS al gt i S g El BS g elo Se El il g el g 5 i 3 9 9 EE T LDVDATA A Pio nsosan Sa 1 2 eai ga Sagas aa ag 931993333 S i i i ee es EEE d 9 12 gt E LO VOATA 9 A1 ESE E amp ESE ESE 212323283 la la i i E x P E ee e 3 t D VDATA Ch g 13 SVEN _ 1 Lo voATA o JS SE el al z SS E a a 2 5 S 5 5 i D i e LD VDATA Ok q 7 14 200 1 LD PCONT K 5 z E al amp e S i asa 2 9 Z 4 a e 8 2 i i i E nl eg ee PRINTHEAD I emm A als I y i 3 al q 5 116 gt del LD PWR K 3 i P403 E E GND ad 4117 ND a ASM da ae q gt up af AB pa i 2 a GNP 318 D BEE 1 emeng Jr TT H
176. POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Tray 1 media type mismatch error Step Check Yes No 1 Check the media tray assembly 1 for the correct media Go to step 2 Install the correct type media Does the above tray contain the correct type of media 2 Check the media tray assembly 1 for the transparencies Ensure that the Go to step 3 Does the media tray 1 assembly contain transparencies media tray assembly is supposed to be configured for transparencies or replace them with standard media 2 52 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the sensor transparency detect for proper Go to step 5 Go to step 4 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Transparency detect Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor transparency detect for proper Replace the Replace the connection sensor connection Is the above component properly connected Es dd Go to Sensor transparency detect removal on page 4 38 5 Perform a POR Replace the lower Problem solved Does the error remain when the power is turned off on ae card Go to Lower printer engine card assembly re
177. Perform a POR Does the error occur when the power is turned off on 2 Reset the fuser overheat failure lock out condition Remove the Go to step 3 Check the fuser unit assembly for a media jam megia Is there a media jam in the fuser unit assembly 3 Check the fuser unit assembly for proper installation Go to step 4 Install the fuser Is the fuser unit assembly installed properly unit assemoly y propery properly 4 Check the fuser unit assembly for proper connection Go to step 5 Repair the Is the above component properly connected connection 5 Perform a print test Replace the fuser Problem solved Does the error continue unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 6 6 Perform a POR Replace the AC Problem solved Does the error occur when the power is turned off on SE bracket Go to AC drive card bracket assembly removal on page 4 95 920 03 Rear thermistor disconnection error Step Check Yes No 1 Check the fuser unit assembly for a media jam Remove the Go to step 2 media Is there a media jam in the fuser unit assembly Diagnostic information 2 75 5057 XXX Step Check Yes No 2 Check the fuser unit assembly for proper installation Go to step 3 Install the fuser Is the fuser unit assembly installed properly a 3 Check the fuser unit assembly for proper connection Go to step 4 Repair the Is the above component prop
178. R TEST 3 Select Exit level 4 Select Standard bin full 1 Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check the sensor waste toner cartridge full connection Replace the Replace the Is the above component properly connected Ore eee connection full Go to Sensor waste toner cartridge full removal on page 4 40 4 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on de carg again y Go to Upper printer engine card assembly removal on page 4 74 Waste toner cartridge not detected Step Check Yes No 1 Check the waste toner cartridge Go to step 2 Reinstall the waste Is the above component properly installed toner cartridge 2 Check the switch waste toner cartridge interlock Go to step 4 Go to step 3 Is the above component free of damage 3 Check the switch waste toner cartridge interlock for proper Replace the switch Replace the connection waste toner connection Is the above component properly connected cariridge H propery i interlock Go to Switch waste toner cartridge interlock removal on page 4 41 4 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on Ge card again y Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 105 5057 XXX Wast
179. Registration transport roll assembly ane ge d r PRU Description 1 40X3692 1 1 Registration transport roll assembly this comes assembled 2 40X3695 1 1 Sensor transparency detect 3 40X3694 2 1 Sensor registration 4 40X3693 1 1 Registration clutch Parts catalog 7 15 5057 XXX Assembly 13 Printer left door and duplex index gek erg FRU Description 1 40X4078 1 1 Printer left door assembly this comes assembled 2 40X3697 1 1 Printer left door damper assembly 3 40X3696 1 1 Printer left door damper idler gear 4 40X3799 1 1 Duplex unit assembly this comes assembled 5 40X3798 1 1 Printer left door blind cover 7 16 MFP Service Manual Assembly 14 Printer left door assembly 1 5057 XXX folke ee de BO Description 1 40X4078 1 1 Printer left door assembly this comes assembled 2 40X4098 1 1 Printer left door closed actuator 3 40X3699 1 1 Sensor fuser exit 4 40X3698 1 1 2nd transfer roll assembly 5 40X3700 1 1 Printer left door duplex exit guide Parts catalog 7 17 5057 XXX Assembly 15 Printer left door assembly 2 Asm Part FRUs Units Description index number mach FRU 1 40X4078 1 1 Printer left door assembly this comes assembled 2 40X3704 1 1 Printer left door damper sector gear 3 40X3688 30 1 Sensor 2nd transfer roll retr
180. S 3 Select Printer Motor Test 4 Select Registrat clutch Does the above component make an audible clicking sound when activated 10 Check the duplex media inverter clutch for proper Replace the duplex Replace the connection media inverter connection Is the registration clutch properly connected assembly Go to Duplex media inverter assembly removal on page 4 9 11 Perform a 2 sided print test Replace the duplex Problem solved f controller card Does the error remain assembly Go to Duplex controller card assembly removal on page 4 14 Go to step 12 12 Perform a 2 sided print test Replace the lower Problem solved f printer engine card Does the error remain assembly Go to Lower printer engine card assembly removal on page 4 77 241 00 Sensor tray 1 feed out late jam Step Check Yes No 1 Check the media condition Replace the Go to step 2 Is the media in the tray crumpled or damaged a media 2 Check the media size setup Go to step 3 Replace the Does the media size in use match the size set for tray 1 ENER setup 2 34 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the feed roll separation roll and pick roll for media Go to step 4 Clean or replace tray 1 the feed roll Are the above components free of excess wear and E roll or contamination Go to Feed roll removal on page 4 102 Separation roll removal on page 4
181. S from the Diagnostics Menu 2 Select Button Test The LCD displays a graphic of the operator panel buttons that matches the layout of the operator panel buttons 3 Press any button on the operator panel and that button on the LCD appears shaded 4 Release the button and the shading is removed This test continues until you press Stop O then the LCD returns to HARDWARE TESTS Press Back to exit the test Diagnostic aids 3 7 5057 XXX DRAM Test The DRAM Test is used to check the validity of both the printer s standard and optional DRAM The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test 1 Select HARDWARE TESTS from the Diagnostics Menu 2 Select DRAM Test DRAM Test Testing appears on the LCD and then Resetting the Printer appears The printer automatically performs a POR The following type of message appears DRAM Test 256 MB P HHHHHE F JEHHF o PARRA represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 s Fit represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 Initially only four digits appear but additional digits appear as needed To stop this test before completion turn the printer off CACHE Test This test is used
182. Sensor fuser exit lag jam on page 2 27 230 00 Sensor duplex wait late jam The media is late reaching the sensor duplex wait Paper Sm duplex media feed within the specified time after the duplex media per inverter clutch is turned on Go to 230 00 Sensor duplex wait late jam duplex media feed on page 2 28 231 00 Sensor registration late jam The media is late reaching the sensor registration apesta duplex media feed within the specified time after the duplex drive motor per J is turned on Go to 231 01 Sensor registration late jam duplex media feed on page 2 32 231 01 Sensor registration late jam The media is late reaching the sensor registration duplex media feed within the specified time after reaching the sensor Paper jam duplex wait Go to 231 01 Sensor registration late jam duplex media feed on page 2 32 241 00 Sensor tray 1 feed out late The media is late reaching the sensor tray 1 feed Paper Jam jam out within the specified time after the tray 1 media P feed lift motor is turned on Go to 241 00 Sensor tray 1 feed out late jam on page 2 34 Diagnostic information 2 3 5057 XXX Error code or message Error contents Description Action 242 00 Paper jam Sensor tray 2 feed out late jam The media is late reaching the sensor tray 2 feed out within the specified time after the tray 2 media feed lift motor is turned on Go to 242 00 S
183. Sensor static jam Step Check Yes No 1 Check the media position in the area shown on the operator Remove the Go to step 2 panel media Is media present in the area shown on the operator panel 2 Check the sensor in the appropriate area for proper Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Registration Does the display on the operator panel change every time the sensing area of the appropriate sensor is interrupted or blocked 3 Check the appropriate sensor for proper connection Replace the Replace the Is the above component properly connected E connection Diagnostic information 2 23 5057 XXX Step Check Yes No POR the machine Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved removal on page 4 77 200 03 Sensor media on belt late jam Step Check Yes No 1 Check the media condition Replace the Go to step 2 Is the media in the tray crumpled curled or damaged Sie Zeng meda 2 Check the media position Remove the Go to step 3 Does the media touch the sensor media on belt mega 3 Check the 2nd transfer roll assembly for excess wear or Go to step 4 Replace the 2nd damage transfer roll Is the above component free of excess wear and damage assembly Go to 2nd transfer
184. TM media tray 3 assembly removal on page 4 117 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 121 Remove the media feed unit assembly See 2000 sheet dual input TTM media feed unit assembly 2 removal on page 4 130 2000 sheet dual input TTM media feed unit assembly removal tray 3 on page 4 130 or 2000 sheet dual input TTM media feed unit assembly removal tray 4 on page 4 125 Remove the harness from the bracket A Remove the three screws securing the bracket A to the media feed unit assembly Remove the bracket A Note The gears may become detached from the bracket A Remove the tray lift one way clutch B De gt KIA Zee A Harness Repair information 4 135 5057 XXX 10 Remove the tray lift one way gear 24 tooth C Replacement note 4 136 Printer Service Manual 2 Harness D Before re installing ensure all gears and washers are securely attached to the bracket A 5057 XXX 2000 sheet dual input TTM media out actuator removal 1 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media t
185. TTM left door interlock 4 148 4 176 4 197 switch TTM media size 4 129 4 130 4 159 4 184 top cover 4 111 tray 3 assembly 4 117 tray 3 front cover 4 117 tray 3 lift gear assembly 4 149 tray 3 media guide lock assembly 4 121 tray 4 assembly 4 116 tray 4 front cables 4 109 4 124 tray 4 front cover 4 121 tray 4 lift gear assembly 4 149 tray 4 media guide lock assembly 4 125 tray 4 media guide rack and pinion 4 125 tray 4 rear cables 4 121 tray 4 transport assembly 4 121 tray support roll 4 114 removals 3X 500 sheet drawer 3TM top cover 4 153 4 154 4 155 4 156 4 179 4 180 4 181 4 182 S safety information xxi safety inspection guide 6 1 scheduled maintenance 6 2 Service checks 2 20 size and weight without finisher 1 1 T tools required 1 59 TTM theory 1 33 main components 1 39 media transport 1 34 media tray assembly 1 35 TTM media feed units 1 38 Index l 3 5057 XXX LA Printer Service Manual 5057 XXX Part number index P N 40X0269 40X0270 40X0271 40X0273 40X0275 40X0277 40X0280 40X0281 40X0288 40X0297 40X0301 40X0553 40X0553 40X0553 40X0613 40X0636 40X0708 40X0711 40X0723 40X0755 40X0880 40X0888 40X0948 40X0949 40X0952 40X1375 40X1376 40X1377 40X1378 40X1381 40X1454 40X1455 40X1508 40X1509 40X1510 40X1512 40X1513 40X1514 40X1515 40X1562 40X1592 40X1593 40X1594 40X1767 40X1772 40X1773 40X1774 40X2359 40X2767 40X2768 40X2769 40X2
186. X 2 Remove the tray module left cover A 2000 sheet dual input TTM rear cover removal 1 Remove the four screws securing the rear cover A 2 Remove the rear cover A 2000 sheet dual input TTM caster removal k Remove the media tray 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 4 Remove media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Place the right side of the drawer down Remove three screws securing the caster A D ao oo Repair information 4 113 5057 XXX 7 Remove the caster A 2000 sheet dual input TTM tray support roll removal 1 2 OR Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Remove the foot cover See 2000 sheet dual input TTM foot cover removal on page 4 111 Remove the two screws securing the two brackets A Remove the two
187. a SENSOR standard ell Ela ees retract motor assembly Rear up onl p DEVE FAN ran S E ase ms PULL ena 2 H I SENSOR TO Upper printer engine card ASM J414 A8 5V RTN 2 a media bin full q n At MED BIN FULL SNR 33 MOT COM B INTLK Cooling al DEVE FANON THs mge TH KO TO Upper printer engine card ASM J414 A6 5V RTN 1 CH 3 SV RTN 4115 MOT NA K la I mt Tall al ig y l Standard media MED EXIT SHFT MOT CW MOT NB SENSOR A AB S tehi 1 1016 FUSER EXIT aam TN exit shift motor 2 MED EXIT SHFT MOT CCW 917 NC z CMY developer 1 be voc Fg son oe na THI a SENSOR MPF 1 f MPF MED OUT SNA am il P568 1 drive motor CMY PC dia out 2 pen Id Ko ps 2 5 los assembly i media out SHH 610 mi lan K developer transport cartridge drive motor MPF FEED SOL MEDIA ON BELT SNR SENSOR media on 6 PE rm an Al seawo WEA eno Zi Jp H drive motor assembly 24VDC SQ 1 4112 3 elt id IP Se TO Upper printer engine card ASM P400 O E MPF pick Ger 3 STEI 313 SV RIN TTT 1 L Scanner 2 TO lower printer engine card ASM P530 all MPF WIDTH SNR I 5 q g RETRACT SNR ol SENSOR 2nd o ei Outlet lt AA o 1 Savoe 14 ya 300 JU 3 X transfer roll retract HP 5 Ke U d Laser diode d nines ae SENSOR AB O 2 d E a 9 power card Finisher MPF media width zo 3 bl Outlet iz g 1 O 5 assem y a z aa a al au en Jin Jo RN elo i x E 2 SS a 8 E E gt TT y o QA o a amp SE Ss i i UI Ka z RHEE 2 R i re AR O o Acce
188. a transport roll assembly The tray module transport roll assembly feeds media from the tray 2 Tray module drive motor This motor is used to drive the media transport mechanism in the tray module 1TM controller card assembly The 1TM controller card assembly which contains a CPU controls media feed in the 1TM upon receiving a command from the upper printer engine card assembly and sensor switch information Tray module drive motor 1TM controller card assembly Switch tray module interlock Switch Sensor media size tray 2 feed out 1 54 Printer Service Manual 5057 XXX Switch media size The following table gives on off states of the switches on the switch media size corresponding to the media sizes of the media tray assembly Note The switches media size are denoted by S W1 and S W3 respectively from the left side Analog switch Media Size S W1 S W3 Or B5L 7 25 x 10 5 L Off SENN General information 1 55 5057 XXX Layout of media transport path The main components associated with the media path and transport with the duplex installed Inverter forward Standard media Inverter clutch exit roll assembly reverse clutch G media bin ED Standard Sensor fuser exit Exit duplex diverter gate gt WZ Fuser unit assembly XD exit roll assembly ov Transfer belt Registration clutch DD Regis
189. ace the K developer transport drive motor Go to step 9 Go to step 8 assembly for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select K developer transport drive motor Does the above component operate properly 8 Check the K developer transport drive motor assembly for Replace the K Replace the proper connection developer connection transport drive Is the above component properly connected Geer Go to K developer transport drive motor assembly removal on page 4 92 9 Perform a print test Replace the lower Problem solved e printer engine card Does the error continue assembly Go to Lower printer engine card assembly removal on page 4 77 200 01 Sensor registration lag jam Step Check Yes No 1 Check the media position Remove the Go to step 2 Does the media touch the sensor registration media 2 Check the registration transport roll assembly Go to step 3 Clean or replace Is the above component free of excess wear and le bad contamination ranSport TO assembly Go to Registration transport roll assembly removal on page 4 36 3 Check the fuser unit drive gear for excess wear and Go to step 4 Replace the fuser damage unit assembly Is the above component free of excess wear and damage Go to Fuser unit assembly
190. ace the sensor tray 3 feed out Replace the connection 2 44 Printer Service Manual 5057 XXX Step Check Yes No 5 Check the sensor tray 4 feed out for proper operation Go to step 7 Go to step 6 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 4 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor tray 4 feed out for proper Replace the sensor Replace the connection tray 4 feed out connection Is the above component properly connected 7 Check the tray module drive motor for proper operation Go to step 9 Skip to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select Tray module drive motor Does the above component operate properly 8 Check the tray module drive motor for proper Replace the tray Replace the connection module drive motor connection Is the above component properly connected Go to 2000 sheet dual input TTM tray module drive motor assembly removal on page 4 150 or 2000 sheet dual input TTM tray module drive motor assembly removal on page 4 150 Diagnostic information 2 45 5057 XXX Step Che
191. act HP 4 40X3701 1 1 2nd transfer roll retract cam assembly 5 40X3702 1 1 2nd transfer retract motor assembly 6 40X3703 1 1 Sensor media on belt 7 18 MFP Service Manual 5057 XXX Duplex media inverter assembly Assembly 16 Duplex media inverter assembly E e 2 O o a 22 7 co DUL 35 as we 5 S N 20m e EJ X 65 0 D Ei El oO si E Parts catalog 7 19 5057 XXX Assembly 17 Duplex 1 Asm Part FRUs Units ea index number mach FRU Description 1 40X3799 1 1 Duplex unit assembly this comes assembled 2 40X3798 1 1 Printer left door blind cover 7 20 MFP Service Manual Assembly 18 Duplex 2 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3799 1 1 Duplex unit assembly this comes assembled 2 40X3802 1 1 Duplex drive motor 3 40X3801 1 1 Sensor duplex wait 4 40X3800 1 1 Duplex controller card assembly 5 40X3803 1 1 Switch duplex left door interlock Parts catalog 7 21 5057 XXX Assembly 19 Standard media exit shift ge Ge Se ag Description 1 40X3705 1 1 Standard media exit shift assembly this comes assembled 2 40X3707 1 1 Standard bin ful
192. aft assembly B Rear 9 Remove the two tray 3 rear cables E from the tray lift shaft assembly B 10 Remove two E clips with a prying tool securing the two small pulleys F on the rear of the frame assembly 11 Remove the two small guides G and the two small pulleys F 12 Remove the E clip with a prying tool securing the large guide H and the large pulley I to the frame assembly 13 Remove the large guide H and the large pulley I 14 Remove the tray 3 rear cables E from the bottom plate J Replacement note Before re installing Ensure tray 3 rear cables E are not twisted or kinked Route the cables properly as shown in the figure Replacement note Replace the cables by setting the frame assembly on its side as shown in the figure Repair information 4 119 5057 XXX 2000 sheet dual input TTM tray 3 front cable assembly removal 1 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 3 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 4 Remove the tray 3 front cover See 2000 sheet dual input TTM tray 3 front cover removal on page 4 117 5 Remove the E clip with a prying tool securing the tray l
193. after the front booklet tamper starts moving to ES the home position Refer to the Finisher Service Manual 991 01 Sensor booklet front tamper The sensing area of the sensor booklet front Service finisher HP lag error tamper HP remains interrupted within the specified or time after the front booklet tamper starts moving Sro from the home position Refer to the Finisher Service Manual 991 02 Sensor booklet rear tamper The sensing area of the sensor booklet rear tamper Service finisher HP late error HP is not interrupted within the specified time after error the rear booklet tamper starts moving to the home position Refer to the Finisher Service Manual 991 03 Sensor booklet rear tamper The sensing area of the sensor booklet rear tamper Service finisher HP lag error HP remains interrupted within the specified time Sek after the rear booklet tamper starts moving from the home position Refer to the Finisher Service Manual 991 04 Sensor booklet end guide The sensing area of the sensor booklet end guide Service finisher HP late error HP is not interrupted within the specified time after error the booklet end guide starts moving to the home position Refer to the Finisher Service Manual 2 16 Printer Service Manual 5057 XXX Error code or message Error contents Description Action 991 05 Service finisher error Sensor booklet end guide HP lag error The sensing area of the sensor booklet end guide HP
194. age 4 34 4 Check the 2nd transfer roll retract motor for proper Go to step 6 Skip to step 5 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media Path 4 Select 2nd transfer roll retract HP Does the above component operate properly 5 Check the 2nd transfer roll retract motor for proper Replace the 2nd Replace the connection transfer roll retract connection Is the above component properly connected motor assembly Go to 2nd transfer roll retract motor assembly removal on page 4 35 6 Perform a print test Replace the lower Problem solved Does the error continue AN S card Go to Lower printer engine card assembly removal on page 4 77 7 Perform a POR Replace the lower Problem solved printer engine card Does the error occur when the power is turned off on assembly Go to Lower printer engine card assembly removal on page 4 77 904 04 Sensor 2nd transfer roll retract HP lag error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 64 Printer Service Manual 5057 XXX Step Check Yes No 2 Check the sensor 2nd transfer roll HP for proper Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select Base Sensor Tests 3 Select Media Path 4 Select 2nd transfer roll re
195. al 4 120 2000 sheet dual input TTM media tray 4 front cover removal 4 121 2000 sheet dual input TTM TTM tray 4 media transport assembly removal 4 121 2000 sheet dual input TTM tray 4 rear cables removal 000 cece eee eens 4 121 2000 sheet dual input TTM tray 4 front cables removal ee eee eee eee 4 124 2000 sheet dual input TTM media feed unit assembly removal tray 4 4 125 2000 sheet dual input TTM sensor tray 4 feed out removal oooooooomooo 4 127 2000 sheet dual input TTM switch media Size removal ooooooooconnooooo 4 128 2000 sheet dual input TTM switch TTM media size removal oooooooo 4 129 2000 sheet dual input TTM media feed unit assembly 2 removal 4 130 2000 sheet dual input TTM media feed unit assembly removal tray 3 4 130 2000 sheet dual input TTM sensor tray 3 feed out removal oocoooooooooo 4 132 2000 sheet dual input TTM sensor tray 2 feed out removal ooooooooooooo 4 133 2000 sheet dual input TTM media feed lift motor removal 4 133 2000 sheet dual input TTM one way clutch gear assembly removal 4 135 2000 sheet dual input TTM media out actuator removal 2000 cee eee eee 4 137 2000 sheet dual input TTM sensor media level removal oooooooomooo 4 138 2000 sheet dual i
196. al on page 4 97 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 82 Remove the CMYK transfer HVPS card assembly See CMYK transfer HVPS card assembly removal on page 4 90 Remove the AC drive card assembly See AC drive card bracket assembly removal on page 4 95 Disconnect the heavy gauge connector from the circuit breaker Remove the screw securing the noise filter assembly A to the machine Release the two plastic retainers with needle nose pliers securing the noise filter assembly A to the machine 4 96 Printer Service Manual 5057 XXX 11 Remove the noise filter assembly A Connector Rear upper cooling fan bracket assembly removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 2 Disconnect the connector from the rear upper cooling fan bracket assembly A 3 Remove the two screws securing the upper cooling fan bracket assembly A to the machine 4 Remove the rear upper cooling fan bracket assembly A Repair information 4 97 5057 XXX Rear upper cooling fan removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4
197. al on page 4 74 Perform a print test Does the problem continue 2 138 Printer Service Manual card assembly Go to RIP card assembly removal on page 4 71 Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the problem remain 2 Replace the transfer belt unit assembly Go to Go to step 3 Problem solved Transfer belt unit assembly removal on page 4 16 Does the problem remain 3 Check the upper printer engine card assembly Replace the RIP Problem solved High frequency bands Leading edge DNO NA a pr la j y SN LC SCH ZER S X S S s f CS Kies d iG 5057 XXX Trailing edge Step Check Yes No 1 Check the four PC cartridges for proper installation Go to step 2 Correct and clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 2 Replace the four developer units and four developer Go to step 3 Problem solved carriers Go to Developer unit assembly removal on page 4 53 and Developer carrier removal and replacement on page 4 54 Does the problem remain 3 Replace the printhead Go to Printhead assembly Go to step 2 Problem solved removal on
198. al Assembly 47 TTM media tray 4 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3836 1 1 TTM tray 4 front cover 2 40X4126 4 1 TTM tray lift idler pulley 3 40X4127 4 1 TTM tray lift idler pulley guide 4 40X4085 4 1 TTM tray 4 lift cable 5 40X0723 1 2 TTM tray 4 rear support roll 2 6 40X0711 2 1 TTM tray separation pad Parts catalog 7 63 5057 XXX Assembly 48 TTM media tray 4 transport 7 64 MFP Service Manual ae gek dia FRU Description 1 40X3838 1 1 TTM tray 4 media transport assembly 2 40X3679 1 1 Media feed unit assembly 3 40X3841 1 1 TTM tray 4 lower media guide 4 40X3840 1 1 TTM tray 4 upper media guide 5 40X3694 2 1 Sensor tray 4 feed out Assembly 49 TTM media transport 5057 XXX index aa d r Git Description 1 40X3817 2 1 Sensor tray 2 feed out 2 40X3843 1 1 TTM vertical turn guide 3 40X3679 1 1 Media feed unit assembly 4 40X3842 1 1 Tray 3 feed out sensor assembly this comes assembled 5 40X3818 2 1 Tray 2 feed out sensor cable assembly 6 40X4119 2 1 Tray module media transport roll assembly Parts catalog 7 65 5057 XXX Assembly 50 TTM left door Asm Part FRUs Units SA index number mach FRU Description 1 40X3844 1 1 TTM left door assembly this comes assembled 2 40X3821 1 1 Switch tray module left door interloc
199. al on page 4 71 Tray 2 media size mismatch error Step Check Yes No 1 Check the media tray assembly 2 side guide Go to step 2 Properly set the Is the above component set properly in ade guide 2 Check the media tray assembly 2 end guide Go to step 3 Properly set the Is the above component set properly de i guide 3 Check the media tray assembly for damage Replace the media Go to step 4 Is the above component damaged tray assembly 4 Check the switch media size for proper connection Replace the switch Replace the Is the above component properly connected media size SERIES 2 50 Printer Service Manual 5057 XXX Step Check Yes No 5 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on ele carg Go to Upper printer engine card assembly removal on page 4 74 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Tray 3 media size mismatch error Step Check Yes No 1 Check the media tray assembly 3 side guide Go to step 2 Properly set the Is the above component set properly Mee ae guide 2 Check the media tray assembly 3 end guide Go to step 3 Properly set the Is the above component set properly Eg guide 3 Check the media tray assembly for damage Replace the media Go
200. ally check it Urge Is the switch media size for media tray 1 and media tray 2 correctly installed correctly 4 Check the switch media size connection for tray 1 and or Replace the Replace the tray 2 required switch connection Is the switch media size properly connected for tray 1 and or media size tray 2 Go to Switch media size removal on page 4 110 5 Perform a print test Replace the Problem solved Does the error continue when the power is turned off on eg assembly Go to Upper printer engine card assembly removal on page 4 74 Media size mismatch in width Step Check Yes No 1 Check the media Go to step 2 Load media Pull out the tray and visually check it properly Is the media loaded in tray properly 2 Check the media Go to step 3 Set the parts Pull out the tray and visually check it correcily Are the front media guide and rear media guide on tray 3 or tray 4 set correctly 3 Check the switch TTM media size for proper Go to step 4 Install the switch installation TTM media size Pull out the tray and visually check it one Is the switch TTM media size for tray 3 or tray 4 dual input TM installed properly switch TTM media size removal on page 4 129 Diagnostic information 2 95 5057 XXX Step Check Yes No Check the switch TTM media size for proper connection Check tray 3 and tray 4 Are the above sensors connected properly Replace the
201. anel change every time the actuator on the above switch is operated 3 Check the switch transfer belt access door interlock for Replace the switch Replace the proper connection transfer belt connection Is the above component properly connected ee Go to Switch transfer belt access door interlock removal on page 4 79 4 Perform a print test Replace the upper Problem solved Does the error continue when the power is turned off on dle ENG carg Go to Upper printer engine card assembly removal on page 4 74 Printer left lower door assembly open Step Check Yes No 1 Check the printer left lower door for proper operation Go to step 2 Replace the Does the above component open and close properly printer left lower door assembly Go to Printer left lower door assembly removal on page 4 8 Diagnostic information 2 101 5057 XXX Step Check Yes No 2 Check the switch printer left lower door interlock for Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Cover and Door 4 Select Door B left lower Does the display on the operator panel change every time the actuator on the above switch is operated 3 Check the switch printer left lower door interlock Replace the switch Replace the connection printer left lower connection Is the above component properly connected door interlock Go to
202. ansport roll assembly 00 00 c eee eee eee 7 15 Assembly 13 Printer left door and duplex oococcccccococ tees 7 16 Assembly 14 Printer left door assembly e 7 17 Assembly 15 Printer left door assembly 2 o0 oooccoccococr tee 7 18 Assembly 16 Duplex media inverter assembly oooooccoccoo narrer 7 19 Assembly I7 Duplex 22 coi irradia 7 20 Assembly 16 DUPEK 2 vu sansene TET emer daee A 7 21 Assembly 19 Standard media exit shit 7 22 Assembly 20 Printhead assembly coccccccoc tte eae 7 23 Assembly 21 Xerographic and waste oner 7 24 Assembly 22 Erase lamps and developer interlock plate ooococooooooo 7 25 Assembly 23 Transfer belt it EE 7 26 Assembly 24 Transfer bet 7 27 Assembly 25 Transfer belt lift2 0 0 cette eee 7 28 Assembly 26 Toner Dispense csaccececcieeeceeerdenSsde estes egst ass anec RRE cas 7 29 Assembly 27 Developer unit assemblieS oo oooooccoocr eee 7 30 Assembly 28 Fuser assembly ociosas 7 31 Assembly 29 RT EE 7 32 Assembly 30 Betel 2sccos ascadsasecsckwatssagsse eget AAA 7 33 Assembly 31 Electtical 2 iorri sies vrede aks AAA MEG Tee ek das 7 35 Assembly 32 Electrical 9 6 05 650 5 bac cssded EE od 7 36 Assembly 33 Electrical 4 2 65 2 0002cse sens desea rre 7 38 Assembly 34 gt TIM COVES cis cari RU eds Rare CURE kodede dn 7 40 Assembly 35 1TM feed unit assembly 0 0 0 0 cece tee eae 7 41
203. appropriate switch TTM media size Go to 2000 sheet dual input TTM switch TTM media size removal on page 4 129 Replace the connection Check the appropriate 1TM 3TM or TTM controller card assembly and the printer engine card assembly for proper connection Are connectors P541 and P413 on the above cards connected properly Go to step 6 Replace the connection Perform a print test Does the error remain Replace the appropriate 1TM 3TM or TTM controller card assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 Go to 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or Go to 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 7 Problem solved Perform a print test Does the error remain Replace the printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved No media in the selected media tray Step Check Yes No Check the media Is media loaded in the selected tray Go to step 2 Load media properly 2 96 Printer Service Manual 5057 XXX Step Check Yes No 2 Check the sensor media out for operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS
204. area of the above sensor is interrupted or blocked 4 Check the sensor tray 1 feed out for proper connection Replace the Replace the sensor tray 1 connection Is the above component properly connected feed out Diagnostic information 2 37 5057 XXX Step Check Yes No 5 Check the sensor tray 2 feed out for proper operation Go to step 7 Go to step 6 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 2 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor tray 2 feed out for proper connection Replace the Replace the Is the above component properly connected dr 2 connecuon 7 Check the MPF transport drive motor for proper operation Go to step 9 Skip to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select MPF transport drive motor Does the above component operate properly 8 Check the MPF transport drive motor for proper connection Replace the MPF Replace the Is the above component properly connected ae drive connection Go to MPF transport drive motor assembly removal on page 4 101 9 Perform a print test Replace the lower Problem solved printer engine
205. arged toner on the Magnet Roll toner transfers from the Magnet Roll to that point on the drum There is now a visible toner image on the drum surface The image is called a developed image Magnet roll Magnetic Metering AMES Roll Blade A Fam D VDC e VDC Drum Surface Drum Surface Image Voltage bei Toner at VDC Developer Bias value Discharge Level Visible Developed Image Transfer As the paper travels between the 2nd transfer Roll and the transfer belt surface the Transfer Roll applies a positive charge to the back of the printing paper This positive charge transfers the negative charged toner image from the transfer belt to the top surface of the paper The toner image is now on the paper and the paper 1 30 Printer Service Manual 5057 XXX is now stuck to the transfer belt due to the relative electrical differences between the negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper HVPS VDC Transfer roll Sheet of paper Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process The toner that the Cleaning Blade removes is collected inside the sealed PC Cartridge and reused Used Toner Cleaning Blade Charge roll Discharge At both the start and the end of each individual printer cycle the erase lamps electrically clean the drum The light emit
206. artridge A to the assembly Remove the appropriate sensor RFID toner cartridge A Remove the connection from the sensor RFID toner cartridge A Repair information 4 105 5057 XXX Fuser exit roll assembly removal 1 Open the printer left door assembly 2 Remove the E clip securing the fuser exit roll assembly A to the machine 3 Remove the bushings B 4 Remove the fuser exit roll assembly A MPF media out actuator removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the two screws securing the upper frame cover A Remove the upper frame cover A Using a prying tool gently pry the MPF media out actuator B from the upper frame cover A Remove the MPF media out actuator B NOOB OD Actuator 4 106 Printer Service Manual 5057 XXX Sensor MPF media out removal NOOR OD Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the two screws securing the upper frame cover A Remove the upper frame cover A Release the hook
207. assembly allow it to loosely hang out of the way Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the inner cover See Inner cover removal on page 4 42 4 48 Printer Service Manual 5057 XXX 7 Remove the three CMY toner add assemblies See CMY toner add assembly removal on page 4 46 8 Remove the K toner add assembly See K toner add assembly removal on page 4 48 9 Remove the harnesses from the clamps on the developer interlock plate assembly A Warning Use extreme caution when disconnecting the next seven connectors from the upper harness strip or damage will occur Harnesses and connectors Harness strip 10 Disconnect the seven connectors from the upper harness strip 11 Remove the four developer harnesses from the four clamps on the developer interlock plate assembly A 12 Remove the six screws securing the developer interlock plate assembly A to the machine 13 Remove the purple harness from the large black plastic clamp on the developer interlock plate assembly A Warning Note the orientation of the four developer unit harnesses and the three erase lamp harnesses to ensure proper reinstallation or damage may occur Repair information 4 49 5057 XXX 14 While
208. ation values appear on the LCD If required reset the values and Select y to submit the changes Adj Lead Reg ALL appears on LCD Adj lead reg all trays Adj Lead Reg Tr165 appears on LCD Adj lead reg tray 1 plain color Adj Lead Reg MSI165 appears on LCD Adj lead reg MPF plain color Adj Lead Reg MSIhp2 appears on LCD Adj lead reg MPF heavy weight 2 Adj Lead Reg DUP165 appears on LCD Adj lead reg duplex plain color MSI Guide Max Val appears on LCD MPF guide maximum analog value MSI Guide Min Val appears on LCD MPF guide minimum analog value Adj Side Reg Trl appears on LCD Adj side reg tray 1 Adj Side Reg Tr2 appears on LCD Adj side reg tray 2 Adj Side Reg Tr3 appears on LCD Adj side reg tray 3 Adj Side Reg Tr4 appears on LCD Adj side reg tray 4 Adj Side Reg ALLtr appears on LCD Adj side reg all trays Adj Lead Reg Trhpl appears on LCD Adj lead reg tray 1 heavy weight 1 Adj Lead Reg MSIhp appears on LCD Adj lead reg MPF heavy weight 1 Adj Lead Reg Duphpl appears on LCD Adj lead reg duplex heavy weight 1 Adj Lead Reg Tr208 appears on LCD Adj lead reg tray 1 plain BW Adj Lead Reg MSI208 appears on LCD Adj lead reg MPF plain BW Adj Lead DUP 208 appears on LCD Adj lead reg duplex plain BW 5057 XXX Registration values appear on the LCD If required reset the values and Select to submit the changes Registration
209. bin full 1 Does the display on the operator panel change every time the sensing area is blocked 3 Check the sensor standard media bin full connection Replace the Replace the tandard connection Is the sensor standard bin full 1 properly connected sensor s media bin full Go to step 4 Go to Sensor standard media bin full removal on page 4 21 4 Perform a print test Replace the Problem solved e printer engine card Does the error continue assembly Go to Upper printer engine card assembly removal on page 4 74 Toner cartridge error Step Check Yes No 1 Check the toner cartridge installation Go to step 2 Install the correct e e toner cartridge Is the correct toner cartridge properly installed properly 9 2 Checking the sensor RFID toner cartridge for proper Go to step 3 Install the sensor installation RFID toner i cartridge Is the sensor RFID toner cartridge installed correctly eae Diagnostic information 2 103 5057 XXX Step Check Yes No Checking the sensor RFID toner cartridge connection Is the sensor RFID toner cartridge properly connected Replace the sensor RFID toner cartridge Go to Go to Sensor RFID toner cartridge removal on page 4 105 Replace the connection e Perform a print test e Does the error continue Replace the printer engine card assembly Go to Upper printer engine card assembly
210. blem solved 244 00 Sensor tray 4 feed out late jam Step Check Yes No Check the media condition Is the media in the tray crumpled or damaged Replace the damaged media with new Go to step 2 Check the media size setup Does the media size in use match the size set for tray 4 Go to step 3 Replace the media or change the media size setup Check the feed roll separation roll and pick roll for media tray 4 Are the above components free of excess wear and contamination Go to step 4 Clean or replace the feed roll separating roll or pick roll Go to Feed roll removal on page 4 102 Separation roll removal on page 4 104 and Pick roll removal on page 4 103 Check the media position 2 42 Printer Service Manual Remove the media Go to step 5 Does the media touch the sensor tray 4 feed out 5057 XXX Step Check Yes No Check the sensor tray 4 feed out for proper operation 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 4 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 7 Go to step 6 Check the sensor tray 4 feed out for proper connection Is the above component properly connected Replace the sensor tray 4 feed out
211. bly Feed rolls 4 each e Pick rolls 4 each e Separation rolls 4 each NS 40X4093 15 100K printer maintenance kit 220V includes e 220V fuser unit assembly e Transfer belt cleaner assembly e 2nd transfer roll assembly e Feed rolls 4 each e Pick rolls 4 each e Separation rolls 4 each NS 40X4032 600K printer maintenance kit includes 4 developer unit assemblies empty C developer carrier Y developer carrier M developer carrier K developer carrier Transfer belt unit assembly NS 40X4088 Banner media tray assembly NS 40X0948 Assorted E clip packet NS 40X0949 Assorted screw packet NS 40X4102 aia sch aia sch SFP relocation kit NS 40X4112 SFP relocation kit with options NS 56P2129 Lexmark MarkNet N7020e 4 USB ports 1 0 100 1000 w out power cord NS 56P2744 N4050e 802 119 Wireless Print Server Americas Argentina amp Brazil w out power cord NA 56P2745 N4050e 802 11g Wireless Print Server European UK Ireland amp Australia w out power cord NS 40X0269 Power cord USA Canada Latin America Asia Pacific LV 8ft right angle NS 40X0270 Power cord Japan 15A LV 8ft straight NS 40X0271 Power cord United Kingdom 8ft straight NS 40X0273 Power cord Chile Italy Uruguay HV 8ft straight NS 40X0275 Power cord Israel HV 8ft straight NS 40X0277 Power cord Brazil high amp LV 6
212. bmit the changes SNR Output Ref TC K Registration values appear on the LCD If required reset the values and Select y to submit the changes ATC Sensor Adjust Cycle Testing Pass RegCon color registration This procedure is used to adjust the printhead color registration Select RegCon Adjust and then select Appears on the LCD Measurement Cycle Reg Measuring Testing Control Sensor Check Reg Control Sensor Testing Control Sensor Cycle Belt Edge Learn Reg Control Sensor Correction Testing Belt Edge Learn Testing Select RegCon Adjust and then select Then select Appears on the LCD Control Setup Cycles Skew Fine Setup IN OUT Setup Center Setup Skew Fine Setup Testing IN OUT Setup Testing Center Setup Testing Skew Rough Setup Skew Rough Setup Testing Cycle Result Value Cycle Result Values appear on the LCD 3 22 Printer Service Manual 5057 XXX Press Stop to return to ENGINE ADJUST Booklet Fold Adjust To perform the Booklet Fold Adjust Test 1 Select Booklet Fold Adjust from the Diagnostics Menu The following tests appear on the LCD Select the following Appears on the LCD Booklet Tamper Shift Adjust Booklet Staple Fold Fine Adjust values appear on the LCD If required reset the values and submit Booklet Compile position Booklet Compile position values appear on the LCD If required reset the values and submit Booklet 2 sheet Booklet 2 sheet values a
213. card Does the error continue assembly Go to Lower printer engine card assembly removal on page 4 77 243 00 Sensor tray 3 feed out late jam Step Check Yes No 1 Check the media condition Replace the Go to step 2 Is the media in the tray crumpled or damaged ve medias 2 Check the media size setup Go to step 3 Replace the media Does the media size in use match the size set for ar onanga the media tray 3 ES 2 38 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the feed roll separation roll and pick roll for Go to step 4 Clean or replace the media tray 3 feed roll separating roll or pick roll Are the above components free of excess wear and contamination Go to Feed roll removal on page 4 102 Separation roll removal on page 4 104 and Pick roll removal on page 4 103 4 Check the media position Remove the media Go to step 5 Does the media touch the sensor tray 3 feed out 5 Check the sensor tray 3 feed out for proper operation Go to step 7 Go to step 6 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 3 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor tray 3 feed out for proper Replace the sensor Replace the connection tray 3 feed out connection Is the above c
214. ce the transfer belt lift handle into its home position or damage will occur e Button Image density sensor assembly removal Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the inner cover See Inner cover removal on page 4 42 6 Remove the waste toner agitator motor assembly See Waste toner agitator motor assembly removal on page 4 43 7 Remove the screw securing the harness access cover A to the machine OND a 4 44 Printer Service Manual 5057 XXX Warning Note the orientation of the harnesses to ensure they are not pinched when replacing the harness access cover A or damage will occur 8 Remove the harness access cover A from the machine 9 Disconnect the three connectors from the image density sensor assembly B 10 Release the harnesses from the clamps Connectors 11 Remove the screw securing the image density sensor assembly B to the machine Note Ensure the transfer belt lift handle is in its lower most position before removing the image density sensor assembly B Repair information 4
215. ce_ Hal 4 24V RIN z S 3 Ge SEEEERR EES id 5 8 dada da E Sensor He smacuriann ya y zwee SE F Charge roll HVPS card assembly RED BER TO P668 gt TRAY UNIT di e 3 2523 EEEE b a i ensor D ER sam Frag DEVE WoL 2 235528 3 i I SEEEEER 2 3 BEER 2335 z a Media Out 1 Ovi mora pg Leven 3 Mu P573 P573 EE 8 3 3 3 8 2 GE g ge EEE co B note Hola Eug SNe at LIT SENSOR 35 SG EE q E 5 ER E TO Upper printer engine card ASM P400 ae q E El 2 y dide 3 MOT COMA g g Lage 1 transparency detect R S 5 gt 5 3 R 5 E 3 i 23 aa 3 PERERBRE EEER Si pe mor coms 3 HO rn 3 j SENSOR SP HEBBE 3 5 o 5 TO CONTROLER CARD ASM J300 3 H 5 MOT NA l oO FER 3 A go soNTROLLER 3300 EE 3 m ilele i o od Se iu SES AT transparency detect L a E E E S 92 jo ace 3 1 i 8 mm r SEE 88 je Md 2 H cn i Feed lift motor 1 EE 29 4 MM Registration TO Upper printer engine card ASM P4120 E Deg i m NS ME EU 1 lutch 4 MM gt o i i ane ha evem 3 clute 50 y l MPF transport drive zem e TES SAN N y vi S BRUSH i motor assembly enge anre 147 mg 1 Sensor MOTOR i AB Registration i P541 P531 TO Laser diode power card ASM P502 y uy P53 CMY transfer roll A 2 retract motor MOTA Fray 1 SENSOR CMY transfer MOT NA Fafa ee roll retract HP 3 MOT ols E IT Se MOT NB Fa 4 SVATN li COM A INTLK 815 DUP WAIT SNR 3 a 5V RTN 716 DUPOPEN SW S
216. cement note When replacing the printer left door assembly B ensure that the black lines are aligned on the damper assembly C or the door will not properly operate 4 12 Printer Service Manual 5057 XXX Replacement note When replacing the printer left door assembly B ensure that the duplex media exit guide A is held up or the printer left door assembly B will not close properly Black line Duplex drive motor removal Remove the duplex unit assembly See Duplex unit assembly removal on page 4 10 Remove the screw securing the connector access cover A to the duplex unit assembly B Disconnect the connector from the duplex drive motor C Remove the harness from the clamps Remove the three screws securing the duplex drive motor C to the duplex unit assembly B Note When removing the duplex drive motor C the belt D will become detached 6 Remove the duplex drive motor C ROD A Connector Repair information 4 13 5057 XXX Duplex controller card assembly removal 1 Remove the duplex unit assembly See Duplex unit assembly removal on page 4 10 2 Remove the screw securing the connector access cover A to the duplex unit assembly C 3 Disconnect the connectors from the duplex controller card assembly B 4 Remove the two screws securing the duplex controller card assembly B to the duplex unit assembly C 5 Remove the duplex controller card assembly B
217. ch media size A SS A 4 184 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM media feed lift motor removal 1 Remove the media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 182 2 Disconnect the harness from the media feed lift motor A 3 Remove the two screws securing the media feed lift motor to the media feed unit assembly B 4 Remove the media feed lift motor B 1X 500 sheet drawer 1TM one way clutch gear assembly removal 1 Remove the media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 182 2 Remove the harness from the bracket A 3 Remove the three screws securing the bracket A to the media feed unit assembly 4 Remove the bracket A Note The gears may become detached from the bracket A 5 Remove the tray lift one way clutch B Harness op Repair information 4 185 5057 XXX 6 Remove the tray lift one way gear 24 tooth C Harness ae Y Replacement note Before re installing ensure all gears and washers are securely attached to the bracket A 4 186 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM media out actuator removal 1 Remove the media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 182 2 Release the two bosses on
218. ch Reset Maintenance Counter from the Configuration Menu Reset Maintenance Counter appears in the header and Yes and No appears below the header To cancel the reset operation press Back or No All other button presses are ignored To initiate the reset operation select Yes CAO SON The maintenance count resets to zero and the LCD returns to the Configuration Menu When performing the 100K 150K or 600K scheduled maintenance procedure the following areas should be cleaned of media dust and toner contamination e Media trays e PC cartridge area e Transfer roll area Duplex area e Standard bin e Bridge unit area if equipped e Finisher media bins if equipped Preventive maintenance 6 3 5057 XXX 6 4 Printer Service Manual 7 Parts catalog How to use this parts catalog The following legend is used in the parts catalog 5057 XXX Asm Part index number FRUs mach Units FRU Description e Asm index Identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and item number 1 in the table Part number Identifies the unique number that identifies this FRU FRUs mach Refers to the number of FRUs used in the product Units FRU Refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration
219. ck Yes No Perform a print test Does the error continue Replace the 1TM controller card assembly or the 3TM controller card assembly or the TTM controller card assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 10 Problem solved 10 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 Problem solved 250 00 Sensor registration late jam feeding from the MPF Step Check Yes No 1 Check the media condition Replace the media Go to step 2 Is the media in the MPF tray crumpled or damaged Er ensure 2 Check the media size setup Go to step 3 Replace the media E S A or change the Does the media size in use match the size set for MPF tray media size setup 3 Check the media position Remove the Go to step 4 Does the media touch the sensor registration media 4 Check the pick feed rolls Go to step 5 Clean or replace Are the pick rolls free of excess wear and contamination the pick rolls Go to Pick roll removal on page 4 103 2 46 Printer Service Manual 5057 XXX
220. configuration ID indicates that a ee hard hard drive should be present Go to 849 00 Hard drive configuration ID mismatch on page 2 57 84 K PC cartridge nearly The black PC cartridge is nearing the replacement Black PC unit exhausted interval life warning Go to K PC cartridge nearly exhausted on page 2 108 84 K PC cartridges nearly All color PC cartridges are nearing the replacement Color PC unit exhausted interval life warning Go to K PC cartridge nearly exhausted on page 2 108 84 K PC cartridge exhausted The black PC cartridge requires replacing Replace black Go to K PC cartridge exhausted on page 2 108 PC unit 84 CMY PC cartridges All color PC cartridges require replacing Replace color exhausted Go to CMY PC cartridges exhausted on PC units page 2 107 84 Color PC cartridge invalid A color PC cartridge of an incorrect specification is Unsupported installed color PC unit Got to Color PC cartridge invalid on page 2 107 2 8 Printer Service Manual 5057 XXX Error code or message Error contents Description Action 88 Color toner low Color toner cartridge nearly empty The color toner cartridge is nearing the replacement interval Go to Color toner cartridge nearly empty on page 2 109 88 Replace color toner Color toner cartridge empty The color toner cartridge requires replacing Go to Color toner car
221. continue Diagnostic information 2 117 5057 XXX Step Check Yes No Check the upper printer engine card assembly Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the problem remain Go to step 9 Problem solved Check the printhead assembly for connection Is the above component properly connected 2 118 Printer Service Manual Replace the RIP card assembly Go to RIP card assembly removal on page 4 71 Replace the connection Horizontal white stripes or bands side to side direction Leading edge Ee ON Cer SJ KARN UV 3 9 5057 XXX Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry and recommended media Re print the defective image Does the error continue 2 Are the media transfer route and the media path free of Go to step 3 Remove debris or contamination and debris contamination 3 Check the four toner cartridges Problem solved Replace any pe SEN empty toner Re print the defective image cartridges Is the image density normal 4 Check the 2nd transfer roll assembly for contamination Go to step 5 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd tra
222. d Refer to the Finisher Service Manual 991 11 Service finisher error Booklet stapler error The booklet stapler unit has failed Refer to the Finisher Service Manual 991 12 Service finisher error Communication error with booklet controller card assembly A communication error has occurred with the booklet controller card assembly and the finisher controller card assembly Refer to the Finisher Service Manual 991 13 Service finisher error Booklet unit maker error Booklet set recovery was detected too many times for the same job Perform a POR Refer to the Finisher Service Manual 992 00 Service finisher error Sensor de curler clutch HP late error The sensing area of the sensor de curler cam HP is not interrupted within the specified time after the de curler roll assembly nip starts moving to the home position Refer to the Finisher Service Manual 992 01 Service finisher error Sensor de curler clutch HP lag error The sensing area of the sensor de curler cam HP remains interrupted within the specified time after the de curler roll assembly nip starts moving from the home position Refer to the Finisher Service Manual Close cover F Bridge unit cover is open The bridge unit assembly cover is open Refer to the Finisher Service Manual Diagnostic information 2 17 5057 XXX
223. d NS 40X1513 1 1 Simplified Chinese font card NS 40X1514 1 1 Traditional Chinese font card NS 40X1515 1 1 Korean font card NS 40X1375 1 1 Marknet N8000 10 100BaseTX ethernet NS 40X1376 1 1 Marknet N8020 10 100 1000BaseT Ethernet NS 40X1377 1 1 Marknet N8030 10BaseFL amp 100BaseFX Ethernet multimode fiber NS 40X1378 1 1 Marknet N8050 802 11g wireless US NS 40X1562 1 1 Marknet N8050 802 119 wireless International NS 40X1593 1 1 Lexmark marknet N7000e 1 USB port 10 100 ethernet NS 40X1594 1 1 Lexmark marknet N7002e 1 parallel port 10 100 ethernet NS 40X1592 1 1 Lexmark marknet N7020e 4 USB ports 10 100 1000 ethernet Parts catalog 7 71 5057 XXX 7 72 MFP Service Manual Index Numerics 1TM main components 1 53 1TM theory 1 49 1TM media feed units 1 52 media transport 1 50 media tray assembly 1 51 3TM theory 1 42 STM media feed units 1 45 main components 1 46 media transport 1 43 media tray assembly 1 44 A accessing service menus 3 1 acronyms 1 60 C Configuration Menu available menus 3 24 Energy Conserve 3 27 entering 3 24 Envelope Prompts 3 28 EVENT LOG 3 27 Factory Defaults 3 27 Font Sharpening 3 28 Maintenance Counter Value 3 24 Panel Menus 3 26 Paper Prompts 3 28 PPDS Emulation 3 26 Print Quality Pages 3 25 Require Standby 3 28 Reset Maintenance Counter 3 25 Short Edge Printing 3 28 SIZE SENSING 3 25 Tray Low Message 3 29 connectivity 1 1 D diagnostic aids 3 1 accessing service
224. d in printer engine Service engine aut Go to 905 02 Marking device Xerographics error error on page 2 68 905 03 Marking device other1 error Internal processing error occurred in printer engine Service engine Go to 905 03 Marking device other1 error on error page 2 68 905 04 Marking device paper Internal processing error occurred in printer engine Service engine handling error Go to 905 04 Marking device paper handling error error on page 2 68 905 05 Marking device other2 error Internal processing error occurred in printer engine Service engine Go to 905 05 Marking device other2 error on error page 2 68 907 00 Printhead polygon mirror The printhead polygon mirror motor has failed or does not rotate at the specified speed Go to 907 00 Printhead polygon mirror motor error on page 2 69 2 10 Printer Service Manual 5057 XXX Error code or message Error contents Description Action 907 01 Printhead error SOS internal error The interval of the printhead start of scan Y signals exceed the specified value Go to 907 01 SOS internal error on page 2 69 907 02 Printhead error SOS internal error The interval of the printhead start of scan M signals exceed the specified value Go to 907 02 SOS internal error on page 2 69 907 03 Printhead error SOS internal error The interval of the printhead start of scan C signals exceed the specified value
225. d off on ae card Go to Lower printer engine card assembly removal on page 4 77 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Tray 4 media type mismatch error Step Check Yes No 1 Check the media tray assembly 4 for the correct media Go to step 2 Install the correct type media Does the above tray contain the correct type of media 2 Check the media tray assembly 4 for the transparencies Ensure that the Go to step 3 Does the media tray 1 assembly contain transparencies media tray assembly is supposed to be configured for transparencies or replace them with standard media Diagnostic information 2 55 5057 XXX Step Check Yes No 3 Check the sensor transparency detect for proper Go to step 5 Go to step 4 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Transparency detect Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor transparency detect for proper Replace the Replace the connection sensor connection Is the above component properly connected De Go to Sensor transparency detect removal on page 4 38 5 Perform a POR Replace the lower Problem solved printer engin
226. d transfer roll assembly removal on page 4 35 assembly assembly Go to 2nd Go to 2nd transfer roll transfer roll assembly assembly removal on removal on page 4 35 page 4 35 5 Check the toner add motor assembly Go to step 6 Problem solved Replace the toner add motor assembly Go to CMYK toner add motor assembly removal on page 4 89 Does the error continue 6 Check the printhead installation Go to step 8 Go to step 7 Is the printhead assembly installed properly with two screws 2 114 Printer Service Manual 5057 XXX Step Check Yes No 7 Check the printhead assembly installation Go to step 8 Problem solved Install the printhead assembly properly and perform a print test Does the problem remain 8 Check the printhead assembly for connection Go to step 9 Replace the Is the above component properly connected connection 9 Check the developer transfer roll HVPS card assembly Go to step 10 Problem solved Replace the developer transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 Perform a print test Does the problem remain 10 Replace the printhead assembly Go to step 11 Problem solved Go to Printhead assembly removal on page 4 90 Does the error continue 11 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Uppe
227. dicated paper size a prompt is sent to the user to load paper in a tray This setting controls the tray the user is directed to fill Selections are Auto default MP Feeder and Manual Paper To change this setting 1 Select Paper Prompts from the Configuration Menu 2 Make your selection and press d 3 To exit this screen without changing the setting s value select Back Envelope Prompts This setting controls the tray the user is directed to refill wnen a specific envelope size is out The selections are Auto default MP Feeder and Manual Env To change the value of this setting 1 Select Env Prompts from the Configuration Menu 2 Make your selection and press d 3 To exit this screen without changing the setting s value select Back Font Sharpening This setting allows you to set a text point size below which the high frequency screens are used when printing font data For example at the default 24 all text in font sizes 24 and less will use the high frequency screens The values for this setting range from 0 to 150 To change this setting 1 Select Font Sharpening from the Configuration Menu 2 Press p to increase the value or 4 to decrease the value 3 Press d to save the change This setting affects the PostScript PCL PDF and XL emulators This function is not supported when the device generates output at 600 dpi resolution Require Standby This setting determines if the Standby Mode is On or Off T
228. door assembly opeh concisa ori AAA AAA Asma 2 94 Media size mismatch in Width sesseassa vs ia AAA 2 95 Media size MIsmMaicn Ih MOD acordar eee eek ke nae eege a 2 95 No media in the selected media tray 0 ccc eect eee eee eee eee eee eens 2 96 Paper is installed short edge in the media paper tray 2 98 PC cartridge end Of life s e assesaanasanesaneaesp e hemme AA Geek A 2 98 Printer front door assembly Open ee EE EEN ga nes Hees eee e RR 2 99 Printer left door open EERSTEN eews pean cakes tne eee 2 100 Transfer belt access door Open seg gg EE EELER weed ER ESAs Hamme 2 101 Printer left lower door assembly open 2 101 100K maintenance required 53 30 bikes eae een ke RR ERS sew RS eGR 2 102 600K maintenance required ococooccccconcr eee eee eee eee eee 2 102 ADP maintenance FEQUIESO css tcctcnneeeer ciara bekk tta ibe ka VEGG AA 2 103 standard us EP RR RR are 2 103 Toner Gartler ener cerro ad ska tee eee Cena AA 2 103 Toner NEEN 2 104 Waste toner carttidge Tull aaasassansransar ks io AAA ARA A 2 104 Waste toner cartridge not detected 0 c cee cece eee eee eee eee eee 2 105 Waste toner cartridge nearly full 0 0 ccc eee eee eee eee 2 106 Color PC cartridge not detected lt lt lt 0 0 00000 00800 eee were eee 2 106 Color PG Cartridge invalid ooo ri orriewsaeieg deg See ENER 2 107 CMY PC cartridges nearly exhausted 0 0c cece e eect eee eens 2 107 CMY PG cartridges exhausted coche
229. e 2 121 Horizontal stripes Horizontal stripes side to side direction on page 2 123 Partial lack Partial lack on page 2 125 Spots Spots on page 2 127 Afterimage After image on page 2 128 Background fog Background fog on page 2 130 Skew Skew on page 2 132 Media damage Media damage on page 2 134 No fuse No fuse on page 2 136 Color mis registration Go to Color misregistration on page 2 137 Deletions Go to Deletions on page 2 138 High frequency bands Go to High frequency bands on page 2 139 Note When horizontal lines and or spots occur periodically it is possibly caused by a particular roll In this case measure the interval on the print test and check the relation to the roll in the printer The interval does not necessarily match circumference of the roll Diagnostic information 2 111 5057 XXX Image Quality Faint print Low contrast Leading edge Trailing edge Before starting check the media route for foreign objects such as staples clips and scraps in the media path Step Check Yes No 1 Check the media condition Problem solved Go to step 2 Load new dry recommended media and perform a print test Is the image density normal 2 Check the four toner cartridges Problem solved Replace any pr See empty toner Re print the defective image cartridges Is the image dens
230. e Go to step 6 e fuser unit Remove the fuser unit assembly assembly CAUTION Allow the fuser unit assembly to Go to Fuser cool down unit assembly removal on page 4 15 Is there contamination or cracks on the heat roll and or pressure roll Diagnostic information 2 123 5057 XXX 2 124 Printer Service Manual Step Check Yes No 7 Check the developer transfer roll HVPS card assembly Go to step 8 Problem solved Replace the developer transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 Perform a print test Does the problem remain 8 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly card assembly Go to Upper printer engine card assembly removal SAR card on page 4 74 removal on Perform a print test page 4 71 Does the error continue Partial lack Leading edge 5057 XXX Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the problem remain 2 Check the four toner cartridges Re print the defective image Is the image density normal Problem solved Replace any empty toner cartridges Install the printhead assembly properly and perform a print test Does the problem re
231. e card Does the error remain when the power is turned off on assembly Go to Lower printer engine card assembly removal on page 4 77 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 841 00 Image pipeline ASIC error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Replace the RIP Problem solved Does the error occur when the power is turned off on again card assembly Go to RIP card assembly removal on page 4 71 2 56 Printer Service Manual 849 00 Hard drive configuration ID mismatch 5057 XXX Step Check Yes No 1 Check the hard drive data and power connections Replace the Replace the Are the above connections connected properly hard drive connecuons Go to Hard drive removal on page 4 71 Perform a POR Does the error remain when the power is turned off on again Replace the RIP card assembly Go to RIP card Problem solved assembly removal on page 4 71 900 XX RIP card assembly software error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem
232. e drive motor A Repair information 4 177 5057 XXX 3X 500 sheet drawer 3TM 3TM controller card assembly removal 1 Remove the rear cover See 3X 500 sheet drawer 3TM rear cover removal on page 4 155 2 Disconnect the nine connectors from the 3TM controller card assembly A 3 Remove the four screws securing the 3TM controller card assembly A to the machine 4 Remove the 3TM controller card assembly A 4 178 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM removals 1X 500 sheet drawer 1TM top cover removal 1 Pull out tray 2 assembly A 2 Remove the two screws securing the top cover B 3 Remove the top cover B Repair information 4 179 5057 XXX 1X 500 sheet drawer 1TM foot cover removal 1 Open the 1TM front door 2 Remove the two screws securing the foot cover A to the machine 3 Remove the foot cover A 1X 500 sheet drawer 1TM right cover removal 1 Remove the four screws securing the right cover A 2 Remove the right cover A by lifting up and out in the direction of the arrow 4 180 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM tray module left cover removal 1 Remove the four screws securing the tray module left cover A 2 Remove the tray module left cover A 1X 500 sheet drawer 1TM rear cover removal 1 Remove the four screws securing the rear cove
233. e the appropriate area of the printer so the sensor s value will toggle to Open or Closed If the panel inaccurately displays the sensor s status then the sensor must be malfunctioning Press Stop to cancel the test Diagnostic aids 3 15 5057 XXX PRINTER SETUP To enter the PRINTER SETUP screen select PRINTER SETUP from the Diagnostics Menu PRINTER SETUP values appear on the LCD If required reset the values and submit Defaults The value of this setting determines whether the printer uses the US or Non US factory default value for the printer settings listed below Printer Setting US Value Non US Value Paper Sizes Letter A4 applies only to input sources which do not have hardware size sensing capability Envelope Size 10 Envelope DL Envelope applies only to envelope feeding sources which do not have hardware size sensing capability PCL Symbol Set PC 8 PC 850 PPDS Code Page 437 850 Universal Units of Measure Inches Millimeters Select Submit to change the value of this setting then the LCD returns to the Diagnostics menu To return to the PRINTER SETUP menu without changing the value of this setting select Back PAGE COUNTS e Prt Color Pg Count e Prt Mono Pg Count e Perm Page Count The value of these settings enables you to gauge the amount of usage on a device The Printed Page Count cannot be reset by the servicer Serial Number This printer setting records the printe
234. e the media out actuator A I Ww Y UZ Bosses Lower view 4 166 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM sensor media level removal 1 Remove the media feed unit assembly See 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 on page 4 162 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 160 2 Disconnect the connector from the sensor media level A Release the hooks securing the sensor media level A to the media feed unit assembly w 4 Remove the sensor media level A gt gt E gt Da D Harhess 7 Repair information 4 167 5057 XXX 3X 500 sheet drawer 3TM sensor media out removal 1 Remove the media feed unit assembly See 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 on page 4 162 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 160 2 Remove the media out actuator See 3X 500 sheet drawer 3TM media out actuator removal on page 4 166 3 Disconnect the connector from the sensor media out A Release the hooks securing the sensor media out A to the media feed unit assembly S 5 Remove the sensor media out A
235. e toner cartridge and drive the auger inside the toner add assembly Waste toner agitator motor assembly Waste toner agitator motor assembly Switch waste toner cartridge interlock Sensor waste toner cartridge full The waste toner agitator motor assembly is used to rotate an auger inside the waste toner cartridge in order to distribute collected waste toner evenly to prevent spillage and overflow Electrical components and controller Switch main power Turning on off the switch power supplies cuts off the main power of the printer Finisher AC output Supplies power to the finisher from the AC drive card assembly Switch printer front door interlock and switch printer left door interlock The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt power supply HVPS card assembly printer engine card assembly and to the dual motor assembly while the printer front door assembly and the printer left door assembly are open Switch printer left lower door interlock The switch left lower door interlock detects open or close of the printer left lower door assembly 1 22 Printer Service Manual 5057 XXX Fuser cooling fan The fuser cooling fan discharges air from the printer to prevent excessive temperature increase AC drive card assembly The AC drive card assembly accepts the main source voltage and distributes it to secondary power supplies and circuit boards
236. e toner cartridge nearly full Step Check Yes No 1 Check the waste toner cartridge Go to step 2 Reinstall the waste Is the above component properly installed toner cartridge 2 Check the sensor waste toner cartridge full for proper Go to step 5 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Exit level 4 Select Standard bin full 1 Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check the sensor waste toner cartridge full connection Replace the Replace the Is the above component properly connected Fed full Go to Sensor waste toner cartridge full removal on page 4 40 4 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on printer engine card i assembly again Go to Upper printer engine card assembly removal on page 4 74 Color PC cartridge not detected Step Check Yes No 1 Check the appropriate PC cartridge Go to step 2 Reinstall the Is the above component properly installed ee PG Go to PC cartridge unit removal on page 4 43 2 Replace the appropriate PC cartridge Go to step 3 Problem solved Does the error remain 3 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on printer engine card i assembly again Go to Upper printer
237. e tray 1 switch media size detected an invalid Service tray 1 failure sensing error tray 1 size setting Go to 941 00 Switch media size size sensing error tray 1 on page 2 83 941 01 Service tray 1 failure sensor media level late error tray 1 The sensing area of the sensor media level in the media tray 1 is not interrupted within the specified time after the lift tray has risen to operating level Go to 941 01 Sensor media level late error tray 1 on page 2 84 942 00 Service tray 2 failure Switch media size size sensing error tray 2 The tray 2 switch media size detected an invalid size setting Go to 942 00 Switch media size size sensing error tray 2 on page 2 85 942 01 Service tray 2 failure Sensor media level late error tray 2 The sensing area of the sensor media level in the media tray 2 is not interrupted within the specified time after the lift tray has risen to operating level Go to 942 01 Sensor media level late error tray 2 on page 2 85 943 00 Service tray 3 failure Switch media size size sensing error tray 3 The tray 3 switch media size detected an invalid size setting Go to 943 00 Switch media size size sensing error tray 3 on page 2 86 Diagnostic information 2 13 5057 XXX Deg Error contents Description Action 943 01
238. e user to schedule the appropriate maintenance on the device To view the Maintenance Counter Value select Maintenance Counter Value from the Configuration Menu The panel displays the current value of the maintenance counter Press Back to return to the Configuration Menu 3 24 Printer Service Manual 5057 XXX After installing the required maintenance kit reset this count to zero Reset Maintenance Counter After scheduled maintenance reset the Maintenance Counter To reset the maintenance page counter to zero Select Reset Maintenance Counter from the Configuration Menu Reset Maintenance Counter appears in the header Select 100K Kit or 600K Kit Yes and No appear in a menu To cancel the reset operation select Back or No All other button presses are ignored To initiate the reset operation select Yes St Za Sa cx Black Only Mode To change this setting 1 Select Black Only Mode from the Configuration Menu 2 Press Back to cancel and return to the Configuration Menu 3 Press d to save the change Print Quality Pages Configuration Menu This entry enables you to print a report that contains a limited set of the information that appears in the Diagnostics version of the Print Quality Pages report The limited Configuration and the full Diagnostics printed versions of this report display the same panel messages when they print and follow the same layout guidelines To print the Print Quality Pages
239. ear cables D from the bottom plate H Replacement note Before re installing Itis recommended that all four cables be replaced Ensure tray 4 rear cables D are not twisted or kinked Route the cables properly as shown in the figure Replace the cables by setting the frame assembly on its side as shown in the figure Repair information 4 123 5057 XXX 2000 sheet dual input TTM tray 4 front cables removal a Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 2 Remove the tray 4 front cover See 2000 sheet dual input TTM media tray 4 front cover removal on page 4 121 3 Place the media tray 4 assembly on its right side as shown in the figure 4 Remove the E clip with a prying tool securing the front tray lift pulley A to the tray lift shaft assembly B 5 Remove the front tray lift pulley A Note The tray 4 front cables C become detached 6 Remove the tray 4 front cables C from the tray lift shaft assembly B 7 Place the media tray 4 assembly back in its upright position 8 Remove two E clips with a prying tool securing the two small pulleys D on the front of the frame assembly 9 Remove the two small guides E and the two small pulleys D 4 124 Printer Service Manual 5057 XXX 10 Remove the tray 4 front cables C from the bottom plates F Replacement note Before
240. ece eee eee 4 168 3X 500 sheet drawer 3TM feed roll removal 0 0 00 c cece eee eee eee eee 4 169 3X 500 sheet drawer 3TM feed roll one way clutch removal o ooooooooo 4 170 3X 500 sheet drawer 3TM one way 22 tooth removal 0 00sec eee eee eee 4 171 3X 500 sheet drawer 3TM separation roll one way friction clutch removal 4 172 3X 500 sheet drawer 3TM separation roll removal 0000 eee eee e eee eee 4 173 3X 500 sheet drawer 3TM pick roll removal 000 cc eee eee eee 4 175 3X 500 sheet drawer 3TM 3TM left door assembly removal o ooooooommmo 4 176 3X 500 sheet drawer 3TM switch tray module left door interlock removal 4 176 3X 500 sheet drawer 3TM tray module drive motor assembly removal 4 177 3X 500 sheet drawer 3TM 3TM controller card assembly removal 4 178 1X 500 sheet drawer 1TM removals 4 179 1X 500 sheet drawer 1TM top cover removal 0 cece cece eee nee eee 4 179 1X 500 sheet drawer 1TM foot cover removal 0 00 eee eee eee eee 4 180 1X 500 sheet drawer 1TM right cover removal 00 eee e eee eee ee eens 4 180 1X 500 sheet drawer 1TM tray module left cover removal ooooooooooomo 4 181 1X 500 sheet drawer 1TM rear cover removal ooococccccoc o 4 181 1X 500 sheet drawer 1TM caster removal 4 182 1X 500 sheet dra
241. ection cartridge drive Is the above component properly connected motor i Go to CMYK PC cartridge drive motor assembly removal on page 4 86 4 Perform a POR Replace the lower Problem solved Does the error occur when the power is turned off on a carg Go to Lower printer engine card assembly removal on page 4 77 903 02 CMY PC drive motor error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 Diagnostic information 2 59 5057 XXX Step Check Yes No 2 Check the CMYK PC cartridge drive motor assembly for Go to step 4 Go to step 3 proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Tests 4 Select CMY cartridge drive motor Does the above component operate properly 3 Check the CMYK PC cartridge drive motor assembly for Replace the Replace the proper connection CMYK PC connection cartridge drive Is the above component properly connected motor Seene Go to CMYK PC cartridge drive motor assembly removal on page 4 86 4 Perform a POR Replace the lower Problem solved Does the error occur when the power is turned off on dd i ae Go to Lower printer engine card assembly removal
242. ectly and machine reassembly can begin Replacement warning Ensure that the erase lamp harnesses and developer unit assembly harnesses are correctly installed in the clamps or they may become detached Verify that the harnesses are properly secured in the clamps by moving the transfer belt lift handle up and down several times before reinstalling the inner cover Erase lamp amp developer unit assembly harnesses Developer carrier removal and replacement Note The following procedure can be applied to the C M Y and K developer carriers Warning Always perform the sensor ATC sensor setup and adjustment if required or print quality problems may occur Go to Sensor ATC setup on page 4 199 Warning Always perform color registration adjustment RegCon when removing or reinstalling the printhead developer unit assembly or developer interlock plate assembly or print quality problems may occur Go Color registration RegCon on page 4 203 1 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 2 Remove the front left cover See Front left cover removal on page 4 9 4 54 Printer Service Manual oOo CON D 10 11 12 13 5057 XXX Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Note The waste toner cartridge sensor assembly does not need to be removed from the machine It may be allowed to
243. ed by the driving force of the motor on the media feed unit assembly The bottom plate is pushed up by the rotation of the lift up shaft which causes the supplied media to come in contact with the pick roll Tray 2 3 4 media tray assembly Rear media guide Bottom plate End guide 3TM media feed units Media feed unit assembly Since the tray 2 tray 3 and tray 4 are functionally equivalent in terms of the switch media size sensor media out sensor media level and sensor pre feed only the components of one tray are described here The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three roll assemblies to feed media When the pick roll picks up sheets of media and the remaining media decreases the media level actuator of the sensor media level lowers accordingly Media feed lift motor The media feed lift motor is activated to feed media and to lift the bottom plate While feeding media it rotates forward to drive the pick roll When lifting the bottom plate it rotates in reverse to drive the tray module gears to turn the lift up shaft Switch media size The switch media size switches the setting of the size of media supplied from each media tray assembly A signal indicating the set size is transmitted as a voltage to the printer engine card assembly
244. ed to long edge Turn media 90 degrees or enable short edge feeding which is found in the config menu press select and right arrow at power on and then find the menu item short edge printing Go to step 2 Perform a print test Does the error remain Replace the printer engine card assembly Go Upper printer engine card assembly removal on page 4 74 Problem solved PC cartridge end of life Step Check Yes No Check the appropriate PC cartridge for proper installation Is the appropriate PC cartridge installed properly Go to step 2 Install the appropriate PC cartridge properly Check the appropriate PC cartridge for damage Does the appropriate PC cartridge appear damaged Replace the appropriate PC cartridge Go to step 3 Check the developer interlock plate assembly for damage Is the above component damaged Replace the developer interlock plate assembly Go to Go to Developer interlock plate assembly removal on page 4 48 Go to step 4 Perform a print test Does the error continue Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved 2 98 Printer Service Manual Printer front door assembly open 5057 XXX Step Check Yes No 1 Check the printer front door for proper operation Go to s
245. ee SIZE SENSING on page 3 25 Tray 4 Sensing Statement A5 See A5 Statement on page 3 26 Executive B5 See B5 Executive on page 3 26 Panel Menus See Panel Menus on page 3 26 PPDS Emulation See PPDS Emulation on page 3 26 Factory Defaults See Energy Conserve on page 3 27 Energy Conserve See Energy Conserve on page 3 27 EVENT LOG See EVENT LOG Configuration Menu on page 3 27 Paper Prompts See Paper Prompts on page 3 28 Envelope Prompts See Envelope Prompts on page 3 28 Font Sharpening See Font Sharpening on page 3 28 Require Standby See Require Standby on page 3 28 Short edge Printing See Short Edge Printing on page 3 28 Tray Low Message See Tray Low Message on page 3 29 Exiting Configuration Menu See Exiting Configuration Menu on page 3 29 Maintenance Counter Value This setting enables you to view the current maintenance count value of each maintenance kit After selecting this item you can choose a specific kit in order to view its current maintenance count value To return to the Configuration Menu press Back All other control panel keys are ignored When a kit s maintenance count value equals its kit size 150K for the ADF Kit the device posts the appropriate 80 Scheduled Maintenance IR and a status indicator to notify th
246. ee eee 4 14 Fuser unit assembly removal 4 15 Transfer belt unit assembly removal 4 16 Transfer belt cleaning assembly removal 4 17 Standard media exit shift assembly removal 0000 e cece eee eee eee eee 4 17 Standard media exit bin full actuator removal 0020s 4 18 Switch printer left door interlock removal 0 0 cece eee eee eee eee 4 19 Sensor standard media bin full removal 4 21 Media feed unit assembly 1 removal oo ooocoococcnccn eee eee eee eee 4 21 Sensor media out EMOVEl ca siopssiesariasarins ste same ais a 4 22 Media OULACIUAIOr fEMOVEl att AAA AAA ANS 4 22 Sensor media leve removal ET a EES 4 24 Sensor fuser exit removal 22 2200 0c0sie2eeteserd eee KEES REINER E AE NEE 4 25 Printer left door assembly removal oocococccoccc 4 26 Printer left door damper removal 4 29 Sensor media On belt removal ege SEELEN teenie wears Reed o sek e 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 EE 4 35 Registration transport roll assembly removal 00 0 c eee eee eee eee eee 4 36 Registration clutch TEMOVAl as An RSR EE AAR N ARA 4 37 Sensor reqisifallon rem val EE 4 37 Sensor transparency detect removal 000 e eee cece ee eee eee eee eens 4 38 Waste toner cartridge cover remova
247. ee eens 4 67 RIP card cooling fan cover assembly removal 00 cece eee eee eee eee eee 4 67 Controller box assembly removal 4 68 Switch main power removal se cece ene rr andre eee sone escent 4 69 Bridge card assembly removal gan apro gece een ee EES EIERE EES 4 70 RIP card access cover removal age E EEN Ei Ss ee REISER EISE E doa nee 4 71 RIP card assembly removal 00m anar a RARE AA aun 4 71 Hard GT tica ira 4 71 Upper printer engine card bracket assembly removal 0000 200 cece eee eens 4 72 Upper printer engine card assembly removal ocoooccocnccn ee 4 74 Lower printer engine card bracket assembly removal 0 000 c eee e eee eens 4 76 Lower printer engine card assembly removal 000 c cee eee eee eee eee eee 4 77 Transfer belt drive motor cooling fan removal 2020 e cece eee eee eee 4 78 Transfer belt drive motor assembly removal 4 79 Switch transfer belt access door interlock removal 4 79 Laser diode power card assembly removal 4 81 24V LVPS card bracket assembly removal 0 00 e cece eee eee eee eee eee 4 82 24V LVPS card assembly removal NENNEN EIERE ieee eee ee eee DNA 4 83 5V LVPS card bracket assembly removal 22200200 ccc EE EEN eee tata 4 83 5V LVPS card assembly removal ENEE anke krukke bable h nd ken 4 84 2AV LPS cooling tamremoval EE 4 84 Rear lower cooling fan assembly 0 0c cece eee eee eee eee eee eee e neta ee enee 4 85 CMY dev
248. eet dual input TTM switch TTM media size removal k Note This removal procedure may be applied to media tray 3 and media tray 4 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 or media tray 4 assembly 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Disconnect the connector from the switch TTM media size A Remove one screw securing the switch TTM media size A Remove the switch TTM media size A Repair information 4 129 5057 XXX 2000 sheet dual input TTM media feed unit assembly 2 removal 1 2 3 Remove the media tray 2 Open the TTM left door assembly Disconnect the connector from the media feed unit assembly A 4 Release the harness from the clamp 5 6 Remove the two screws securing the media feed unit assembly A to the machine Remove the media feed unit assembly 2000 sheet dual input TTM media feed unit assembly removal tray 3 1 meim W Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove the two
249. einstalling the transfer roll assembly B do not touch the roll surface Registration transport roll assembly removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 Open the printer left lower door assembly Disconnect the connector from the registration transport roll assembly A Remove the two screws securing the registration transport roll assembly A to the machine Remove the registration transport roll assembly A 0 JO Om P Co b Connector 4 36 Printer Service Manual 5057 XXX Registration clutch removal arWwWN N O Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 Remove the registration transport roll assembly See Registration transport roll assembly removal on page 4 36 Disconnect the connector from the registration clutch A Remove the E clip sec
250. eloper drive motor assembly 0 cee cece eee eee ee eee 4 86 CMYK PC cartridge drive motor assembly removal 0 0 e cece eee eee eee 4 86 Fusercoolingtan removal ocios cd mat a eee eis we cin came aime ee 4 87 Main power switch actuator removal o ooccoccocccn eee eee eee 4 88 CMYK toner add motor assembly removal 0 eee cece eee eee ee eee 4 89 CMYK transfer HVPS card assembly removal 4 90 Printhead assembly removal sya rsessrs rr EE E A a 4 90 Transfer belt waste toner auger assembly removal 0020 e cece eee e eee eee 4 92 K developer transport drive motor assembly removal 4 92 K Geveloper ee TT ieee Ae EE ES 4 95 AC drive card bracket assembly removal 0 0c c eee eee eee eee eee 4 95 Noise filter assembly removal La sico sene denne sana een bk haa ee A e 4 96 Rear upper cooling fan bracket assembly removal 0000 2 cee eee eee eee eee 4 97 Rear upper cooling fan removal EE 4 98 Developer transfer roll HVPS card assembly removal 0200 cee eee eee eee 4 99 Charge roll HVPS card assembly removal 4 100 MPF transport drive motor assembly removal ocococccncco eee 4 101 Feed roll removal osos i ppm eee ES Ree oa OR EE ke 4 102 Pick roll removal o ciec oes cc cease tress sane See wea eae een ne bie dy Sled ska se eee 4 103 Separation roll removal ev osos EES see ar ELSEN kw eRe Gs RRR ERR ORT RRS SST 4 104 Sensor RFID toner cartridge removal 4 10
251. em solved Replace the printhead assembly Go to Printhead assembly removal on page 4 90 Does the error continue 9 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the problem remain card assembly Go to RIP card assembly removal on page 4 71 Diagnostic information 2 113 5057 XXX Blank print no print Check the media path for foreign objects such as staples clips scraps of media Step Check Yes No 1 Check the four toner cartridges Problem solved Replace any pr saa empty toner Re print the defective image cartridges Is the image density normal 2 Check the 2nd transfer roll assembly for contamination Go to step 3 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear assembly and contamination Go to 2nd transfer roll assembly removal on page 4 35 3 Check the four PC cartridges for proper installation Go to step 4 Correct and clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 4 Replace the 2nd transfer roll assembly Replace the 2nd Replace the 2nd transfer roll transfer roll Go to 2n
252. embly removal on page 4 89 Replace the connection Diagnostic information 2 79 5057 XXX Step Check Yes No Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly Problem solved removal on page 4 74 924 03 Black toner RFID communication error Step Check Yes No 1 Check the K toner cartridge Go to step 2 Reinstall the K Is the K toner cartridge properly installed toner carriage 2 Check the sensor Y toner RFID for proper connection Replace the Replace the CMYK toner add connection Is the above component properly connected motor assembly Selen Go to CMYK toner add motor assembly removal on page 4 89 3 Perform a POR Replace the upper Problem solved i printer engine card Does the error occur when the power is turned off on assembly Go to Upper printer engine card assembly removal on page 4 74 925 00 Sensor Y ATC Step Check Yes No 1 Reset the Y ATC failure lock out condition Go to step 2 Problem solved 1 Enter diagnostic mode 2 Select Dev unit reset 2 Select Y channel Perform a very large print test Does the error continue 2 Check the sensor Y ATC for proper connection Replace the Y Replace the Is the ab t ted developer unit connection s the above component properly connected assembly
253. embly removal 1 Remove the rear cover See 2000 sheet dual input TTM rear cover removal on page 4 113 2 Disconnect all connectors from the TTM controller card assembly A 3 Remove the four screws securing the TTM controller card assembly A to the machine 4 Remove the TTM controller card assembly A 4 152 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM removals 3X 500 sheet drawer 3TM top cover removal 1 Pull out tray 2 assembly A 2 Remove the two screws securing the top cover B 3 Remove the top cover B Repair information 4 153 5057 XXX 3X 500 sheet drawer 3TM foot cover removal 1 Remove the media tray 4 assembly 2 Remove the two screws securing the foot cover A to the machine 3 Remove the foot cover A 3X 500 sheet drawer 3TM right cover removal 1 Remove the four screws securing the right cover A 2 Remove the right cover A by lifting up and out in the direction of the arrow 4 154 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM tray module left cover removal 1 Remove the four screws securing the tray module left cover A 2 Remove the tray module left cover A 3X 500 sheet drawer 3TM rear cover removal 1 Remove the four screws securing the rear cover A 2 Remove the rear cover A Repair information 4 155 5057 XXX 3X 500 sheet drawer 3TM caster removal Re
254. emoval i ao Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 82 Repair information 4 95 5057 XXX 6 Remove the CMYK transfer HVPS card assembly See CMYK transfer HVPS card assembly removal on page 4 90 7 Remove four screws securing the AC drive card bracket assembly A to the machine 8 Disconnect the six connectors from the AC drive card bracket assembly A 9 Remove the five large connectors from the AC drive card bracket assembly A 10 Remove the three screws securing the AC drive card bracket assembly A to the machine 11 Release the plastic retainer securing the AC drive card bracket assembly A to the machine 12 Remove the AC drive card bracket assembly A Noise filter assembly removal o wo CO oO ON Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly remov
255. emperature in the specified time or the incorrect voltage fuser is installed Go to 920 04 Main lamp warm up error on page 2 76 920 05 Service fuser error Main lamp on time error The main lamp was turned on for 20 seconds or longer Go to 920 05 Main lamp on time error on page 2 77 920 06 Service fuser error Sub lamp warm up error The fuser temperature did not reach the ready temperature in the specified time Go to 920 06 Sub lamp warm up failure on page 2 77 920 07 Service fuser error Sub lamp on time error The Sub lamp was turned on for 20 seconds or longer Go to 920 07 Sub lamp on time error on page 2 78 924 00 Service engine error Yellow toner RFID communication error Communication error with the Y sensor RFID toner cartridge has occurred Go to 924 00 Yellow toner RFID communication error on page 2 78 924 01 Service engine error Magenta toner RFID communication error Communication error with the M sensor RFID toner cartridge has occurred Go to 924 01 Magenta toner RFID communication error on page 2 79 924 02 Service engine error Cyan toner RFID communication error Communication error with the C sensor RFID toner cartridge has occurred Go to 924 02 Cyan toner RFID communication error on page 2 79 924 03 Service engine error Black toner RFID communication error
256. engine card assembly removal on page 4 74 2 106 Printer Service Manual Color PC cartridge invalid 5057 XXX Step Check Yes No 1 Check the appropriate PC cartridge Go to step 2 Reinstall the Is the above component properly installed e SR Go to PC cartridge unit removal on page 4 43 2 Replace the appropriate PC cartridge Go to step 3 Problem solved Does the error remain 3 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on Be i carg again Go to Upper printer engine card assembly removal on page 4 74 CMY PC cartridges nearly exhausted Step Check Yes No 1 Check the CMY PC cartridges Go to step 2 Reinstall the CMY Is the above component properly installed PC cartridges Go to PC cartridge unit removal on page 4 43 2 Replace the CMY PC cartridges Go to step 3 Problem solved Does the error remain 3 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on again printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 CMY PC cartridges exhausted Step Check Yes No 1 Check the CMY PC cartridges Go to step 2 Reinstall the CMY Is the above component properly installed PC cartridges Go to PC cartridge unit removal on page 4 43
257. ensor tray 2 feed out late jam on page 2 36 242 01 Paper jam Sensor tray 1 feed out late jam feeding from tray 2 The media is late reaching the sensor tray 1 feed out within the specified time after reaching the sensor tray 2 feed out Go to 242 01 Sensor tray 1 feed out late jam feeding from tray 2 on page 2 37 243 00 Paper jam 243 01 Paper jam Sensor tray 3 feed out late jam Sensor tray 2 feed out late jam feeding from tray 3 The media is late reaching the sensor tray 3 feed out within the specified time after the tray 3 media feed lift motor is turned on TTM equipped machines go to 243 00 Sensor tray 3 feed out late jam on page 2 38 3TM equipped machines refer to the Options Service Manual The media is late reaching the sensor tray 2 feed out within the specified time after reaching the sensor tray 3 feed out TTM equipped machines go to 243 01 Sensor tray 2 feed out late jam feeding from tray 3 on page 2 40 3TM equipped machines refer to Options Service Manual 244 00 Paper jam Sensor tray 4 feed out late jam The media is late reaching the sensor tray 4 feed out within the specified time after the tray 4 media feed lift motor is turned on TTM equipped machines go to 244 00 Sensor tray 4 feed out late jam on page 2 42 3TM equipped machines refer to Options Service Manual 244 01 Paper jam Sensor
258. enter position Is the image density placed in the center position 4 216 Printer Service Manual 5057 XXX 5 Connector locations Locations Waste toner agitator motor we assembly Sensor waste o gt toner cartridge full Switch waste toner cartridge interlock Connector locations 5 1 5057 XXX 5 2 Printer Service Manual 5057 XXX Fuser unit assembly Thumb screws C toner add motor K toner add motor M toner add motor AN Y toner add motor pen Na Main power switch activator td T Switch main power Connector locations 5 3 5057 XXX Printhead Polygon mirror motor 5 4 Printer Service Manual 5057 XXX ante card assembly n pa a A 24 V LVPS TRA card assembly Developer transfer roll gt HVPS card assembly Connector locations 5 5 5057 XXX d Y 9 G o Printer power Finisher power hookup connector hookup connector Upper printer engine card assembly NVM card assembly 5 6 Printer Service Manual 5057 XXX Lower printer card assembly CMYK transfer roll HVPS card assembly 5V LVPS card assembly Connector locations 5 7 5057 XXX Feed lift motor Sensor media out Sensor media level Media feed unit assembly
259. ep 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 2 5 Select Media level Does the display on the operator panel change every time the media tray is opened and closed Diagnostic information 2 85 5057 XXX Step Check Yes No 3 Check the sensor media level tray 2 for proper Replace the Replace the connection sensor media connection Is the above component properly connected level Go to Sensor media level removal on page 4 24 4 Check the media feed lift motor tray 2 for proper Go to step 6 Go to step 5 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Tray 2 media feed lift motor Warning The media tray must be opened before performing this test or paper jam may occur Does the above component operate properly 5 Check the media feed lift motor tray 2 for proper Replace the media Replace the connection feed lift motor connection Is the above component properly connected Go to Media feed lift motor removal on page 4 109 6 Perform a POR Replace the upper Problem solved Does the error continue when the power is turned off on EE Gel Go to Upper printer engine card assembly removal on page 4 74 943 00 Switch media size size sensi
260. eplace the RIP Problem solved Replace the upper printer engine card assembly card assembly Go to Upper printer engine card assembly removal Goto RIP card assembl on page 4 74 see em Perform a print test page 4 71 Does the error continue Diagnostic information 2 129 5057 XXX Background fog Leading edge Replace the developer transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 Perform a print test Does the problem remain Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the media transfer route Go to step 3 Remove debris e Geet or Is the media path free of contamination or debris contamination 3 Check the four PC cartridges for proper installation Go to step 4 Correct and clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 4 Check the 2nd transfer roll assembly for contamination Go to step 5 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear assembly and contamination Go to 2nd transfer roll assembly removal on page 4 35 5 Replace the four developer uni
261. er Diode Light Emitting Diode Long Edge Feed Low Voltage Power Supply Multi Purpose Feeder Microswitch Nonvolatile Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor Picture element Power on Reset Power on Self Test Pages Per Minute Parallel Synchronous Communications Position Sensing Device Pulse Width Modulation Radio Frequency Identification Raster Imaging Processor Read only Memory Revolutions Per Minute Synchronous Dual Random Access Memory Short Edge Feed Single Inline Memory Module Start of scan 1 60 Printer Service Manual SRAM TTM TVOC UPR Vac Vdc Static Random Access Memory Tandem Tray Module Total Volatile Organic Compound Used Parts Return Volts Volts alternating current Volts direct current 5057 XXX General information 1 61 5057 XXX 1 62 Printer Service Manual 5057 XXX General information 1 63 5057 XXX 1 64 Printer Service Manual 5057 XXX 2 Diagnostic information Start Warning Warning Warning A Be careful to avoid burns by safely handling hot parts CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable electronic board or assembly CAUTION If the printer is kept on never touch the conductive parts if not specifically required The power switch and inlet of the low voltage power supply card LVPS card assembly is live even while the p
262. er add assemblies See CMY toner add assembly removal on page 4 46 Remove the K toner add assembly See K toner add assembly removal on page 4 48 Remove the developer interlock plate assembly See Developer interlock plate assembly removal on page 4 48 Note When removing the developer assembly position it in the way it is removed from the machine or toner spill will occur 10 Ensure that the transfer belt lift handle is in the down position and gently remove the appropriate developer assembly A Note When removing the developer assembly ensure that it is positioned in the same manner in which it is removed from the machine or spillage will occur Warning Ensure that the harness coupler B is removed from the old developer unit assembly A and installed on the new one Harness coupler Replacement warning Ensure that the rear area new developer unit assembly A is properly engaged into the machine or the magnetic rolls will not turn properly Repair information 4 53 5057 XXX Use the following procedure to test for proper magnetic roll engagement immediately after installing the new C Mor Y developer unit assembly A A OEnter the diagnostic mode B Select MOTOR TESTS C Select Finisher Motor Tests D Select CMY developer drive motor this test will not work for the K developer unit assembly If the magnetic roll can be seen turning then the developer unit assembly A is installed corr
263. er belt unit assembly do not touch the belt surface or damage will occur Note It is not required to completely remove the transfer belt unit assembly B from the machine It can be partially pulled out to provide access to the transfer belt cleaning assembly A Remove the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 Remove the two screws securing the transfer belt cleaning assembly A to the transfer belt unit assembly B Remove the transfer belt cleaning assembly A Replacement warning When reinstalling the transfer belt unit assembly do not touch the belt surface or damage will occur Locating pin Locating pin Standard media exit shift assembly removal 1 OO O amp O PP Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Warning Ensure that the rear left middle cover is removed before removing the rear left upper cover or damage will occur Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the rear left upper cover See Rear left upper cover removal on page 4 7 Disconnect the two connectors from the standard media exit shift assembly A Remove the four screws securing the standard media exit shift assembly A to the machine Remove the standard media exit shift assembly A from the machine Repair information 4 17 5057 XXX Connectors Standard med
264. er engine card assembly mtm 7 34 24 V LVPS card assembly a rr rrr rrr rrr 7 34 24 V LVPS cooling fan 7 34 CMYK transfer roll HVPS card assembly 7 34 Noise filter assembly ee 7 34 Laser diode power card assembly 7 34 Rear upper cooling fan ee 7 34 AC drive card bracket assembly 110 V 2222 7 35 AC drive card bracket assembly 220 Ve 7 35 Outlet power panel cable assembly 7 2 0200 r rrr rrr rrr rrr rte 7 35 Developer block cable assembly 0000 r rrr rrr rrr rrr rrr 7 37 Charge roll block cable assembly e 7 37 YM transfer roll cable assembly ee 7 37 CK transfer roll cable assembly ee 7 37 Transfer belt charge cable 2 202 rrr rrr rrr rr rrr rrr 7 37 2nd transfer roll charge connector 7 37 2nd transfer charge roll cable rrr rr rrr rrr rr rrr rrr eee 7 37 DC main cable assembly 7 37 DC rear right cable assembly e 7 37 DC rear left cable assembly 2 7 37 Printer front door assembly e 7 2 Printhead slit glass cleaner assembly nto 7 2 Right cover assembly e 7 2 Top cover assembly ee 7 4 RIP card access cover ee 7 4 Main switch cable assembly notan 7 4 IMMER cover EE 7 4 Main p
265. er front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the inner cover See Inner cover removal on page 4 42 Remove the three CMY toner add assemblies See CMY toner add assembly removal on page 4 46 Remove the screw securing the K toner add assembly A to the machine Warning Pull the shutter to reduce toner spillage into the machine Remove the K toner add assembly A Shutter Developer interlock plate assembly removal Mi Warning Always perform color registration adjustment RegCon when removing or reinstalling the printhead NVM initialization or developer interlock plate assembly See Color registration RegCon on page 4 203 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Note It is not required to remove the waste toner cartridge sensor
266. erlock switches are overridden Warning Only perform this test in segments of three seconds or less or toner spill will occur 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select C M Y or K toner add motor Does the above component operate properly 6 Check the CMYK toner add motor assembly connection Replace the Replace the CMYK toner add connection Is the above component properly connected motor assembly Go to CMYK toner add motor assembly removal on page 4 89 7 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on ea card again y Go to Upper printer engine card assembly removal on page 4 74 2 110 Printer Service Manual 5057 XXX Image quality trouble Printer Related Troubleshooting Note First get a printout as a base and follow the symptom table to identify the possible failing FRU s Image quality symptoms Faint print low contrast Faint print Low contrast on page 2 112 Blank print no print Blank print no print on page 2 114 Solid black Solid black on page 2 116 Vertical blank lines White stripes in media transport direction Vertical lines and bands process direction on page 2 117 Horizontal band Horizontal white stripes or bands side to side direction on page 2 119 Vertical stripes Vertical stripes process direction on pag
267. erly connected connection 4 Perform a POR Replace the fuser Problem solved Does the error occur when the power is turned off on unit assembly Go to Fuser unit assembly removal on page 4 15 920 04 Main lamp warm up error Step Check Yes No 1 Check for proper voltage fuser Go to step 2 Install the appropriate Does the fuser unit assembly voltage match the voltage volta i gt ge fuser unit required for the machine assembly 2 Check the fuser unit assembly for a media jam Remove the Go to step 3 Is there a media jam in the fuser unit assembly WEE 3 Check the fuser unit assembly for proper installation Go to step 4 Install the fuser unit assembly Is the fuser unit assembly installed properly properly 4 Check the fuser unit assembly for proper connection Go to step 4 Repair the Is the above component properly connected connection 5 Perform a print test Replace the fuser Problem solved Does the error continue unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 6 6 Perform a POR Replace the AC Problem solved drive card bracket Does the error occur when the power is turned off on assembly Go to AC drive card bracket assembly removal on page 4 95 2 76 Printer Service Manual 920 05 Main lamp on time error 5057 XXX Step Check Yes No 1 Check the fuser unit assembly for a media jam Remo
268. es something that might damage the product hardware or software There are several types of caution statements CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface gt EE E CAUTION This type of caution indicates a tipping hazard XXIV Printer Service Manual 5057 XXX 1 General information The Lexmark C930 and C935 are color laser printers All information in this service manual pertains to both models unless explicitly noted Printer technology e Color laser Processor e 1 25 GHz Memory e Standard 512 MB Maximum 1024 MB e Hard Drive 80 GB Acoustics 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 54 7 0 Standby mode 32 Environment Specified operating environment Operating temperature 15 6 C to 32 2 C 60 to 90 F Relative humidity 8 to 80 Altitude 2 500 meters 8 200 feet Connectivity e Standard USB and internet e
269. ese font card ree eee eee ee eee 7 71 Korean font card 2 errr ee eee ee eee ee eee 7 71 Marknet N8050 802 119 wireless International 7 71 Lexmark marknet N7020e 4 USB ports 10 100 1000 ethernet 7 71 Lexmark marknet N7000e 1 USB port 10 100 ethernet 7 71 Lexmark marknet N7002e 1 parallel port 10 100 ethernet 7 71 Power cord Austria Belgium Brazil France Germany Greece Italy Luxembourg Netherlands Nordic countries Paraguay Poland Portugal Russia Senegal Spain HV 8ft straight 7 70 Power cord Liechtenstein Switzerland HV 8ft straight 7 70 Power cord South Africa Hong Kong Singapore Thailand Malaysia HV 8ft straight 7 70 Power cord Denmark HV 8ft straight 7 71 Interconnect card assembly 7 39 Bar code card assembly e 7 71 IPDS card assembly 7 71 PRESCRIBE card assembly rrr reer errr ree eee eee 7 71 Printcryption card assembly m mm 7 71 CMYK PC cartridge drive motor assembly 7 6 Part number index I 5
270. eveloper roll HVPS card assembly and the printer engine card assembly for proper connection Is the above component properly connected Go to step 2 Replace the connection Perform a POR Does the error continue when the power is turned off on Replace the developer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 Go to step 3 Problem solved Perform a POR Does the error continue when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved Diagnostic information 2 91 5057 XXX 980 02 Communication error between printer and RIP card assembly Step Check Yes No Check the RIP card assembly and the printer engine card assembly for proper connection Is the above component properly connected Go to step 2 Replace the connection Perform a POR Does the error continue when the power is turned off on Perform a POR Does the error continue when the power is turned off on Replace the RIP card assembly Go to RIP card assembly removal on page 4 71 Go to step 3 Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved Problem solved 980 03 Communication error with fin
271. ft door interlock for proper Reconnect the Go to step 3 operation connector on the 1 Enter the Diagnostics Menu ed cara y 2 Select DUPLEX TESTS 3 Select Sensor Test 4 Select Door D duplex left Does the display on the operator panel change every time the actuator on the above switch is operated 3 Check the switch duplex left door interlock for proper Replace the switch Replace the connection duplex left door connection Is the above switch connected properly interlock Go to Switch duplex left door interlock removal on page 4 11 4 Perform a POR Replace the duplex Problem solved ag the error continue when the power is turned off Ge Go to Duplex controller card assembly removal on page 4 14 Go to step 5 5 Perform a POR Replace the lower Problem solved er the error continue when the power is turned off e h ai ag Go to Lower printer engine card assembly removal on page 4 77 2 94 Printer Service Manual Media size mismatch in width 5057 XXX Step Check Yes No 1 Check the media Go to step 2 Load media properly Is media properly loaded in the tray 2 Check the media Go to step 3 Set the guides Is the rear media tray guide and media tray end guide of tray properly 1 or tray 2 set correctly 3 Check the switch media size for proper installation Go to step 4 Install the switch Pull out the media tray to visu
272. ft straight NS 40X0280 Power cord Korea 10A HV 6ft straight NS 40X0281 Power cord Taiwan 13A LV 6ft straight NS 40X0288 Power cord Argentina HV 8ft straight NS 40X0301 Power cord Australia New Zealand HV 8ft straight NS 40X0303 Power cord China HV 2 44 m straight NS 40X1767 sch sch sch fa far far far sch sr fa ed sch sch far sch far sch 1 sch Power cord Austria Belgium Brazil France Germany Greece Italy Luxembourg Netherlands Nordic countries Paraguay Poland Portugal Russia Senegal Spain HV 8ft straight NS 40X0275 Power cord lsrael HV 8ft straight NS 40X1772 Power cord Liechtenstein Switzerland HV 8ft straight NS 40X1773 7 70 MFP Service Manual Power cord South Africa Hong Kong Singapore Thailand Malaysia HV 8ft straight 5057 XXX Asm Part Units Units kit Description Index number mach or pkg NS 40X1774 1 1 Power cord Denmark HV 8ft straight NS 40X1508 1 1 128MB memory option NS 40X1509 1 1 256MB memory option NS 40X1510 1 1 512MB memory option NS 40X1454 1 1 32MB flash card NS 40X1455 1 1 64MB flash card NS 40X2767 1 1 Bar code card assembly NS 40X2769 1 1 PRESCRIBE card assembly NS 40X2770 1 1 Printcryption card assembly NS 40X2768 1 1 IPDS card assembly NS 40X1512 1 1 Japanese font car
273. fuser Replace the Is the above component properly connected cooling fan SES Go to Fuser cooling fan removal on page 4 87 4 Perform a POR Replace the lower Problem solved i printer engine card Does the error occur when the power is turned off on assembly Go to Lower printer engine card assembly removal on page 4 77 918 00 Standard media exit shift error Step Check Yes No 1 Perform a POR Replace the upper Problem solved Does the error occur when the power is turned off on printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 73 5057 XXX 920 00 Fuser main lamp overheat error Step Check Yes No 1 Reset the fuser overheat failure lock out condition Go to step 2 Go to step 5 1 Enter the Diagnostics Menu 2 Select Fuser temp fail clear 3 Select Fuser temp fail clear Perform a POR Does the error occur when the power is turned off on 2 Reset the fuser overheat failure lock out condition Remove the Go to step 3 Check the fuser unit assembly for a media jam media Is there a media jam in the fuser unit assembly 3 Check the fuser unit assembly for proper installation Go to step 4 Install the fuser Is the fuser unit assembly installed properly unit assembly y propery properly 4 Check the fuser unit assembly for proper connection Go to step 5 Repair the Is t
274. g area of the sensor media eject shaft Service finistier HP lag error HP remains interrupted within the specified time GE SIS after the media eject shaft starts moving from the home position Refer to the Finisher Service Manual 988 01 Sensor punch unit side The sensor punch unit side reg 1 or sensor punch Service finisher reg 1 lag error unit side reg 2 did not detect any media correctly error Sensor punch unit side Refer to the Finisher Service Manual reg 2 lag error 989 00 Stapler unit error The sensing area of the sensor stapler unit motor WE HP inside the stapler unit assembly is not aoe finisher interrupted within the specified timer after the stapler unit motor starts moving to the home position Refer to the Finisher Service Manual 990 00 Sensor stapler carriage HP The sensing area of the sensor stapler carriage errr late error HP is not interrupted within the specified time after ve finisher the stapler carriage starts moving to the home position Refer to the Finisher Service Manual 990 01 Sensor stapler carriage HP The sensing area of the sensor stapler carriage get lites lag error HP remains interrupted within the specified time le finisher after the stapler carriage starts moving from the home position Refer to the Finisher Service Manual 991 00 Sensor booklet front tamper The sensing area of the sensor booklet front Service finisher HP late error tamper HP is not interrupted within the specified SC time
275. g from tray 3 Step Check Check the media condition Is the media in the tray crumpled or damaged Check the media position Does the media touch the sensor tray 2 feed out Yes Replace the damaged media with new Remove the media No Go to step 2 Go to step 5 Check the sensor tray 2 feed out for proper operation 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 2 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 5 Go to step 4 Check the sensor tray 2 feed out for proper connection Is the above component properly connected Replace the sensor tray 2 feed out Replace the connection 2 40 Printer Service Manual 5057 XXX Step Check Yes No 5 Check the sensor tray 3 feed out for proper operation Go to step 7 Go to step 6 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor test 4 Select Tray 3 5 Select Feed out Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 6 Check the sensor tray 3 feed out for proper Replace the sensor Replace the connection tray 3 feed out connection Is the above component properly connected 7 Check the tray module drive motor for pro
276. ge 4 194 3 Remove the separation roll spacer A 4 Remove the separation roll one way friction clutch B Repair information 4 193 5057 XXX 1X 500 sheet drawer 1TM separation roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the separation roll B to the shaft C 4 Remove the separation roll B Note Do not touch the rubber surface of the feed roll B Replacement note Before re installing do not touch the rubber surface of the separation roll B 4 194 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM pick roll removal 1 Remove the media tray assembly 2 Move the front guide A toward the front in the direction of the arrow 3 Release the hook securing the pick roll B to the shaft C 4 Remove the pick roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before re installing do not touch the rubber surface of the pick roll B Repair information 4 195 5057 XXX 1X 500 sheet drawer 1TM tray module left door assembly removal 1 Open the 3TM TMM left door assembly 2 Remove the two screws securing the two supports straps A to the machine 3 Remove the screw securing the bracket B to the machine 4 Remove the bracket B 5 Move the tray module
277. gt P668 1 3 1 1 1 SC S 24VDC S Tray module TTM tray 4 save la y ae media transport eiser Ude ms 4 3 A P552 4 drive motor rive motor Er 15 Q 6 6 61 7 lt
278. h waste toner cartridge interlock A to the assembly Remove the switch waste toner cartridge interlock A Connectors Repair information 4 41 5057 XXX Inner cover removal a RON 0 Y 0 10 Open the printer front door assembly Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the toner waste cartridge Press the button and raise the transfer belt lift latch assembly A to its upper most position Move the transfer belt lift handle B to the lower most position 9 Remove the four PC cartridge units Remove the four screws securing the inner cover C to the machine 11 Remove the inner cover C Button 4 42 Printer Service Manual 5057 XXX Waste toner agitator motor assembly removal OND CONDO Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste
279. h the heater lamp to on Fuser exit sensor The fuser exit sensor detects the arrival of media at the detection point in the exit area of the fuser and also detects the ejection of media from this point Exit Standard media exit roll assembly Standard media exit shift motor Sensor standard bin full The standard media exit ejects printed media from the printer to the standard bin 1 1 18 Printer Service Manual 5057 XXX Standard media exit roll assembly The media exit roll assembly feeds printed media from the fuser to the standard bin Sensor standard bin full The sensor standard bin full detects whether the standard bin is full by moving the actuator up and down Standard media exit shift motor The standard media exit shift motor allows the standard media exit roll assembly to shift back and forth to perform off set sorting Duplex diverter gate The duplex diverter gate switches the media transport path When the duplex diverter gate is lifted media is fed to the standard bin When it is lowered media is fed to the duplex Inverter forward clutch Standard media exit roll assembly Inverter reverse clutch 4 Duplex Z diverter gate A Duplex drive motor Se a Duplex diverter solenoid Sy Switch duplex left door interlock Sensor duplex wait Duplex media transport roll assembly Drive K developer transport drive motor assembly The K
280. hang by the wires Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the inner cover See Inner cover removal on page 4 42 Remove the three CMY toner add assemblies See CMY toner add assembly removal on page 4 46 Remove the K toner add assembly See K toner add assembly removal on page 4 48 Remove the developer interlock plate assembly See Developer interlock plate assembly removal on page 4 48 Remove the developer unit assembly See Developer unit assembly removal on page 4 53 Using a prying tool gently release the two tabs securing the top cover A to the assembly Remove the top cover A Completely remove the carrier B from the assembly by dumping it and using a toner vacuum or if installing a new developer unit assembly go to next step Replacement warning If reusing an existing developer unit assembly ensure that all traces of old carrier B are removed from the developer unit assembly or print quality issues may occur Repair information 4 55 5057 XXX To install the new carrier B Warning Ensure that the carrier is installed evenly and uniformly in the assembly or spillage may occur 1 Open the appropriate bag and dump the appropriate carrier into the appropriate a
281. he above component properly connected connection 5 Perform a print test Replace the fuser Problem solved Does the error continue unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 6 6 Perform a POR Replace the AC Problem solved Does the error occur when the power is turned off on GE SES Go to AC drive card bracket assembly removal on page 4 95 920 01 Front thermistor disconnection error Step Check Yes No 1 Check the fuser unit assembly for a media jam Remove the Go to step 2 Is there a media jam in the fuser unit assembly media 2 Check the fuser unit assembly for proper installation Go to step 3 Install the fuser Is the fuser unit assembly installed properly unit assembly y popen properly 3 Check the fuser unit assembly for proper connection Go to step 4 Repair the Is the above component properly connected EEN 2 74 Printer Service Manual 5057 XXX Step Check Yes No Perform a POR Does the error occur when the power is turned off on Replace the fuser unit assembly Go to Fuser unit Problem solved assembly removal on page 4 15 920 02 Fuser sub lamp overheat error Step Check Yes No 1 Reset the fuser overheat failure lock out condition Go to step 2 Go to step 5 1 Enter the Diagnostics Menu 2 Select Fuser temp fail clear 3 Select Fuser temp fail clear
282. he connector access cover A Connectors N Disconnect the three connectors from the printer left door assembly B Gently pull the harnesses through the hole in the machine frame Open the printer left door assembly B 9 Remove the front left cover See Front left cover removal on page 4 9 10 Remove the safety screw from the machine 11 Detach the safety arm C from the machine 12 Remove the C clip from the machine 13 Remove the support arm D from the machine 14 Lower the printer left door assembly B to an approximate 75 angle as shown in the graphic 15 Lift the printer left door assembly B up to remove it from the machine 16 Remove the printer left door assembly B CON O 4 26 Printer Service Manual 5057 XXX Approximately 75 Replacement warning When replacing the printer left door assembly B ensure that the black lines are aligned on the damper assembly E or the door will not properly operate Black line Repair information 4 27 5057 XXX Replacement warning When replacing the printer left door assembly B ensure that the duplex media exit turn guide F is held in its upper most position or the printer left door assembly B will not close properly 4 28 Printer Service Manual 5057 XXX Printer left door damper removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left
283. he default is On To change this setting 1 Select Require Standby from the Configuration Menu 2 Select Back to cancel and return to the Configuration Menu 3 Press d to submit the change If Standby Mode is on the printer begins functioning in Standby Mode when it remains idle for an amount of time The Standby Mode enables the printer To consume less energy than when operating in normal mode but not as little as when operating in Power Saver e To return to the Ready state more quickly than when operating in Power Saver Short Edge Printing The default printing orientation is long edge This setting allows you to enable or prohibit short edge fed paper If the setting Disabled default is selected letter and A4 paper can only be fed long edge If they are fed short 3 28 Printer Service Manual 5057 XXX edge a prompt will ask you to use the correct paper size When the setting is Enabled you can feed paper either long edge or short edge To change this setting 1 Select Short Edge Printing from the Configuration Menu 2 Select Back to cancel and return to the Configuration Menu 3 Press d to save the change Tray Low Message This setting allows you to disable any Tray Low warnings that the printer may register Selecting Disabled turns off the tray low prompts The default is Enabled To change this setting 1 Select Require Standby from the Configuration Menu 2 Select Back to cancel and return to the Configu
284. he five screws securing the 24V LVPS card bracket assembly A to the machine Remove the 24V LVPS card bracket assembly A IW NOOO P OO Connector E ES onnector 4 82 Printer Service Manual 5057 XXX 24V LVPS card assembly removal 1 Disconnect the three connectors from the 24V LVPS card assembly A 2 Remove the three screws securing the 24V LVPS card assembly A 3 Remove the 24V LVPS card assembly A Connectors A Connector 5V LVPS card bracket assembly removal k Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 3 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 Disconnect the six connectors from the 5V LVPS card bracket assembly A Release the harnesses from the clamps Remove the four screws securing the 5V LVPS card bracket assembly A to the machine Remove the 5V LVPS card bracket assembly A MD NOOR Connectors gt Repair information 4 83 5057 XXX 5V LVPS card assembly removal 1 2 a Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly remo
285. he screw CW 10 clicks EG Y Skew adjustment 10 Turn the screw CCW 10 clicks Printhead adjusting screw at I ane a Ree Have the appropriate printhead adjustment screw been adjusted 6 Check the image density sensor assembly connection Go to step 7 Replace the connection Is the above component properly connected Repair information 4 213 5057 XXX Step Check Yes No 7 Check the image density sensor assembly for toner Remove and clean Go to step 8 contamination the image density Is the above component dirty or contaminated sengor assembly See Image density sensor assembly removal on page 4 44 8 Re Perform the In out setup Perform the Replace the image 1 Enter the Diagnostics Menu Center setup er se assembly 2 Select ENGINE ADJUST er Ge ec 3 Select RegCon adjust page 4 215 density sensor 4 Select Control setup cycles assembly 5 Select In out setup removal on page 4 44 Does the above test pass 9 Re Perform the In out setup Perform the Contact next level 1 Enter the Diagnostics Menu Center setup of support 2 Select ENGINE ADJUST A e 3 Select RegCon adjust page 4 215 4 Select Control setup cycles 5 Select In out setup Does the above test pass 4 214 Printer Service Manual Center setup 5057 XXX Step Check Yes No Warning Ensure that the image density sensor assembly is moved to the center position or the test wi
286. he upper printer engine card B assembly and the lower printer engine card assembly C are connected Repair information 4 73 5057 XXX Upper printer engine card assembly removal 1 2 3 4 5 o N 10 11 12 13 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the RIP card assembly See RIP card assembly removal on page 4 71 Remove the controller box top cover assembly See RIP card cooling fan cover assembly removal on page 4 67 Remove the switch main power See Switch main power removal on page 4 69 Remove the controller box assembly See Controller box assembly removal on page 4 68 Remove the upper printer engine card bracket assembly See Upper printer engine card bracket assembly removal on page 4 72 Remove the six screws securing the metal cover A to the upper printer engine card assembly B Remove the metal cover A Remove the five screws securing the upper printer engine card assembly B to the bracket C Remove the upper printer engine card assembly B Remove the NVM board D from the upper printer engine card assembly B 4 74 Printer Service Manual 5057 XXX Ss Bottom view Replacement warning When reinstalling the
287. he upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue Problem solved Replace the RIP card assembly Go to RIP card assembly removal on page 4 71 2 122 Printer Service Manual Horizontal stripes side to side direction 5057 XXX Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the media transfer route Go to step 3 Remove Check the media route for contamination or obstacles See contamination 3 Check the four PC cartridges for proper installation Go to step 4 Correct and s clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 4 Check the 2nd transfer roll assembly for contamination Go to step 5 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd transfer roll assembly removal on page 4 35 5 Replace the transfer belt unit assembly Go to Transfer Go to step 6 Problem solved belt unit assembly removal on page 4 16 Does the problem remain 6 Check the heat roll and pressure roll Replace th
288. head adjusting screw Have the appropriate printhead adjustment screw been adjusted 6 Check the image density sensor assembly connection Go to step 7 Replace the connection Is the above component properly connected Repair information 4 209 5057 XXX Step Check Yes No 7 Check the image density sensor assembly for toner Remove andclean Go to step 8 contamination the image density Is the above component dirty or contaminated Sensor assembly See Image density sensor assembly removal on page 4 44 8 Re Perform the Skew fine setup Perform the In Out Replace the image 1 Enter the Diagnostics Menu setup density sensor assembly 2 Select ENGINE ADJUST EM ag See 3 Select RegCon adjust page 4 211 density sensor 4 Select Control setup cycles assembly 5 Select Skew fine setup removal on page 4 44 Does the above test pass 9 Re Perform the Skew fine setup Perform the In Out Contact next level 1 Enter the Diagnostics Menu setup of support 2 Select ENGINE ADJUST Ee oeh 3 Select RegCon adjust page 4 211 4 Select Control setup cycles 5 Select Skew fine setup Does the above test pass 4 210 Printer Service Manual In out setup 5057 XXX Step Check Yes No Perform the In out setup 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select I
289. heet drawer 1TM 1TM controller card assembly removal 4 198 Setup ANd AGIUSINGNIS coi ia Ee edda eder 4 199 Sens r ATC setup see EE EE EIERE EE teen eee eee KEES a 4 199 Terre rere Tete TE AA OA AAA 4 200 Color registration RegCon ENEE NEEN EEN EEN EIERE EIERE EELER 4 203 MERE TEIE EEE EEE EP EE EE EE 4 203 Control SeNS r ehalk Lasrovasskekkreenared Reeder SETENE Eee CURE vane des Od THROES 4 205 COMUO SENSO EE as EE 4 205 Belt edge A EE EE 4 206 SEE ENE eege Er EEE 4 206 INMOUPSCIUD sisi 4 211 GA A EE EE eg AN 4 215 Connector TE 5 1 A isse 5 1 EE EE ET EE ARA 5 9 Preventive maintenance 2ssaniesssasiensserdeeetkvedne ours SEET SSES AER d 6 1 Sarek El 6 1 Scheduled MAMENANG sg SE Sege AA 6 2 o AA EN 7 1 How to use his parts Catalog 2 sie dE erg EES tend Geant dew nthe beer eder d 7 1 5057 XXX Assembly 1 COYS EE Ciea aud ea akse LOO Rae Aae ed 7 2 Assembly 2 Covers EE 7 3 Assembly 3 COVES A ocx acer sacs ARA A ee PAO MEET Ree Tee ERS 7 5 Assembly 4 PC cartridge and developer drive 7 6 Assembly 5 ID sensor and transfer belt steering 0 cece eee eee 7 7 Assembly 6 Media Way sc 3cccccctieeense ros Senket kanten 7 8 Assembly 7 Printer left lower door and media feed unn 7 9 Assembly 8 Media feed unt 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 tr
290. heet dual input TTM media feed unit assembly 2 removal on page 4 130 2000 sheet dual input TTM media feed unit assembly removal tray 3 on page 4 130 or 2000 sheet dual input TTM media feed unit assembly removal tray 4 on page 4 125 Remove the media out actuator See 2000 sheet dual input TTM media out actuator removal on page 4 137 Disconnect the connector from the sensor media out A Release the hooks securing the sensor media out A to the media feed unit assembly Remove the sensor media out A EV Lower view Repair information 4 139 5057 XXX 2000 sheet dual input TTM feed roll removal 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before re installing do not touch the rubber surface of the feed roll B 4 140 Printer Service Manual 5057 XXX 2000 sheet dual input TTM feed roll one way clutch removal 1 Remove the media tray assembly 2 Remove the feed roll See 2000 sheet dual input TTM feed roll removal on page 4 140 3 Remove the feed roll one way clutch A from the shaft B
291. her Standard media exit roll assembly Pisseng Bridge unit bin exit roll assembly o F 3 Ka Buffer roll assembly i op a bl gt Media eject S e e roll assembly CK E R d Q I 0 p Fuser Duplex media s Lower media exit transport roll lt q Sai roll assembly assembly 2nd transfer roll assembly CO Booklet media MPF ieee IS Registration roll assembly transport roll assembly MPF pick roll o gt 2 Q Booklet media Media transport roll assembly Tray 1 o O entrance roll assembly O Booklet maker Got Tray 2 i Booklet media O optional LAA exit roll assembly Tray module transport Tray 3 Finish roll assembly O ints er Booklet folding Tray 4 x optional roll assembly O O O Pick roll O i Feed roll Tray 2 STM optional Separation roll 1TM optional O N O Tray module transport roll assembly Tray 2 TTM a He Tray Al ag Tray 3 Tray 4 transport roll assembly O O Functions of main components When the 3TM is installed under the printer additional trays are available Media tray assembly It is necessary to adjust the rear and the end guide in the media tray assembly to match the media size Rear media guide The rear media guide can be adjusted to different media sizes by moving it to the front or rear The guide comes into contact with the rear edge of the media and holds it in position 1 44 Printer Service Manual 5057 XXX Bottom plate The force pushing up the bottom plate is transmitt
292. hift error An internal processing error occurred in the upper printer engine card assembly Go to 918 00 Standard media exit shift error on page 2 73 920 00 Service fuser error Fuser main lamp overheat error The front thermistor detected an abnormal high temperature This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur Go to 920 00 Fuser main lamp overheat error on page 2 74 920 01 Service fuser error Front thermistor disconnection error The system detected an open circuit in the fuser front thermistor Go to 920 01 Front thermistor disconnection error on page 2 74 Diagnostic information 2 11 5057 XXX 2 12 Printer Service Manual Error code or message Error contents Description Action 920 02 Service fuser error Fuser sub lamp overheat error The rear thermistor detected an abnormal high temperature This error must be reset inside diagnostic mode before troubleshooting or machine operation can occur Go to 920 02 Fuser sub lamp overheat error on page 2 75 920 03 Service fuser error Rear thermistor disconnection error The system detected an open circuit in the fuser rear thermistor Go to 920 03 Rear thermistor disconnection error on page 2 75 920 04 Service fuser error Main lamp warm up error The fuser temperature did not reach the ready t
293. how the value of this setting affects the user default value for the Smartswitch and Printer Language settings Sone Si Resulting value of e Smartswitch setting Resulting value for Printer Language settings Emulation all ports setting Activate Off PPDS Emulation Note You can still switch languages on the operator panel or through the PUL ENTER LANGUAGE command Deactivate On Printer s factory default value 3 26 Printer Service Manual 5057 XXX To change the value of this setting 1 Select PPDS Emulation from the Configuration Menu 2 Select Back to cancel and return to the Configuration Menu 3 Select d to save the change Factory Defaults Warning This operation cannot be undone This setting enables you to restore all of the printer s settings to the base printer settings the network settings or to remove all Lexmark Embedded Solutions LES applications To restore the Factory Default settings 1 Select Factory Defaults from the Configuration Menu 2 Select Restore Base to restore all non critical base printer NVRAM settings 3 Select Restore Network to restore all network NVRAM settings 4 Select Restore LES to remove all Lexmark Embedded Solution applications When you select either value the LCD displays Restoring Factory Defaults andthen Resetting the Device The device immediately performs a POR and restores the appropriate settings to their factory default values The fol
294. ia exit bin full actuator removal SOMNDOAAR WD Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Warning Ensure that the rear left middle cover is removed before removing the rear left upper cover or damage will occur Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the rear left upper cover See Rear left upper cover removal on page 4 7 Remove the screw securing the standard exit top cover A to the machine Gently lift the standard exit top cover A from the machine Remove the standard exit top cover A from the machine Remove the screw securing the bracket B to the machine Remove the bracket B Gently flex the standard media exit bin full actuator C to detach it from the machine Remove the standard media exit bin full actuator C from the machine 4 18 Printer Service Manual 5057 XXX Switch printer left door interlock removal 1 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Warning Ensure that the rear left middle cover is removed before removing the rear left upper cover or damage will occur Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the rear left upper cover See Rear left upper cover removal on page 4 7 Remove the standard media exit shift assembly See Standard media exit shift assembly
295. ift latch assembly with label 4 40X3721 3 1 Left transfer belt lift assembly 7 26 MFP Service Manual 5057 XXX Assembly 24 Transfer belt Asm Part FRUs Units Description index number mach FRU 1 40X3732 1 1 Transfer belt unit assembly 2 40X3733 1 1 Transfer belt cleaner assembly 3 40X3729 1 1 Transfer belt auger front gear 14T 4 40X3731 1 1 Transfer belt auger assembly 5 40X0880 6 1 Bushing 6 mm 6 40X3730 1 1 Transfer belt auger rear gear 18T Parts catalog 7 27 5057 XXX Assembly 25 Transfer belt lift 2 lt Q dg L d E S L l i LA Sec WS i Pr pod rr JJ A n l 1 r f gt 7 ES Sch E ary GF V 1 L de atl i Ir L Asm Part FRUs Units Seng index number mach FRU Description 1 40X3735 4 1 Transfer belt lift rear plunger assembly 2 40X3734 8 1 Transfer belt lift recoil spring 3 40X3736 4 1 Transfer belt lift front plunger assembly 7 28 MFP Service Manual 5057 XXX Assembly 26 Toner Dispense Asm Part FRUs Units Description index number mach FRU 1 40X3740 1 1 K toner dispense assembly 2 40X3739 1 1 C toner dispense assembly 3 40X3738 1 1 M toner dispense assembly 4 40X3737 1 1 Y toner dispense assembly 5 40X3741 1 1 CMYK toner add motor assembly 6 40X0636 4 1 Sensor RFID toner cartridge Parts catalog 7 29 5057 XXX Assembly 27
296. ift pulley A to the tray lift shaft assembly B 6 Remove the lift cable pulley A Note The tray 3 front cables C become detached 7 Remove the tray 3 front cables C from the tray lift shaft assembly B 8 Remove two E clips with a prying tool securing the two small pulleys D on the front of the frame assembly 9 Remove two small guides E and the two small pulleys D 10 Remove the tray 3 front cables C from the bottom plate F Replacement note Before re installing Itis recommended that all four cables be replaced Ensure tray 3 front cables C are not twisted or kinked Route the cables properly as shown in the figure Replace the cables by setting the frame assembly B on its side as shown in the figure 4 120 Printer Service Manual 5057 XXX 2000 sheet dual input TTM media tray 4 front cover removal 1 Pull out the media tray 4 assembly 2 Remove the four screws securing the tray 4 front cover A 3 Remove the tray 4 front cover A 4 Remove the six screws securing the bracket B to the tray 5 Remove the bracket B 2000 sheet dual input TTM TTM tray 4 media transport assembly removal 1 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 2 Remove the TTM tray 4 media transport assembly A Replacement note Before re installing insert the TTM tray 4 media transport assembly
297. ing appears on the LCD Press Stop Ni to return to Trans Blet PH Fail Clear 3 18 Printer Service Manual 5057 XXX Dev Unit Reset To perform the Dev Unit Reset Test 1 Select Dev Unit Reset from the Diagnostics Menu The following tests appear on the LCD Select the following Appears on the LCD Y Channel Y Channel Testing M Channel M Channel Testing M Channel C Channel Testing K Channel K Channel Testing When each test completes the LCD returns to Dev Unit Reset Fuser Temp Fail Clear To perform the Fuser Temp Fail Clear Test 1 Select Fuser Temp Fail Clear from the Diagnostics Menu 2 Select Fuser Temp Fail Clear Fuser Temp Fail Clear Testing appears on the LCD When testing is complete the LCD returns to Fuser Temp Fail Clear ATC SENSOR FAILURE CLEAR To perform the ATC Sensor Failure Clear Test 1 Select ATC SENSOR FAILURE CLEAR from the Diagnostics Menu The following tests appear on the LCD Select the following Appears on the LCD Y Channel 925 00 Y Channel Testing M Channel 925 01 M Channel Testing M Channel 925 02 C Channel Testing K Channel 925 02 K Channel Testing When each test completes the LCD returns to ATC SENSOR FAILURE CLEAR Diagnostic aids 3 19 5057 XXX ENGINE ADJUST To begin PH Adjust media tray registration the test page must be printed To print the test page the printer must be in standard mode 1 Select Menus 2 Select
298. ing motor Does the above component operate properly 4 Check the transfer belt steering motor for proper Replace the Replace the connection transfer belt connection Is the above component properly connected steering motor Go to Go to Transfer belt steering motor removal on page 4 61 5 Perform a POR Replace the lower Problem solved printer engine card Does the error occur when the power is turned off on assembly Go to Lower printer engine card assembly removal on page 4 77 904 03 Sensor 2nd transfer roll retract HP late error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on p int tests If the problem remains go to step 2 2 Check the sensor 2nd transfer roll HP for proper Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select Base Sensor Tests 3 Select Media Path 4 Select 2nd transfer roll retract HP Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Diagnostic information 2 63 5057 XXX Step Check Yes No 3 Check the sensor 2nd transfer roll HP for proper Replace the Replace the connection sensor 2nd connection Is the ab gt transfer roll retract s the above component properly connected HP Go to Sensor 2nd transfer roll retract HP removal on p
299. ing the bottom plate it rotates in reverse to drive the tray module gears to turn the lift up shaft Switch media size This switch media size sets the size of media supplied from each media tray assembly A signal indicating the media size is transmitted as a voltage to the printer engine card assembly Switch TTM media size The switch TTM media size switches the setting of the size of media supplied from each media tray assembly A signal indicating the set size is transmitted as a voltage to the printer engine card assembly Sensor media out If there is no media in the media tray assembly the media out actuator lowers and the flag of the media out actuator that has stayed in the sensor media out sensing area leaves there Thus the light of the sensor is transmitted When the sensing area is blocked media is present the signal turns off Sensor media level This sensor detects by the actuator position whether media in the media tray assembly is lifted When the flag of the actuator leaves the sensor media level sensing area the sensor detects that the media has been lifted 1 38 Printer Service Manual 5057 XXX Media feed lift motor Main components Switch tray module left door interlock The switch tray module left door interlock detects open close of the tray module left door assembly Sensor tray 2 feed out The sensor tray 2 feed out detects media fed from trays 2 3 or 4 Sensor tray
300. inter engine card assembly removal on page 4 77 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Tray 3 media type mismatch error Step Check Yes No 1 Check the media tray assembly 3 for the correct media Go to step 2 Install the correct type media Does the above tray contain the correct type of media 2 Check the media tray assembly 3 for the transparencies Ensure that the Go to step 3 Does the media tray 1 assembly contain transparencies media tray assembly is supposed to be configured for transparencies or replace them with standard media 2 54 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the sensor transparency detect for proper Go to step 5 Go to step 4 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Transparency detect Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor transparency detect for proper Replace the Replace the connection sensor connection Is the above component properly connected Es dd Go to Sensor transparency detect removal on page 4 38 5 Perform a POR Replace the lower Problem solved Does the error remain when the power is turne
301. ion 2 127 5057 XXX Step Check Yes No 7 Check the printhead assembly Go to step 8 Problem solved Replace the printhead assembly Go to Printhead assembly removal on page 4 90 Does the error continue 8 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly card assembly Go to Upper printer engine card assembly removal GE card on page 4 74 removal on Perform a print test page 4 71 Does the error continue After image Leading edge Trailing edge The ghost appears on the media which may be the image from the previous page or part of the page currently printing Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the four toner cartridges Problem solved Replace any Re print the defective image ae Is the image density normal 3 Check the heat roll and the pressure roll Replace the Go to step 4 fuser unit Remove the fuser unit assembly assembly Caution Allow the fuser unit assembly to cool down Go to Fuser Is there contamination or cracks on the heat roll and or unit assembly pressure roll removal on page 4 15 2 128 Printer Service Manual 5057 XXX Step Check Yes No 4 Check the upper printer engine card assembly R
302. is sobre el Laser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe I 1 i segons ha estat certificat en altres llocs s un producte l ser de classe I que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un laser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nanometres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites LFR T 5 BRD t TOTI kk KBCADHHS 21 CFRYTF TFF J DYFAI 1 ORB MA LEV V HMCHSS CE MAEWS MEWS RKKAKBUATIIEC 8250245721205 ALOV VYV WMECHSCEMEWSNTVET KEE EECHER GCHTWETF CO PyUvy wU7F7rAMb 3b L F TRA MLTVNET CO LT HENTTO 7953 72 7 0H T BH 537937 bhOAVDAULWMERHITSLU P CH Got VZzFLET VY H EOS A PDA SF D ES TBM BYTE ARR FATOVANVE LOL P ik HIM NZCLORWELABHAaANTHEF y D EL Ax FT EN OL ae EA ES DHHS 21 CFR Subchapter I WF 44 I 1 BOLT m AI tH HE MX ME AGE SF IEC 825 ARE H IT SLP AH RUDSETER EE FT EN L ABB Ib 3b AY IE EEN Eet EE EEN SS HK EA 770 795 nm 2H FRATATT EE E RAET BORE
303. is turned off on S card Go to Upper printer engine card assembly removal on page 4 74 2 84 Printer Service Manual 942 00 Switch media size size sensing error tray 2 5057 XXX Step Check Yes No 1 Check the media Go to step 2 Load media Is media loaded in tray 2 properly properly 2 Check the media tray Replace the media Go to step 3 Are the size sensing mechanisms on the back and the tray assembly bottom of the media tray damaged 3 Check the tray 2 switch media size for proper operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 2 5 Select Tray 2 present Does the display on the operator panel change every time the media tray is opened and closed 4 Check the tray 2 switch media size for proper connection Replace the switch Replace the Is the above component properly connected media size connection Go to Switch media size removal on page 4 110 5 Perform a POR Replace the upper Problem solved Does the error continue when the power is turned off on eB card Go to Upper printer engine card assembly removal on page 4 74 942 01 Sensor media level late error tray 2 Step Check Yes No 1 Check the media Go to step 2 Load media Is media loaded in tray 2 properly properly 2 Check the sensor media level tray 2 for proper operation Go to st
304. isher controller card assembly Step Check Yes No Check the finisher controller card assembly and the printer engine card assembly for proper connection Is the above component properly connected Go to step 2 Replace the connection Perform a POR Does the error continue when the power is turned off on Replace the finisher controller card assembly Refer to the Finisher Service Manual Go to step 3 Problem solved Perform a POR Does the error continue when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved 2 92 Printer Service Manual 1TM 3TM or TTM left door assembly open 5057 XXX Step Check Yes No 1 Check the 1TM 3TM or TTM left door for proper Go to step 2 Replace the 1TM operation STM or TTM left Is the above component open and close properly der Go to 1X 500 sheet drawer 1TM tray module left door assembly removal on page 4 196 3X 500 sheet drawer 3TM 3TM left door assembly removal on page 4 176 or 2000 sheet dual input TTM eft door assembly removal on page 4 147 2 Check the switch tray module left door interlock for Go to step 4 Go to step 3 proper operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Cover and Door 4 Select Door D t
305. ismatch error d SS EES NEEN stew ner gees mena eee ce ee sele e 2 52 Tray 2 media type mismatch error 2 53 Tray 3 media type mismatch error 00 cece rece eee e ee eee eee 2 54 Tray 4 media type MENSEN ENO cciccas ctaka iite i inari RAATI EE 2 55 841 00 Image pipeline ASIC error 20 cece eee eee eee eee eee 2 56 849 00 Hard drive configuration ID mismatch 00 c eee eee eee 2 57 900 XX RIP card assembly software error 00 e eee eee eee 2 57 Vi Printer Service Manual 5057 XXX 901 xx RIP card assembly software error 2 57 903 00 K developer transport drive assembly motor error 2 58 903 01 K PC drive Motor SEET EENS AAA ka 2 59 90302 CMY PC drive Motor GIOP ccs SE e ieee tien k pe REES 2 59 903 03 Developer drive Motor efrOr sioociicoricrcrir eee rada eee eee eee ee 2 60 904 00 Sensor transfer belt HP late error 2 61 904 01 Transfer belt position failure 00 cece ee eee nee eee eee eens 2 61 904 02 Sensor transfer belt edge failure 2 62 904 03 Sensor 2nd transfer roll retract HP late error 2 63 904 04 Sensor 2nd transfer roll retract HP lag error 2 64 904 05 Sensor CMY transfer roll retract HP late error 2 66 904 06 Sensor CMY transfer roll retract HP lag error 2 66 904 07 CMY transfer roll retract motor time out 0 0 cee eee eee 2 66 905 00 NVM read write cannot be executed error 2 67 905 01 Marking device video GOT Aere Ae i eee tod q
306. isplays BASE SENSOR TEST in the header row and the following categories of sensors below the header row Cover and Door e Devices e Exit Level Media Path e Transfer Belt After you select a category of sensors the panel displays the name of the selected category in the header row and each sensor in that category You must select a specific sensor from this list to view and toggle the sensor s state After you select a specific sensor Sensor Name Testing sensor s name in the header row and the sensor s name and current state appears below the header row Cover and Door Sensors Sensor Name appears on the LCD and displays the 3 14 Printer Service Manual Door A printer left Door C printer left lower Door D tray module left Door E printer front Door J transfer belt access Devices Sensors Sensor Name C PC cartridge present M PC cartridge present Y PC cartridge present K PC cartridge present Waste toner full Exit Level Sensor Sensor Name Standard bin full Media Path Sensors Sensor Name Registration Fuser exit Transparency detect 2nd transfer roll retract Transfer Belt Sensors Sensor Name Transfer belt HP CMY transfer roll retract HP Transfer belt edge Transfer belt position detect 5057 XXX To test any of the displayed sensors you must manipulat
307. it assembly 1 removal on page 4 21 2 Disconnect the harness from the media feed lift motor A 3 Remove the two screws securing the media feed lift motor to the media feed unit assembly B 4 Remove the media feed lift motor B Repair information 4 109 5057 XXX Switch media size removal Note This procedure can be applied to tray 1 or tray 2 switch media size 1 Remove media Tray 1 and media Tray 2 2 Remove one screw securing the switch media size A to the bracket inside the machine 3 Remove the connector from switch media size A 4 Remove the switch media size A Connector 4 110 Printer Service Manual 5057 XXX 2000 sheet dual input TTM top cover removal 1 Pull out tray 2 assembly 2 Remove the two screws securing the top cover A 3 Remove the top cover A 2000 sheet dual input TTM foot cover removal 1 Pull out the media tray 3 assembly 2 Pull out the media tray 4 assembly 3 Remove the two screws securing the foot cover A to the machine Repair information 4 111 5057 XXX 4 Remove the foot cover A 2000 sheet dual input TTM right cover removal 1 Remove the four screws securing the right cover A 2 Remove the right cover A by lifting up and out 2000 sheet dual input TTM tray module left cover removal 1 Remove the four screws securing the tray module left cover A 4 112 Printer Service Manual 5057 XX
308. ity normal 3 Check the 2nd transfer roll assembly for contamination Go to step 4 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd transfer roll assembly removal on page 4 35 4 Check the four PC cartridges for proper installation Go to step 5 Correct and e A clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 5 Check the laser beam route Go to step 6 Remove debris Check for debris between the printhead assembly and a the PC drum assembly Check the four printhead assembly windows for window contamination Is the laser beam route free of debris and the glass window in the printhead assembly free of contamination 2 112 Printer Service Manual 5057 XXX Step Check Yes No 6 Check the toner add motor assembly Go to step 7 Problem solved Replace the toner add motor assembly Go to CMYK toner add motor assembly removal on page 4 89 Does the error continue 7 Check the developer transfer roll HVPS card assembly Go to step 8 Problem solved Replace the developer transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 Perform a print test Does the problem remain 8 Check the printhead assembly Go to step 9 Probl
309. ize S W1 S W3 Of B5L 7 25 x 10 5 L Off SENN General information 1 41 5057 XXX 3TM theory Front 1 42 Printer Service Manual 5057 XXX Media transport Media transport path Media is supplied from tray 3 or tray 4 and is transported to the printer along the media transport path shown below Tray 2 Tray 3 Tray 4 Pick roll Pick roll Pick roll Separation roll Separation roll Separation roll Feed roll Feed roll Feed roll Tray module media Transport roll ASM Y Media transport roll ASM y Registration roll ASM i y 2nd transfer roll assembly Transfer belt Heat roll Pressure roll Fuser unit ASM F I I i Standard media l exit roll assembly 1 i i I I I I Standard media exit Duplex media transport roll ASM Duplex media Center transport roll ASM PRINT EXIT General information 1 43 5057 XXX Media transport path The following is a cross section of the printer and the tandem tray module showing the main components directly associated with the media path and transport Upper media Finisher media entrance transportiroll assembly Bridge unit assembly roll assembly U e E eg pper media exit included with finis
310. jam Jam Refer to the Finisher Service Manual 284 00 Sensor lower media exit late The media is late reaching the sensor lower media Paperiam jam exit within the specified time after reaching the perj sensor buffer path Refer to the Finisher Service Manual 284 03 Sensor lower media exit lag The media reached the sensor lower media exit Paper jam jam but did not clear it within the specified time Refer to the Finisher Service Manual 284 05 Sensor lower media exit Media remains on the sensor lower media exit Paper jam static jam Refer to the Finisher Service Manual 285 00 Sensor compiler media in The media reached the sensor lower media exit Paper jam lag jam but did not clear it within the specified time Refer to the Finisher Service Manual 286 00 Sensor compiler media in Media remains on the sensor compiler media in Paper jam static jam Refer to the Finisher Service Manual Diagnostic information 2 5 5057 XXX bg Error contents Description Action 287 00 Sensor upper media exit The media is late reaching the sensor upper media Paperjam late jam exit within the specified time after reaching the per J sensor finisher media entrance Refer to the Finisher Service Manual 287 01 Sensor upper media exit lag The media reached the sensor upper media exit Paper jam jam but did not clear it within the specified time Refer to the Finisher Service Manual
311. k 7 66 MFP Service Manual 5057 XXX Assembly 51 TTM tray lift drive Asm Part FRUs Units Description index number mach FRU 1 40X3848 2 1 TTM tray lift coupling assembly 2 40X3847 2 1 TTM tray lift gear 17T 3 40X0880 2 1 Bushing 6 mm 4 40X3845 1 1 TTM tray 3 lift gear assembly 5 40X3846 1 1 TTM tray 4 lift gear assembly Parts catalog 7 67 5057 XXX Assembly 52 TTM drive and electrical 7 68 MFP Service Manual 5057 XXX Assembly 52 TTM drive and electrical Asm Part FRUs Units Description index number mach FRU 1 40X3850 1 1 TTM controller card assembly 2 40X3849 1 1 TTM tray 4 transport drive motor assembly 3 40X3812 2 1 Tray module drive motor assembly 4 40X4068 1 1 Tray module left retaining bracket 5 40X3815 2 1 Media transport gear 33T 6 40X3814 1 1 Media transport gear 46T 7 40X3813 1 1 Media transport gear 23 46T 8 40X4034 1 1 Tray module retainer screw 9 40X4117 4 4 Front locking caster 10 40X4143 4 4 Rear non locking caster 11 40X4069 1 1 Tray module right retaining bracket 12 40X4103 1 1 TTM main cable assembly Parts catalog 7 69 5057 XXX Assembly 53 Miscellaneous Asm Part Index number NS 40X4031 Units mach 1 Units kit or pkg 15 Description 100K printer maintenance kit 110V includes 110V fuser unit assembly Transfer belt cleaner assembly 2nd transfer roll assem
312. k roll E Pick roll I n Pick roll I i D H i I a mi eg eg Separation roll i Separation roll H Separation roll pl Separation roll i Feed roll i Feed roll 1 Feed roll 5 Feed roll I H il 1 Media feed I Media feed H Media feed H Media feed unit ASM i unit ASM H unit ASM i unit ASM Y Media transport roll ASM y y Registration roll ASM 2nd Transfer roll ASM Transfer belt Heat roll Pressure belt Fuser unit ASM exit roll assembly q Y 1 Fuser media d I I I Standard I media exit I Standard media exit roll assembly Print exit aie as i I Duplex media transport roll ASM i Ss I I i i 1 4 Printer Service Manual SFP paper path rolls Standard media exit roll assembly Fuser exit roll assembly Duplex media transport roll IS Bridge unit assembly included with finisher Bridge unit bin exit roll assembly Finisher media entrance 5057 XXX Upper media transport roll assembly roll assembly Upper media exit roll assembly Q F 3 O Buffer roll assembly op o Media eject OR E Q roll assembly OF Sg ae Q Lower media exit roll assembly Booklet media transport roll assembly Booklet media entrance roll assembly Booklet media exit roll assembly Booklet folding roll assembly
313. l o coocococonocnccnc eee eee ee eee ee eees 4 39 Waste toner cartridge sensor assembly removal 4 39 Sensor waste toner cartridge full removal 0 cece eee eee eee eee 4 40 Switch waste toner cartridge interlock removal 4 41 liner cover removal osos AAA DROP RRS RRs ERE ROT 4 42 Waste toner agitator motor assembly removal 4 43 PC cartridge unit removal cssid sass ages stana AR A ee EE 4 43 Image density sensor assembly removal 2 2000 e cece teen eee eens 4 44 CMY toner add assembly removal 4 46 K10NeGF add ASSEMDIV EMOVEl cicosiinasciaraicna apra a ames AA 4 48 Developer interlock plate assembly removal 00 00 ccc eee eee eee 4 48 Developer unit assembly removal oo coocoococcnccn eee eee eee eee eee 4 53 Developer carrier removal and replacement 4 54 X Printer Service Manual 5057 XXX Photoconductor PC unit assembly removal 00 20 cece eects 4 57 Transfer belt lift latch assembly removal 4 59 Transfer belt steering motor removal 00 cece eee e eee ee eee eee nett e eens 4 61 CMY erase lamp assembly removal 0 00 cece cece o 4 61 Kerase lamp assembly femoVal ege svekka eee EE sakene wee kn d 4 62 Printhead shutter motor assembly removal 200 0 cee eee eee eee eee 4 64 Switch printer front door interlock removal 0 2060 eee eee eee eee eee 4 66 Sensor printer left lower door interlock removal 00e cece eee e e
314. l 4 102 pick roll 4 103 sensor media level 4 24 sensor media out 4 22 sensor RFID PC cartridge and sensor RFID toner cartridge 4 105 separation roll 4 104 switch media size 4 110 4 128 removals 2000 sheet dual input TTM 2TM TTM controller card assembly 4 152 4 178 4 198 2TTM TTM left door assembly 4 147 4 176 4 196 caster 4 113 drive motor assembly 4 150 4 152 4 177 4 178 4 198 feed roll 4 140 4 169 4 190 feed roll one way clutch 4 141 4 170 4 191 foot cover 4 111 front cable assembly 4 120 left cover 4 112 media feed lift motor 4 133 4 164 4 185 media feed unit assembly tray 3 4 130 4 160 4 162 media feed unit assembly tray 4 4 125 4 156 4 182 media feed unit drive gear 13 tooth 4 137 4 166 4 187 media feed unit drive gear 28 21T 4 140 4 169 4 190 media feed unit drive gear 29T 4 140 4 169 4 190 media guide rack and pinion 4 121 5057 XXX media out actuator 4 137 4 166 4 187 media transport roll assembly 4 132 4 185 one way 22T 4 142 4 171 4 192 one way clutch gear assembly 4 135 4 165 4 185 pick roll 4 146 4 175 4 195 pick roll idler gear 33T 4 146 4 175 4 195 rear cover 4 113 right cover 4 112 sensor media level 4 138 4 167 4 188 sensor media out 4 139 4 168 4 189 sensor tray 3 feed out 4 132 4 163 sensor tray 4 feed out 4 127 4 157 4 183 separation roll 4 144 4 173 4 194 separation roll one way friction clutch 4 143 4 172 4 193 switch 2TM
315. l Stop R is pressed 3 8 Printer Service Manual 5057 XXX Make sure either letter or A4 size paper is loaded in the default paper source If the default source only supports envelopes then the Quick Test will be printed from Tray 1 To run the Quick Test 1 Select DUPLEX TESTS from the Diagnostics Menu 2 Select Quick Test 3 Select Single or Continuous Quick Test Printing appears on the LCD e The single Duplex Quick test cannot be canceled e The printer attempts to print the Quick Test Page from the default paper source If the default paper source only supports envelopes then the page is printed from Tray 1 e Check the Quick Test Page for the correct registration between the placement of the first scan line on the front and back side of a duplexed sheet The single test stops automatically when a single duplex sheet is printed and the continuous test continues until you press Stop Y Sensor Test duplex This test is used to determine whether or not the duplex sensors and switches are working correctly The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path 1 Select DUPLEX TESTS from the Diagnostics Menu 2 Select Sensor Test 3 Select Duplex wait and Duplex wait Testing appears on the LCD 4 Select Door B duplex left and Door B duplex left Testing appears on the LCD You can manipulate the appropriate a
316. l actuator 3 40X3688 30 1 Sensor standard bin full 4 40X0553 3 1 Switch printer left door interlock 5 40X3706 1 1 Standard exit top cover 6 40X4080 1 3 Standard output bin paper weight 7 22 MFP Service Manual Assembly 20 Printhead assembly 5057 XXX Asm Part FRUs Units KR index number mach FRU Description 1 40X3712 1 1 Printhead assembly Parts catalog 7 23 5057 XXX Assembly 21 Xerographic and waste toner Asm Part FRUs Units Description index number mach FRU 1 40X3713 1 1 Waste toner cartridge cover 2 40X3715 1 1 Switch waste toner cartridge interlock 3 40X3717 1 1 Sensor waste toner cartridge full 4 40X3714 1 1 Waste toner cartridge sensor assembly this comes assembled 5 40X3716 1 1 Waste toner agitator motor assembly 7 24 MFP Service Manual Assembly 22 Erase lamps and developer interlock plate 5057 XXX Asm Part FRUs Units Description index number mach FRU 1 40X3720 1 1 K erase lamp assembly 2 40X3719 3 1 CMY erase lamp assembly 3 40X3718 1 1 Developer interlock plate assembly Parts catalog 7 25 5057 XXX Assembly 23 Transfer belt lift 1 Asm Part FRUs Units Description index number mach FRU 1 40X3722 1 1 Right transfer belt lift assembly 2 40X3727 1 1 Transfer belt lift handle assembly 3 40X3723 1 1 Transfer belt l
317. l avaluaci i aprovaci del disseny original i els components especifics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades La informaci pel manteniment d aquest producte esta orientada exclusivament a professionals i no esta destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients gt og o 2 gt o DH ru l a Jm Fr G e rr ren 2 ga ren op H mlo nie Q gt Q y gt La o r gt a u H 2 32 jor T Hu o I r uu Le Er Ho o SE 99 gt T oz o go o 2 o o H oTr H gt TH ar 40 ox MI gt ot I mE qo 2 to o E by lo g Je un RM ME 4430 4 ot YEP DUE MY IRS A ORB ARS E an AG RA DAI PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar rir re ox 02 lo E BERRI Be HE E J SPAT SEE AE ra 1 fE TH mn FESR EEN 32 IRIS AA ATI AAA br
318. l on the PC unit assembly C is properly inserted into the metal track or physical binding and damage will occur In the event that the PC unit assembly C becomes bound it can be removed by twisting it in a clockwise direction while pulling it from the machine E ll ml Rail must slide straight into metal track Transfer belt lift latch assembly removal OND N Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the inner cover See Inner cover removal on page 4 42 Remove the two screws securing the transfer belt lift latch A to the machine Release the harnesses from the clamp Repair information 4 59 5057 XXX 9 Remove the transfer belt lift latch assembly A 4 60 Printer Service Manual 5057 XXX Transfer belt steering motor removal D 0 Y O yg Remove the front left cover See Front left cover removal on page 4 9 Remove the waste
319. lasse 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe lllb 8b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs a des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed amp certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 I prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe lb 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 progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Notices and safe
320. ler obligatoriske servicebetingelser xvi Printer Service Manual 5057 XXX Laserilmoitus Tama tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J standardin mukaiseksi luokan I 1 lasertuotteeksi ja muualla IEC 60825 1 standardin mukaiseksi luokan lasertuotteeksi Luokan lasertuotteita ei pideta haitallisina Tulostimen sisalla on luokan IIIb 3b laser joka on nimellisteholtaan 5 mW n galliumarsenidilaser ja toimii 770 795 nanometrin aallonpituuksilla Laserjarjestelma ja tulostin ovat rakenteeltaan sellaisia ett k ytt j ei joudu alttiiksi luokkaa 1 suuremmalle s teilylle normaalin k yt n yllapidon tai huollon aikana Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan IlIb 8b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett kayttaja ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan kayttajan tekemien huoltotoimien tai muiden huoltotoimien yhteydessa VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Ala katso sateeseen VARNING Osynlig laserstr lning n
321. let folding exit drive motor Booklet media entrance drive motor Booklet transport motor Booklet knife solenoid Booklet bin media transport motor Bridge unit diverter gate solenoid De curler clutch Bridge unit transport drive motor Booklet diverter gate solenoid Booklet stapler motor Bridge unit bin media exit solenoid Diagnostic aids 3 5 5057 XXX The following Printer Motor Tests are available e Transfer belt steering motor e Y toner add motor e CMY PC cartridge drive motor e K PC cartridge drive motor e Printhead polygon mirror motor e Tray 1 media feed lift motor e Registration clutch e 2nd transport roll retract motor e K developer transport drive motor e MPF pick solenoid e MPF transport drive motor e Duplex drive motor e Inverter clutch e Duplex diverter gate solenoid e CMY transfer roll retract motor e Transfer belt drive motor e C toner add motor e M toner add motor K toner add motor CMY developer drive motor K developer clutch Fuser cooling fan Image density sensor shutter solenoid Rear upper rear lower cooling fans K erase lamps CMY erase lamps Tray module drive motor TTM tray 4 media transport motor Tray 2 media feed lift motor Tray 3 media feed lift motor Tray 4 feed lift motor 3TM drive motor Waste toner auger motor Printhead shutter motor Standard exit shift motor 3 During the test Motor Running appears on the LCD Note If available Forward and Reverse options appea
322. ling fan A Remove the two screws securing the transfer belt drive motor cooling fan A to the machine Remove the transfer belt drive motor cooling fan A NOOO fF 4 78 Printer Service Manual 5057 XXX Transfer belt drive motor assembly removal k Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the transfer belt drive motor cooling fan See Transfer belt drive motor cooling fan removal on page 4 78 Disconnect the connector from the transfer belt drive motor assembly A Remove the transfer belt drive motor assembly A Switch transfer belt access door interlock removal k Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the transfer belt drive motor cooling fan See Transfer belt drive motor cooling fan removal on page 4 78 Disconnect the connector from the switch
323. ll not function Move the image density sensor assembly to the center position 1 Open the Printer front door 2 Remove the waste toner cartridge 3 Remove the printhead cleaning tool from the printer front door 4 Place the hook on the end of the printhead cleaning tool into the front of the image density sensor assembly as shown in the diagram 5 Remove the screw as shown in the diagram 6 Push the image density sensor assembly toward the center of the machine as far as it will go using the printhead cleaning tool 7 Gently detach the printhead cleaner from the image density cleaning assembly 8 Replace the waste toner cartridge 9 Close the printer front door assembly Screw y Printhead cleaning tool E Image density sensor assembly Have all of the above steps been performed Go to step 2 Repeat step 1 Repair information 4 215 5057 XXX Step Check Yes No 2 Perform the center setup Move the image Go to step 3 density sensor 1 Enter the Diagnostics Menu back to its original 2 Select ENGINE ADJUST position 3 Select RegCon adjust Thecolor 4 Select Control setup cycles registration 5 Select Center setup RegCon Does the above test pass procedure is now complete 3 The image density sensor is not properly set in the center Go to step 2 Repeat step 3 position Ensure the image density is placed in the c
324. ll HP is used to detect the home position of the 2nd transfer roll assembly Transfer belt Sensor 2nd transfer roll retract HP 2nd transfer roll assembly 2nd transfer roll retract motor Printhead assembly The printhead scans the four drum surface with four laser beams It consists of four components laser diode LD card assembly printhead motor polygon mirror and four start of scan card assemblies 1 LD card assembly generates a laser beam with the four LDs The beam is turned on or off according to a print data signal The printhead contains 4 LD card assemblies for the colors CMY amp K 2 Printhead motor polygon mirror the polygon mirror is mounted to the shaft of the printhead motor and is rotated at a high speed by the printhead motor The mirror rotation shifts the incidence and reflection angles of a laser beam to scan the laser beam in the drum axial direction The laser beam reaches the polygon mirror as it passes through multiple lenses mirrors and windows The laser beam then arrives at the drum surface 3 SOS card assembly when a laser beam hits the SOS sensor on the SOS card assembly the beam is converted to an electrical signal SOS signal and detects the initial position where a scan starts on each line When a laser beam is scanned across the drum surface from one end to the other while turning on and off the beam one line of latent image is created If the scanning by the laser beam is
325. ll assembly can detect whether media exists in the registration path Sensor transparency detect This sensor is used to detect transparency media in order to automatically adjust feed speed charge biases and fuser temperatures Registration clutch The registration clutch transmits the drive force of the K developer transport drive motor to the registration roll assembly Media transport roll assembly The media transport roll assembly feeds paper from tray 2 tray 3 and tray 4 toward the registration roll assembly Registration roll assembly 1 10 Printer Service Manual 5057 XXX The registration roll assembly feeds the media at the precise moment to ensure that printed images are precisely placed The registration roll assembly feeds media from all trays to the transfer belt Registration clutch Sensor he transparency detect Sensor registration Transfer 1st transfer rolls C M Y K Sensor CMY transfer roll retract HP Transfer belt x drive motor 23 Transfer belt cleaning assembly CMY transfer roll retract motor assembly Transfer belt steering motor Transfer belt drive motor assembly This motor is used to rotate the transfer belt Transfer belt cleaning assembly This assembly is used to remove residual toner images from the transfer belt after 2nd transfer and before the next print cycle General information 1 11 5057 XXX Transfer belt unit assembly The tran
326. locks 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 detects by the actuator position whether media in the media tray assembly is lifted When the flag of the actuator unblocks the sensing area of the sensor media level the sensor detects that the media has been lifted Sensor feed out This sensor detects the media just after it is fed from the media feed unit When the flag of the actuator unblocks the sensing area of the sensor feed out the sensor detects that the media is present The sensor feed out is also used as a relay sensor along the media path up to the sensor registration in order for the engine to monitor media location Media feed lift motor media level Sensor media out Media feed unit asm Switch media size Front Tray asm 1 8 Printer Service Manual Multi purpose feeder MPF 5057 XXX The MPF is a mechanical unit suppling media to the printer The driving force from the MPF transport drive motor is transmitted to the MPF feed roll to feed media MPF feed roll The MPF feed rolls feed media set on the MPF and into the printer MPF pick solenoid The MPF pick solenoid transmits the driving force from the MPF transport drive to the MPF feed rolls Sensor MPF media out The sensor MPF media out detects whether media is prese
327. lowing settings are not changed e Display Language general settings Network Ports Menu e Standard USB USB x Menus if an ENA is installed Energy Conserve This menu controls what values appear on the Power Saver menu If Off is selected in the Energy Conserve menu then Disabled appears in the Power Saver menu and Power Saver can be turned off If On is set in the Energy Conserve menu the Power Saver feature cannot be disabled To change this setting 1 Select Energy Conserve from the Configuration Menu 2 Select Back to cancel and return to the Configuration Menu 3 Select d to save the change EVENT LOG Configuration Menu This entry enables you to print a report that contains a limited set of the information that appears in the Diagnostics version of the Event Log report See EVENT LOG on page 3 17 The limited Configuration and the full Diagnostics printed versions of this report display the same panel messages when they print and follow the same layout guidelines To print the Event Log 1 Select EVENT LOG from the Configuration Menu 2 Select Print Log Select Back to return to the Configuration Menu Note An event log printed from the Configuration Menu will not contain debug information or secondary codes for 900 service errors However the event log printed from the Diagnostics Menu does include this information Diagnostic aids 3 27 5057 XXX Paper Prompts When a tray is out of the in
328. ly Go to Upper printer engine card assembly Problem solved removal on page 4 74 905 03 Marking device other1 error Step Check Yes No 1 Perform a POR Replace the upper Problem solved Does the error occur when the power is turned off on printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 905 04 Marking device paper handling error Step Check Yes No 1 Perform a POR Replace the upper Problem solved Does the error occur when the power is turned off on printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 905 05 Marking device other2 error Step Check Yes No 1 Perform a POR Replace the upper Problem solved Does the error occur when the power is turned off on 2 68 Printer Service Manual printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 907 00 Printhead polygon mirror motor error 5057 XXX Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on panties If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Perform a POR Replace the R
329. ly into the printer Re print the defective image Does the error continue 3 Check for obstructions in the area of the media feed Go to step 4 Remove units obstructions Are the media feed unit assembly free from any obstructions 4 Is the printer left door assembly properly and evenly Go to step 5 Open then closed properly close the printer left door assembly 5 Check the 2nd transfer roll assembly for contamination Go to step 6 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear assembly and contamination Go to 2nd transfer roll assembly removal on page 4 35 2 132 Printer Service Manual 5057 XXX Step Check Yes No 6 Check the registration transport roll assembly Go to step 7 Replace e e registration Are all drive rolls on the registration transport roll transport roll assembly free of contamination wear and damage assembly Go to Registration transport roll assembly removal on page 4 36 7 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue card assembly Go to RIP card assembly removal on page 4 71 Diagnostic information 2 133 5057 XXX Media damage Leading edge Trailing edge
330. m the CMY developer drive motor assembly A Release the harnesses from the clamps Remove the two screws securing the CMY developer drive motor assembly A to the machine Remove the CMY developer drive motor assembly A ONO P Clamp 0 ib CMYK PC cartridge drive motor assembly removal Warning Ensure that all four PC cartridges are concealed from all sources of light or damage will occur 1 Remove the four PC cartridges from the machine 2 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 3 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 4 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 4 86 Printer Service Manual 5057 XXX al Remove the 5V LVPS card bracket assembly See 5V LVPS card bracket assembly removal on page 4 83 6 Remove the transfer belt drive motor cooling fan See Transfer belt drive motor cooling fan removal on page 4 78 7 Remove the transfer belt drive motor assembly See Transfer belt drive motor assembly removal on page 4 79 8 Remove the K developer transport drive motor assembly See K developer transport drive motor assembly removal on page 4 92 9 Remove the two connectors from the CMYK PC cartridge
331. main 3 Check the laser beam route Go to step 4 Remove debris Check for debris between the printhead assembly and ae the PC drum assembly Check the four printhead assembly windows for window contamination Is the laser beam route free of debris and the glass window in the printhead assembly free of contamination 4 Check the 2nd transfer roll assembly for contamination Go to step 5 Replace the 2nd and wear transfer roll Is the 2nd transfer roll assembly free of excess wear and assembly contamination Go to 2nd transfer roll assembly removal on page 4 35 5 Replace the transfer belt unit assembly Go to Transfer Go to step 6 Problem solved belt unit assembly removal on page 4 16 Does the problem remain 6 Check the printhead installation Go to step 8 Go to step 7 Is the printhead assembly installed properly with two screws 7 Check the printhead assembly installation Go to step 8 Problem solved Diagnostic information 2 125 5057 XXX Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue Step Check Yes No 8 Check the printhead assembly Go to step 9 Problem solved Replace the printhead assembly Go to Printhead assembly removal on page 4 90 Does the error continue 9 Check the upper printer engine card assembly Problem solved Replace the RIP
332. mbly Go to Duplex media inverter assembly removal on page 4 9 7 Check the duplex drive motor for proper operation Go to step 9 Go to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex drive motor Does the above component operate properly 8 Check the duplex drive motor for proper connection Replace duplex Replace the drive motor connection Is the above component properly connected Go to Duplex drive motor removal on page 4 13 Diagnostic information 2 31 5057 XXX Step Check Yes No 10 Check the duplex media inverter clutch for proper operation A 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Registrat clutch Caution When performing motor tests ensure that all cover and door interlock switches are overridden Does the above component make an audible clicking sound when activated Check the duplex media inverter clutch for proper connection Is the registration clutch properly connected Go to step 11 Replace the duplex media inverter assembly Go to Duplex media inverter assembly removal on page 4 9 Go to step 10 Replace the connection 11 Perform a 2 sided print test Does the error remain Replace the duplex cont
333. mbly Lasssessp rsatekeneesnnadeke task cahednegecree eacedis 1 10 ERE SR EE RE ETE 1 11 Transfer belt drive motor assembly avaavav ane never teen eee 1 11 Transfer belt cleaning assembly 1 11 rss desse se EE SEN 1 12 Transier belt steering Motor core aroti Ee dee e reir AER der 1 12 2na HANSEN rolllassemblY s 5 c c5 civic vn v ken Ses ibero Sige ards 1 12 znd transfer roll retract m ler EEN andre seine ER EE E 1 12 Sensor 2nd fanster e Ne LEET 1 13 se ETT 1 13 PIM FSS Leer Me ek GEL ie ee alke eks Ans 1 16 5057 XXX FUSE EE IA eH Re Raa ead Re nd 1 17 ROAM UNE 1 17 Pressure EEE EE EEE ER 1 18 e gt EE 1 18 TROMS EE Rete Pee PG Meee OEE eee det 1 18 et ue 1 18 R E ie degt fetteg o eee ed ROE iene ee eS 1 18 EEE PT EN ERE EE aches cada 1 18 Et E A 1 18 Standard media exit roll assembly 1 19 Sensor standard DIN TUI ccdcee gees EE E AT ee EE r e ee tee 1 19 standard media Cxi SMEMO EEE EEE Gee Reem BREED 1 19 Duplex diverter Gale 2 422 EIER been Here hbase ws EE EE E ta 1 19 DING cic anaieaaaale 25428856 E TEE 1 19 K developer transport drive motor assembly 1 19 Mile ee ss AGS GRETE oe co ded PERM PPE Adee eae 1 19 CMYK PG cartridge drive motor assembly Aa se dE TRIER E ro EAR 1 20 CMY developer drive motor assembly 1 21 AS ENE VO EECHER 1 21 CMYK toneradd motor assembly 2 226c4sieeeyeneasetod eens Ey kB Pose anew eens 1 21 Waste toner agitator motor assembly ooooococcccccc eet 1 22
334. mbly and the upper printer engine card device assembly assembly and the Go to 980 02 Communication error between printer and RIP card assembly on page 2 92 980 03 Communication error with A communication error has occurred with the upper E finisher controller card printer engine card assembly and the finisher pad finisher assembly controller card assembly Go to 980 03 Communication error with finisher controller card assembly on page 2 92 981 00 Sensor stacker bin level 1 The sensing area of the sensor stacker bin level 1 E E late error or Sensor stacker bin level 2 is not interrupted nor Sensor stacker bin level 2 pa raare period after the stacker bin late error H Refer to the Finisher Service Manual 981 01 Stacker bin upper limit error The sensing area of the sensor stacker bin upper T limit is not interrupted when the stacker bin raises SS finisher to its uppermost limit Refer to the Finisher Service Manual 981 02 Stacker bin lower limit error The stacker bin lowers beyond the specified lower Service finisher limit within the specified time error Refer to the Finisher Service Manual 982 00 Sensor front tamper HP late The sensing area of the sensor front tamper HP is E error not interrupted when the front tamper starts moving T finisher to the home position Refer to the Finisher Service Manual 2 14 Printer Service Manual 5057 XXX Error code or message Error contents Description Action
335. middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 Remove the E clip securing the shaft A to the machine Remove the shaft A Remove the printer left door damper idler gear B Remove the screw securing the printer left door damper C to the machine Remove the printer left door damper C 00 JO Om P ON Le A B Replacement warning When replacing the printer left door assembly D ensure that the black lines are aligned on the damper assembly C or the door will not properly operate Black line Repair information 4 29 5057 XXX Replacement warning When replacing the printer left door assembly D ensure that the duplex media exit turn guide E is held in its upper most position or the printer left door assembly D will not close properly Sensor media on belt removal 1 Open the printer left door assembly 2 Remove the screw securing the sensor media on belt A to the machine 3 Disconnect the connector from the sensor media on belt A 4 Remove the sensor media on belt A gt KES EG AY IA 4 30 Printer Service Manual 5057 XXX 2nd transfer roll retract cam assembly removal k 11 Remove the 2nd transfer roll assembly See 2
336. moval 1 Remove the media tray assembly 2 Move the feed unit front guide A toward the front in the direction of the arrow 3 Release the hook securing the feed roll B to the shaft C 4 Remove the feed roll B Note Do not touch the rubber surface of the feed roll B Front Replacement note Before re installing do not touch the rubber surface of the feed roll B 4 190 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM feed roll one way clutch removal 1 Remove the media tray assembly 2 Remove the feed roll See 1X 500 sheet drawer 1TM feed roll removal on page 4 190 3 Remove the feed roll one way clutch A from the shaft B Front Repair information 4 191 5057 XXX 1X 500 sheet drawer 1TM one way 22 tooth removal 1 Remove the media tray assembly 2 Remove the feed roll See 1X 500 sheet drawer 1TM feed roll removal on page 4 190 3 Remove the feed roll one way clutch See 1X 500 sheet drawer 1TM feed roll one way clutch removal on page 4 191 4 Remove the feed roll one way gear 22 tooth A Front 4 192 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM separation roll one way friction clutch removal 1 Remove the media tray assembly 2 Remove the separation roll See 1X 500 sheet drawer 1TM separation roll removal on pa
337. moval on page 4 77 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Tray 2 media type mismatch error Step Check Yes No 1 Check the media tray assembly 2 for the correct media Go to step 2 Install the correct type media Does the above tray contain the correct type of media 2 Check the media tray assembly 2 for the transparencies Ensure that the Go to step 3 Does the media tray 1 assembly contain transparencies media tray assembly is supposed to be configured for transparencies or replace them with standard media Diagnostic information 2 53 5057 XXX Step Check Yes No 3 Check the sensor transparency detect for proper Go to step 5 Go to step 4 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Transparency detect Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor transparency detect for proper Replace the Replace the connection sensor connection Is the above component properly connected De Go to Sensor transparency detect removal on page 4 38 5 Perform a POR Replace the lower Problem solved Does the error remain when the power is turned off on eee i card Go to Lower pr
338. move the media tray 2 assembly Remove the media tray 3 assembly Remove the media tray 4 assembly Place the right side of the drawer down Remove the three screws securing the caster A Remove the caster A OO TROND 3X 500 sheet 3TM media feed unit assembly removal tray 4 Remove the media tray 4 assembly Open the 3TM left door assembly Remove the two screws securing the two support straps A to the machine Release the harness from the clamp Disconnect the connector from the media feed unit assembly B Remove the two screws securing the media feed unit assembly B to the machine Remove the media feed unit assembly B JORODD Connector 4 156 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM sensor tray 4 feed out removal NOoORWD Open the 3TM left door assembly Remove the two screws securing the two support straps A to the machine Disconnect the connector from the sensor tray 4 feed out B Remove the two screws securing bracket C to the machine Remove the bracket C Release the hooks securing the sensor tray 4 feed out B to the bracket C Remove the sensor tray 4 feed out B alr AE mA oe 85 Be Connector Repair information 4 157 5057 XXX 3X 500 sheet drawer 3TM sensor tray 2 feed out removal 1 Open the 3TM left door assembly 2 Remove the two screws securing b
339. n Disconnect the connector from the K erase lamp assembly B Release the harness from the clamp 10 11 12 Remove the screw securing the bracket C to the machine Lower the transfer belt lift handle A to its lower most position Access to the rear mounting hook on the K erase lamp B can be gained by reaching into the transfer belt unit opening from the right side of the machine 4 62 Printer Service Manual 5057 XXX 13 Gently raise the rear of the K erase lamp assembly B to detach the mounting hook from the machine 14 Remove the K erase lamp assembly B Connector Repair information 4 63 5057 XXX Mounting hook Printhead shutter motor assembly removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 Remove the registration transport roll assembly See Registration transport roll assembly removal on page 4 36 6 Disconnect the connector from the printhead shutter motor assembly A Remove the two screws securing the printhead shutter motor assembly A to the machine
340. n 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Registration clutch Does the above component make an audible clicking sound when activated 9 Check the registration clutch for proper connection Replace the Replace the Is the above component properly connected registration clutch connection Go to Registration clutch removal on page 4 37 2 22 Printer Service Manual 5057 XXX Step Check Yes No 10 Check the Replace the K developer transport drive motor assembly for proper operation A 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select K developer transport drive motor Caution When performing motor tests ensure that all cover and door interlock switches are overridden Does the above component operate properly Go to step 12 Go to step 11 11 Check the Replace the K developer transport drive motor assembly for proper connection Is the above component properly connected Replace the K developer transport drive motor assembly Go to K developer transport drive motor assembly removal on page 4 92 Replace the connection 12 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved removal on page 4 77 200 02
341. n out setup Does the above test pass Perform the Center setup See Center setup on page 4 215 Go to step 2 Analyze the In out setup 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Cycle result values Locate the following new values for the following settings Y Skew adjustment M Skew adjustment C Skew adjustment K Skew adjustment Is the value for all of the above settings a 0 Go to step 3 Go to step 5 Perform the skew rough setup 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles Select Skew rough setup Does the above test pass Go to step 4 Go to step 7 Repair information 4 211 5057 XXX Step Check Yes No Perform the skew rough setup printhead adjustment 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Cycle result values Locate the following new values for the following settings Y Skew adjustment M Skew adjustment C Skew adjustment K Skew adjustment Turn the appropriate printhead adjustment screws located behind the waste toner cartridge the number of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values requi
342. n page 4 166 2 Disconnect the harness from the media feed lift motor A 3 Remove the two screws securing the media feed lift motor to the media feed unit assembly B 4 Remove the media feed lift motor B 4 164 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM one way clutch gear assembly removal 1 Remove the media feed unit assembly See 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 on page 4 162 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 160 2 Remove the harness from the bracket A 3 Remove the three screws securing the bracket A to the media feed unit assembly 4 Remove the bracket A Note The gears may become detached from the bracket A 5 Remove the tray lift one way clutch B Harness 6 Remove the tray lift one way gear 24 tooth C yl FO LA E ANO Harness Replacement note Before re installing ensure all gears and washers are securely attached to the bracket A Repair information 4 165 5057 XXX 3X 500 sheet drawer 3TM media out actuator removal 1 Remove the media feed unit assembly See 3X 500 sheet drawer 3TM media feed unit assembly removal tray 2 on page 4 162 or 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 on page 4 160 2 Release the two bosses on the media out actuator A from the media feed unit assembly 3 Remov
343. n when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 2 48 Printer Service Manual lt Color gt toner cartridge detection error 5057 XXX Step Check Yes No 1 Check the lt color gt toner cartridge for proper installation Go to step 3 Reinstall the Is the above component properly installed lt color gt toner P propery cartridge 2 Replace the lt color gt toner cartridge Got to step 3 Problem solved Does the error continue 3 Check the sensor RFID toner cartridge for the lt color gt Replace the Replace the toner cartridge for proper connection sensor RFID connection Is the above component properly connected toner cartridge Go to Sensor RFID toner cartridge removal on page 4 105 4 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on led card Go to Upper printer engine card assembly removal on page 4 74 5 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Incorrect black toner cartridge error Step Check Yes No 1 Check the black toner cartridge for correct specification Install a new Reinstall the according to product make and model correct correct Is the correct specification black toner cartridge ins
344. nd transfer roll assembly removal on page 4 35 Remove the two screws securing the registration pinch guide assembly A to the machine Remove the registration pinch guide assembly A Remove the screw securing the bracket B to the machine Slide the bracket B to remove it from the machine Move the bracket B toward the front of the machine Detach the bracket B Disconnect the connector from the transfer roll retract motor assembly C Remove the three screws securing the transfer roll retract cam assembly D to the machine Lift the transfer roll retract cam assembly D up Note When removing the transfer roll retract cam assembly D the bushing E pin F and washer may become detached Remove the transfer roll retract cam assembly D Repair information 4 31 5057 XXX Connector NN J x SER N A NW Be A NS VA NAN Replacement note When reinstalling the transfer roll retract cam assembly D ensure that the bushing E pin F and washer are replaced Connector C 4 32 Printer Service Manual 5057 XXX Repair information 4 33 5057 XXX Sensor 2nd transfer roll retract HP removal Remove the 2nd transfer roll assembly See 2nd transfer roll assembly removal on page 4 35 Remove the two screws securing the registration pinch guide assembly A to the machine Remove the registration pinch guide assembly A Remove the screw
345. ne 4 Remove the 1TM controller card assembly A 4 198 Printer Service Manual 5057 XXX Setup and adjustments Sensor ATC setup Step Check Yes No Warning Before installing any new developer unit assembles in the machine record the bar code number located on the sensor ATC for all new developer units being installed Example Sensor C ATC XXX Sensor M ATC XXX Sensor Y ATC XXX Sensor K ATC XXX Using the bar code number recorded from the sensor ATC on each of the new developer unit assemblies in step 1 locate the values for the following settings using the ATC value conversion chart shown after step 4 Sensitivity gradient Sensor output reference Update the following settings using the newly converted values from step 2 for all newly installed developer units Sensitivity gradient Sensor output reference 1 Enter the Diagnostics Menu 2 Touch ENGINE ADJUST 3 Touch ATC Sensor Adjust Values 4 Enter new values 5 Touch Submit Warning This procedure must be done for all new developer unit assemblies being installed or print quality problems may occur Repair information 4 199 5057 XXX Step Check Yes No 4 Note Ensure that all photoconductor unit assemblies are installed before performing this step Finalize the newly updated settings 1 Enter the Diagnostics Menu 2 Touch ENGINE ADJUST 3 Touch ATC Senso
346. ng error tray 3 Step Check Yes No 1 Check the media Go to step 2 Load media i properly Is media loaded in tray 3 properly 2 Check the media tray Replace the media Go to step 3 Are the size sensing mechanisms on the back and the tray assembly bottom of the media tray damaged 2 86 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the tray 3 switch media size for proper Go to step 5 Go to step 4 operation 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 3 5 Select Tray 3 present Does the display on the operator panel change every time the media tray is opened and closed 4 3TM equipped machines check the tray 3 switch media Replace the switch Replace the size for proper connection media size for connection TTM equipped machines check the tray 3 Switch TTM STM media size for proper connection Go to 3X 500 Is the above component properly connected dreven media size removal on page 4 159 Replace the switch TTM media size for TTM 2000 sheet dual input TTM switch TTM media size removal on page 4 129 5 Perform a POR Replace the upper Problem solved e printer engine card the error continue when the power is turned off assembly Go to Upper printer engine card assembly removal on page 4 74 943 01 Sensor media level late error tray 3 Step Check Yes
347. nication error 2 78 924 01 Magenta toner RFID communication error 2 79 924 02 Cyan toner RFID communication error 2 79 924 03 Black toner RFID communication error 2 80 S25 00 Sensor AVG ses sche idad riera cri 2 80 925 01 Sensor MAIC cc ic vase reg babe Stree seder veske 2 81 925 02 Sensor CATG ege Enn A EEN eee ibe EIERE e EES Pets Wied ORES 2 81 925 03 Sensor KATG EE EE 2 82 940 00 MPF tray 5 size sensing error 2 20 c eee eee eee eee eens 2 82 941 00 Switch media size size sensing error tray 1 2 2 60 eee eee 2 83 941 01 Sensor media level late error tray 1 2 cee eee eee 2 84 942 00 Switch media size size sensing error tray 2 0 0 eee eee 2 85 942 01 Sensor media level late error tray 2 0 2 eee eee 2 85 943 00 Switch media size size sensing error tray 3 0c e eee 2 86 943 01 Sensor media level late error tray 3 2 cee eee 2 87 944 00 Switch media size size sensing error tray Ai 2 88 944 01 Sensor media level late error tray 4 0 cee eee 2 89 980 00 Communication error with 1TM 3TM or TTM assembly oooooooomoo 2 90 980 01 HVPS controller communication error 2 91 980 02 Communication error between printer and RIP card assembly 2 92 980 03 Communication error with finisher controller card assembly 2 92 Vii 5057 XXX 1TM 3TM or TTM left door assembly open 2 93 Duplex lett
348. nisher media entrance Bridge unit media bin exit Buffer path Upper media exit Lower media exit Compiler media in De curler cam HP Available Media Path 2 Sensors Sensor Name Diverter gate Front tamper hp Rear tamper hp Media eject clamp hp Media eject shaft hp Available Booklet Path Sensors Sensor Name Booklet end guide HP Booklet knife HP Booklet knife folding Diagnostic aids 3 13 5057 XXX Booklet front tamper HP Booklet rear tamper HP Booklet unit media entrance Booklet unit media exit Booklet bin media present Booklet compiler media present Booklet unit interlock Booklet front low staple Booklet rear low staple Available Punch and Staple Sensors Sensor Name Punch side reg1 Punch side reg2 Punch box set Low staple Punch carriage shift hp Punch unit hp Stapler carriage shift hp Punch cam front Punch hole select After selecting one of the available sensors you can manually toggle the sensor between its two values Open or Closed The LCD displays Open when the sensor is open and Closed when the sensor is closed Press Stop to exit the test BASE SENSOR TEST This test verifies that the sensors in the base machine are operating properly To run the Base Sensor Test Select BASE SENSOR TEST from the Diagnostics Menu The panel d
349. nostics Menu 2 Select DUPLEX TESTS 3 Select Sensor Test 4 Select Duplex wait Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 2 28 Printer Service Manual 5057 XXX Step Check Yes No 4 Check the sensor duplex wait for proper connection Replace the sensor Replace the Is the above component properly connected duplex wait connection Go to Sensor duplex wait removal on page 4 11 5 Check the duplex diverter gate solenoid for proper Go to step 7 Go to step 6 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly 6 Check the duplex diverter gate solenoid for proper Replace duplex Replace the connection media inverter connection Is the above component properly connected assembly Go to Duplex media inverter assembly removal on page 4 9 7 Check the duplex drive motor for proper operation Go to step 9 Go to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex drive motor Does the above component operate pro
350. nput TTM sensor media out removal 00000ee eee eee eee 4 139 2000 sheet dual input TTM feed roll removal 0002 cece eee eee eee 4 140 2000 sheet dual input TTM feed roll one way clutch removal oooooooooooo 4 141 2000 sheet dual input TTM one way 22 tooth removal essen eens 4 142 2000 sheet dual input TTM separation roll one way friction clutch removal 4 143 2000 sheet dual input TTM separation roll removal 002 eee eee ee eee 4 144 2000 sheet dual input TTM pick roll removal 4 146 2000 sheet dual input TTM left door assembly removal 4 147 2000 sheet dual input TTM switch TTM left door interlock removal 4 148 2000 sheet dual input TTM tray 3 lift gear assembly removal oooooooooo 4 149 2000 sheet dual input TTM tray 4 lift gear assembly removal oo oooooooo 4 149 2000 sheet dual input TTM tray lift coupling assembly removal 4 150 2000 sheet dual input TTM tray module drive motor assembly removal 4 150 2000 sheet dual input TTM TTM tray 4 transport motor removal 4 152 2000 sheet dual input TTM TTM controller card assembly removal 4 152 3X 500 sheet drawer STM removalS oooccoococcocno eee 4 153 3X 500 sheet drawer 3TM top cover removal 000 cece eee e eee eee 4 153 3X 500 sheet drawer 3TM
351. ns portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pieces de rechange non agr es e Les consignes d entretien et de r paration de ce produit s adressent uniquement a un personnel de maintenance qualifi e Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Norme di sicurezza e La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non amp responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti e Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona amp pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodott
352. nsfer roll assembly removal on page 4 35 5 Replace the transfer belt unit assembly Go to Transfer Go to step 6 Problem solved belt unit assembly removal on page 4 16 Does the problem remain 6 Replace the four developer units and four developer Go to step 7 Problem solved carriers Go to Developer unit assembly removal on page 4 53 and Developer carrier removal and replacement on page 4 54 Does the problem remain 7 Check the developer transfer roll HVPS card assembly Go to step 8 Problem solved Replace the developer transfer roll HVPS card assembly Go to Developer transfer roll HVPS card assembly removal on page 4 99 Perform a print test Does the problem remain Diagnostic information 2 119 5057 XXX Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue card assembly Go to RIP card assembly removal on page 4 71 Step Check Yes No 8 Check the printhead assembly Go to step 9 Problem solved Replace the printhead assembly Go to Printhead assembly removal on page 4 90 Does the error continue 9 Check the upper printer engine card assembly Replace the RIP problem solved 2 120 Printer Service Manual Vertical stripes process direction Leading edge Trailing edge 5057 XXX
353. nt on the MPF Sensor MPF media width The MPF side guides detects the width length in the main scanning direction of media on the MPF MPF pick solenoid Sensor MPF media wi Media size EE JE dth y MPF pick rolls Sensor MPF media out The following table details the standard paper and envelope sizes supported by the Lexmark C930 C935 and options Media Width Length A4 210 mm 297 mm A5 148 mm 210 mm A3 297 mm 420 mm JIS B5 182 mm 257 mm JIS B4 257 mm 364 mm Letter 8 5 inches 11 inches Tabloid 11 inches 17 inches Legal 8 5 inches 14 inches Executive 7 25 inches 10 5 inches General information 1 9 5057 XXX Media Width Length Folio 8 5 inches 13 inches Statement 5 5 inches 8 5 inches Universal 140 to 297 mm 98 4 to 432 mm 5 5 to 11 7 inches 3 9 to 17 inches MPF only 105 to 305 mm 148 to 482 mm 4 1 to 12 inches 5 8 to 19 inches 7 3 4 Envelope 98 4 mm 190 5 mm 3 875 inches 7 5 inches 10 Envelope 104 8 mm 241 3 mm 4 12 inches 9 5 inches DL Envelope 110 mm 220 mm 4 33 inches 8 66 inches CS Envelope 162 mm 229 mm 6 38 inches 9 01 inches Other Envelope 89 mm to 297 mm 3 5 to 11 7 inches 98 4 to 431 mm 3 8 to 17 inches Transparencies Letter and A4 8 5 inches 210 mm 11 inches 297 mm Registration Sensor registration The sensor registration is located just before the registration ro
354. nting conos rs seas eer Led eee ken breene see 3 28 5057 XXX Tray Low Message c aecenagiritanrceeea tags dhe RR ERE Sodas ES e 3 29 Exiting Configuration Men EE 3 29 Repair information rr RPR 4 1 Handling ESD sensitive pals gcc ee caged caricia da a SRO EREE ia ae we 4 1 ete ETT 4 2 Before starting Service WOM aasaasar saa daaer ska er eee EE A AAA 4 2 Printer front door assembly removal 2 c0ccs ccc ence eed ie attr ke dama eee kaka 4 3 Right cover assembly removal is seh Eege cine eas a Eten had 4 4 Top cover assembly remn v e ae EEN A AAA AAA RR 4 4 Rear cover assembly removal icsccccca dads stasis EELER RE baket EELER kb 4 5 Rear left middle cover removal Lasss aksisspaksksker saks kaka E Pee GE RE PERE bike 4 6 Rear left upper cover removal ee EIERE NIR E REIS EELER EIER weed ees die ee eee 4 7 Printer left lower door assembly removal 4 8 MPF feed unit assembly removal 4 8 Front left cover removal 2025 mias ira rs e DHS A AR bd 4 9 Duplex media inverter assembly removal oocococccccncon eee eee 4 9 Duplex unit assembly rem val na REES EELER EEEEEEE EE EES E 4 10 Sensor duplex Wall At erg r E e aa iia 4 11 Switch duplex left door interlock removal 0000 eee eee eee eee eee 4 11 Duplex media exit turn guide removal ooooococcnccncncn eee e eneren meme 4 12 Duplex drive motor feMOVal ssciciorioma a a dd ceed AR AAN i 4 13 Duplex controller card assembly removal oococcoccnccn eee e
355. nual 281 03 Sensor bridge unit media Media remains on the sensor bridge unit media Paper jam exit static jam exit Refer to the Finisher Service Manual 281 04 Sensor bridge unit exit bin Sensor bridge unit exit bin is not turned on within Paperjam late jam the specified time after the sensor bridge unit per J media entrance is turned on Refer to the Finisher Service Manual 281 05 Sensor bridge unit exit bin Sensor bridge unit exit bin is not turned off within Paper jam lag jam the specified time after the sensor bridge unit exit per bin is turned on Refer to Finisher Service Manual 281 06 Sensor bridge unit exit bin Paper remains on the sensor bridge unit exit bin Paper jam static Jam Refer to the Finisher Service Manual 282 00 Sensor finisher media The media is late reaching the sensor finisher Paperjam entrance late jam media entrance within the specified time after per J reaching the sensor bridge unit media exit Refer to the Finisher Service Manual 282 01 Sensor finisher media Paper remains on the sensor finisher media Paper jam entrance static jam entrance Refer to the Finisher Service Manual 283 00 Sensor buffer path late jam The media is late reaching the sensor buffer path Paperjam within the specified time after reaching the sensor per finisher media entrance Refer to the Finisher Service Manual 283 03 Sensor buffer path static Paper remains on the sensor finisher buffer path Paper
356. number mach FRU 1 40X3679 4 1 Media feed unit assembly 2 40X3687 4 1 Media out actuator 3 40X3688 30 1 Sensor tray media out 4 40X3688 30 1 Sensor tray media level 5 40X3684 4 1 Media feed lift motor 6 40X0888 6 1 Bushing 6 mm 7 40X3686 4 1 Media tray lift one way gear 8 40X3685 4 1 Media tray lift one way clutch 9 40X4086 4 2 Separation roll friction clutch 10 40X3689 2 1 Feed unit roll kit e Feed roll 2 e Pick roll 2 e Separation roll 2 11 40X3690 4 1 Feed roll one way clutch 12 40X3691 4 1 Feed roll one way gear 22T 13 40X0952 6 1 Bushing 6 mm Parts catalog 7 11 5057 XXX Assembly 9 MPF feed unit assembly 1 Asm index Part number FRUs mach Units FRU Description 40X4079 MPF feed unit assembly this comes assembled 7 12 MFP Service Manual 5057 XXX Assembly 10 MPF feed unit assembly 2 ae ge Gen Gg Description 1 40X4079 1 1 MPF feed unit assembly this comes assembled 2 40X3688 30 1 Sensor MPF media out 3 40X3709 1 1 MPF media out actuator 4 40X0755 1 1 MPF pickup spring Parts catalog 7 13 5057 XXX Assembly 11 MPF feed unit assembly 3 7 14 MFP Service Manual her aie d PRU Description 1 40X4079 1 1 MPF feed unit assembly this comes assembled 2 40X3711 1 2 MPF pick roll kit e MPF pick roll 2 3 40X1381 4 1 Bushing 8 mm 5057 XXX Assembly 12
357. nvironment vas SEELEN ceca AA EEE AAA sea AMEE 1 1 EI EEE EE ER Soe ob pelos 1 1 Size and weight without finisher 0 20 cece eee eee eee eee eee 1 1 Printer OVERVIEW ci nerder MOREE ER Se SEEN OS aoe sense Feie b e 1 2 Basic madel i A ee ee ee AA 1 2 Configured model EE t ment 1 3 PHINIGEINGOLY ss ties RE chatted Cee vane tu cise ea hee AA AAA A 1 4 En EE NG 1 4 Media Trans DOM POUT aar ech Spacey dike Er Sk Mi ORE RR a 1 4 SEP paper Dal tous gt co Ae seed sd eek baade 1 5 SEP SPSS sk eee EE Acid Saeed TK are See 1 6 Functions of main COMPONEN S ses cogs a EELER EE Lek A 1 6 Media tray assembly EEE Ar 1 6 Rear eC GUJE EE EEE SEE EE EP EE 1 7 ERHALE EE 1 7 SONO e EE AA rd 1 7 Media EE 1 7 Detection ol Media SZE gasser tags ae Seca Paesa dave a cased eaoude wed 1 7 Media feed se EE 1 7 Media FEET MEET saue rar vater Saeed ke be EEE bene ends Reo ad 1 8 KS EE 0 gr EEE ETE ENE EE 1 8 Se AE EE 1 8 Sensor 0 EE ERE ba 1 8 Se EEE EEE EE EEE 1 8 Multi purpose feeder MPF 025 oa seus rr a ER EE EES EES E EELER EE ELSE 1 9 MPF teed tolllscdcncouscedqeed EE 1 9 WPF lee ie EE EE 1 9 Sensor MPF media EE 1 9 Sensor Me Media WIM EE EE EE OE EEE 1 9 NEE ee EE 1 9 ER EL EE ARERR ERS EARLIER AGS OES a 1 10 SENSO E LEE dde 1 10 Sensor iransparency G66 see ass gane ae kar Senke korka Rees RoR beer eee 1 10 Registration Es De OE EEE 1 10 Media tansport FO ASSEMBIY vergeet ege me akse deem dets ee 1 10 MEQ aon roll ss
358. o Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Safety information XXI 5057 XXX Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspringlichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine gefahrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein muB Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del disefio original y componentes especificos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Exi
359. o information is printed on the test page To run the Feed Test 1 Select FINISHER TESTS from the Diagnostics Menu 2 Select Feed Tests You cannot specify the output bin to which the device will feed the test page Once begun the Feed Test cannot be canceled No buttons are active during the test During this test Feed Test Running appears on the LCD Sensor Test Finisher This test verifies that the sensors in the finisher are operating properly To run the Sensor Test 1 Select FINISHER TESTS from the Diagnostics Menu 2 Select Sensor Test The LCD displays the option s name in the header row and each of the option s sensors below the header row You must select a specific sensor from this list in order to view and toggle the sensor s state After selecting a specific sensor Sensor Name Testing appears on the LCD with the sensor s current state below this message The tables below indicate which sensors are available for testing 3 12 Printer Service Manual 5057 XXX Available Cover and Door Sensors Sensor Name Door G finisher front Surface H eject cover Cover F bridge unit top Available Bin Level Sensors Sensor Name Finisher upper media bin full Stacker bin level1 Stacker bin level2 Stacker bin upper limit Stacker bin no media Stacker bin level encod Available Media Path 1 Sensors Sensor Name Bridge unit media entrance Bridge unit media exit Fi
360. o submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Diagnostic aids 3 21 5057 XXX PRO CON ATC sensor setup and adjust This procedure is used to adjust the following Sensor C ATC Sensor M ATC Sensor Y ATC Sensor K ATC Select PRO CON and select Then Select Appears on the LCD ATC Sensor Adjust values Sen Grad SNR Y Registration values appear on the LCD If required reset the values and Select y to submit the changes Sen Grad SNR M Registration values appear on the LCD If required reset the values and Select y to submit the changes Sen Grad SNR C Registration values appear on the LCD If required reset the values and Select y to submit the changes Sen Grad SNR K Registration values appear on the LCD If required reset the values and Select y to submit the changes SNR Output Ref TC Y Registration values appear on the LCD If required reset the values and Select y to submit the changes SNR Output Ref TC M Registration values appear on the LCD If required reset the values and Select y to submit the changes SNR Output Ref TC C Registration values appear on the LCD If required reset the values and Select y to su
361. o to 2nd transfer roll assembly removal on page 4 35 4 Check the sensor fuser exit for proper operation Go to step 6 Go to step 5 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Fuser exit Caution The area around the actuator is very hot Allow the fuser area to cool before proceeding Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 5 Check the sensor fuser exit for proper connection Replace the Replace the Is the above component properly connected sensor fuser exit connection Go to Sensor fuser exit removal on page 4 25 6 Check the duplex diverter gate solenoid for proper Go to step 8 Go to step 7 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Duplex diverter gate solenoid Does the above component operate properly Diagnostic information 2 25 5057 XXX 2 26 Printer Service Manual Step Check Yes No 7 Check the duplex diverter gate solenoid for proper Replace the Replace the connection duplex media connection Is the above component properly connected ge Go to Duplex media inverter assembly removal on page 4 9 8 Check the registration clutch for proper operation Go to s
362. om the sensor printer left lower door interlock A Connector RIP card cooling fan cover assembly removal NOOR OND A Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the RIP card assembly See RIP card assembly removal on page 4 71 Disconnect the connector from the RIP card cooling fan cover assembly A Remove the four screws securing the controller box top over assembly A to the machine Move the RIP card cooling fan cover assembly A toward the front of the machine Repair information 4 67 5057 XXX 8 Remove the RIP card cooling fan cover assembly A S KE i RO SS Ss d Connector Q Controller box assembly removal NPD IDE Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the RIP card assembly See RIP card assembly removal on page 4 71 Remove the controller box top cover assembly See RIP card cooling fan cover assembly removal on page 4 67 Remove the switch main power See Switch main power removal on page 4 69
363. omponent properly connected 7 Check the media feed lift motor in media tray 3 for Go to step 9 Skip to step 8 proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select Tray 3 media feed lift motor Does the above component operate properly 8 Check the media feed lift motor for proper connection Replace the media Replace the feed lift motor connection Is the above component properly connected Go to Media feed lift motor removal on page 4 109 Diagnostic information 2 39 5057 XXX Step Check Yes No Perform a print test Does the error continue Replace the 1TM controller card assembly or the 3TM controller card assembly or the TTM controller card assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 10 Problem solved 10 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 Problem solved 243 01 Sensor tray 2 feed out late jam feedin
364. on page 4 77 903 03 Developer drive motor error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Check the CMY developer drive motor assembly for proper Go to step 4 Go to step 3 operation A 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor tests 4 Select CMY developer drive motor Caution When performing motor tests ensure that all cover and door interlock switches are overridden Does the above component operate properly 2 60 Printer Service Manual 5057 XXX Step Check Yes No Check the CMY developer drive motor assembly for proper connection Is the above component properly connected Replace the CMY developer drive motor assembly Go to CMY developer drive motor assembly on page 4 86 Replace the connection Perform a POR Does the error occur when the power is turned off on Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved removal on page 4 77 904 00 Sensor transfer belt HP late error Step Check Yes No 1 Reset the transfer belt HP failure lock out condition Go to step 2 Go to step 3 1 Enter the Diagnostics Menu 2 Select Trans belt fail HP 3 Select Trans belt
365. onnected wire or incorrect connection in the power cord e The printer is properly grounded Check the power cord ground terminal The printer is not installed at a place subjected to extreme temperature extreme humidity or rapid changes in temperature The printer is not installed close to water service humidifier heat generating unit fire in a very dusty place or a place exposed to air flow from the air conditioning system The printer is not installed in a place where volatile gas or inflammable gas is generated e The printer is not installed in direct sun The printer is installed on a level and stable surface Media meets specifications and is installed properly e Customer maintenance parts have been replaced at the specified intervals e Check all attached options for proper attachment and electrical connection e Refer to the User s Guide for proper installation Power on Reset sequence The following is an example of the events that occur during the POR sequence Turn the machine on The Lexmark splash screen appears with a progress bar in the center until the code is loaded The scanner exposure lamp flashes several times The fuser cooling fan turns on The fuser unit assembly lamps turn on The RIP card assembly cooling fan turns on Operator panel LED becomes solid The transport motor turns on Sno bebes To enter the diagnostic menu 1 Turn off the printer 2 Press and hold the w and p but
366. or InterlockK Age REES EES rr tanis adipi tiis 1 53 Sensor May 2 te6d Ollt cccpce tere eect lee ated desde eats gamed heen A enes at 1 54 Tray module media transport roll assembly 1 54 Tray NOTE JIS MOG ses age et Sa Bote a bee eres 1 54 ITM controller card assem EE a one 1 54 STED EE ER ER 1 55 Duplex ee AA KST AAA RS EA AG A A 1 56 Layout of media transport patll 2 sc00cdecesaeee aedrra dined ttr E rrine reier 1 57 s Of ain GOMPORGIMS EE EE 1 57 Switch duplex left door Mterlock ccvcisseudencetcadecseceurwesiveeedaduetseeaes 1 57 Sensor dup Wall ass wedge 2oAe o ceded ka Ger Keke REG pea ae 1 57 Duplex media transport Toll ss mbly sscsccccacecresy eeeaseecee ess ee ease desabsade 1 57 Duplex contraller Card SS EE 1 58 DUNS GIVE MOON vacas cantadas ies iras dad 1 58 Tools Fequlred TOS Selge isc ds cand AAA ANDAS AA 1 59 EEE PN TT 1 60 Diagnostic information 383 5 cghscddererceddacseeens e 2 1 SAN EE 2 1 Gontira the Installation Stas ng ei dr bun teececsadars be EE t 2 2 Power on Reset Sequence 6022 6 0 cc IER EES EEN ee tarer ees eens see era wees ee 2 2 To enter the diagnostic Meal cnica canis SARK GREER FRAGA ae 2 2 lt ERE EE 2 3 Serice CHECKS venias EES ORES CHT EELER EE ORE LEDS HORM is Sees Rees 2 20 200 00 Sensor registration late jam 2 20 200 01 Sensor registration lag jam 2 21 20002 Sensorstae am ee e EE riada taa 2 23 200 03 Sensor media on belt late jam 2 2
367. or torn in half The transfer belt cleaning assembly is missing If this error has occurred more than three times it must be reset inside diagnostic mode before troubleshooting can begin or the machine can operate Go to 904 00 Sensor transfer belt HP late error on page 2 61 904 01 Service transfer belt Transfer belt position failure The transfer belt is out of correct position or the transfer belt cleaning assembly is missing Go to 904 01 Transfer belt position failure on page 2 61 904 02 Service transfer belt Sensor transfer belt edge failure The sensor transfer belt edge detect is not detecting the transfer belt edge properly Go to 904 02 Sensor transfer belt edge failure on page 2 62 Diagnostic information 2 9 5057 XXX Error code or Error contents Description Action transfer belt message 904 03 Sensor 2nd transfer roll The sensing area of the sensor 2nd transfer roll Bide retract HP late error retract HP is not interrupted within the specified time when the 2nd transfer roll is moving to the home position Go to 904 03 Sensor 2nd transfer roll retract HP late error on page 2 63 904 04 Service transfer belt Sensor 2nd transfer roll retract HP lag error The sensing area of the sensor 2nd transfer roll retract HP remains interrupted within the specified time when the CMY retract rolls are moving from the
368. ores the size detected by the hardware and treats the input source as a non sensing source The media size can be set by the operator panel or the data stream A5 Statement Due to engine limitations Trays 1 through 4 cannot simultaneously sense A5 and statement size paper The value of this setting determines which of the two paper sizes these trays will sense automatically This setting will apply to all automatic trays but not to the MP Feeder The MP Feeder can support these paper sizes regardless of the value of this setting B5 Executive Due to engine limitations Trays 1 through 4 cannot simultaneously sense executive and JIS B5 size paper The value of this setting determines which of the two paper sizes these trays will sense automatically This setting will apply to all automatic trays but not to the MP Feeder The MP Feeder can support these paper sizes regardless of the value of this setting Panel Menus Selections are to Disable or Enable default operator panel menus To change the value of this setting 1 Select Panel Menus from the Configuration Menu 2 Select Back to cancel and return to the Configuration Menu 3 Select d to save the change PPDS Emulation The value of the PPDS Emulation menu item determines if a device can recognize and use the PPDS data stream The current value of this setting appears in parentheses to the right of the setting on the Configuration Menu screen The following table indicates
369. ould show 900 Service RIP Software Log entries appear in chronological order If additional log entries exist select to view the next log entries Continue following this procedure until you reach the end of the logged entries To view earlier log entries select a Select Back to return to the EVENT LOG Print the Event Log Each page of the printed Event Log report has the title Event Log at the top of each page followed by the model name and serial number The following is a sample of a printed Event Log Model and Event Log Serial number kexmark X8540 fafa XXX XXXX Information Printer information 4 Panel display when error occurred 1 Page count 1 _ Earliest error code HA Next error code 4 mmm As the Event Log report prints Printing EVENT LOG appears on the LCD Clear the Event Log To clear the Event Log 1 Select Event Log from the Diagnostics Menu 2 Select Clear Log Yes and No appears on the menu If you select Yes Deleting EVENT LOG appears on the LCD and erases all Event Log information including information from the printed report Select No to cancel deletion and return to the EVENT LOG menu or select Back to exit Clear Log and return to the EVENT LOG menu Trans Belt HP Fail Clear To perform the Trans Belt Fail Clear Test 1 Select Trans Belt Fail Clear from the Diagnostics Menu 2 Select Trans Belt HP Fail Clear Trans Belt HP Fail Clear Test
370. over 3 40X3826 2 1 Tray module left cover 4 40X3827 1 1 Tray module rear cover 5 40X3823 1 1 Tray module top cover 7 58 MFP Service Manual 5057 XXX Assembly 45 TTM media trays Parts catalog 7 59 5057 XXX Assembly 45 TTM media trays Asm Part FRUs Units Beleeg index number mach FRU p 1 40X3678 3 6 Media tray assembly kit e Media tray assembly e 1 label e 2 label e 3 label e 4 label e Instruction label 40X3830 2 1 Switch TTM media size 3 40X3831 4 1 TTM tray support roll 40X3829 1 3 TTM media tray 4 assembly kit e TTM media tray 4 e 4 label e Instruction label 5 40X3828 1 2 TTM media tray 3 assembly kit e TTM media tray 3 e 3 label e Instruction label 6 40X3677 3 1 Switch media size 7 40X3675 3 1 Media tray catch 8 40X3676 2 1 Media tray slide 7 60 MFP Service Manual 5057 XXX Assembly 46 TTM media tray 3 Parts catalog 7 61 5057 XXX Assembly 46 TTM tray 3 Asm Part FRUs Units Description index number mach FRU 1 40X0711 2 1 TTM tray separation pad 2 40X3832 1 1 TTM tray 3 front cover 3 40X4126 4 1 TTM tray lift idler pulley 4 40X4127 4 1 TTM tray lift idler pulley guide 5 40X4084 4 1 TTM tray 3 lift cable 6 40X0708 2 1 TTM large idler pulley kit e TTM large idler pulley e TTM large idler pulley guide 7 40X3834 2 1 TTM tray 3 slide strip 8 40X3835 2 1 TTM tray 3 slide button 7 62 MFP Service Manu
371. ower supply is cut off Never touch the live parts CAUTION CAUTION The standard finisher weight is 59 kg 130 Ib and requires at least two people to lift it safely The booklet finisher weight is 87 5 kg 193 Ib and requires at least four people to lift it safely Make sure your fingers are not under the finisher when you lift or set it down The MFP weighs approximately 173kg 383 Ib and requires at least four people to lift it safely Make sure your fingers are not under the MFP when you lift or set it down When operating the driving units using the diagnostics or other tools be sure to keep them covered unless otherwise specified When operating the driving units using the diagnostics or other tools never touch the driving units When operating the driving units using diagnostics or other tools be sure to follow the procedures in this manual Servicers should wear a wrist band or the like to remove static electricity from their body grounding their body while working Go to Handling ESD sensitive parts on page 4 1 Note There may be printer error messages that are not contained in this service manual Call your next level support for assistance Diagnostic information 2 1 5057 XXX Confirm the installation status Be sure to check the following items before starting the troubleshooting procedures With the power cord unplugged from the wall outlet check that the cord is free from breakage short circuit disc
372. ower switch actuator 7 7 0 r rrr rrr rrr rrr rrr tee 7 4 Part number index l 7 5057 XXX 40X3787 40X3788 40X3791 40X3792 40X3793 40X3794 40X3795 40X3796 40X3797 40X3798 40X3799 40X3800 40X3801 40X3802 40X3803 40X3804 40X3807 40X3808 40X381 1 40X3812 40X3813 40X3814 40X3815 40X3816 40X3817 40X3818 40X3819 40X3820 40X3820 40X3821 40X3823 40X3824 40X3825 40X3826 40X3827 40X3828 40X3829 40X3830 40X3831 40X3832 40X3834 40X3835 40X3836 40X3838 40X3840 40X3841 40X3842 40X3843 40X3844 40X3845 40X3846 40X3847 40X3848 40X3849 40X3850 40X4031 40X4032 40X4034 40X4035 Switch main power 7 4 Hear blind cover SE BEE E EE cece Stee See ee Ree eee RS eee 7 5 Rear cover assembly 110 V 7 5 Rear cover assembly 220 V ee 7 5 Rear left middle cover e 7 5 Rear leftlower Cover EE Ee EE oo SSE pe i eee ee See eS St ee ee 7 5 Left front cover rrr rrr reer ree 7 5 Rear left uppercover EE ee p se eee maane seer eos eee cece 7 5 Duplex media inverter assembly e 7 19 Printer left door blind cover 7 16 7 20 Duplex unit assembly m gt 7 16 7 20 7 21 Duplex controller card assembly 7 21 Sensor duplex wait mmmeememm 7 21 Duplex drive motor ee ee ne ee sense sees
373. per operation Go to step 9 Skip to step 8 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select Tray module drive motor Does the above component operate properly 8 Check the tray module drive motor for proper Replace the tray Replace the connection module drive motor connection Is the above component properly connected Go to 2000 sheet dual input TTM tray module drive motor assembly removal on page 4 150 or 2000 sheet dual input TTM tray module drive motor assembly removal on page 4 150 Diagnostic information 2 41 5057 XXX Step Check Yes No Perform a print test Does the error continue Replace the 1TM controller card assembly or the 3TM controller card assembly or the TTM controller card assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 10 Problem solved 10 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 Pro
374. perly 8 Check the duplex drive motor for proper connection Replace duplex Replace the drive motor connection Is the above component properly connected Go to Duplex drive motor removal on page 4 13 Diagnostic information 2 29 5057 XXX Step Check Yes No 9 Check the duplex media inverter clutch for proper Go to step 11 Go to step 10 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Registrat clutch Does the above component make an audible clicking sound when activated 10 Check the duplex media inverter clutch for proper Replace the duplex Replace the connection media inverter connection Is the registration clutch properly connected assembly Go to Duplex media inverter assembly removal on page 4 9 11 Perform a 2 sided print test Replace the duplex Problem solved f controller card Does the error remain assembly Go to Duplex controller card assembly removal on page 4 14 Go to step 12 12 Perform a 2 sided print test Replace the lower Problem solved f printer engine card Does the error remain assembly Go to Lower printer engine card assembly removal on page 4 77 231 00 Sensor registration late jam duplex feed Step Check Yes No 1 Check the media position Remove the
375. plays the selected input source in the header row and then displays the name of each of the source s sensors below the header row one to a line You must select a specific sensor from this list in order to view and toggle the sensor s state The table below indicates which sensors are available in each input tray Sensors Input source Feed out Media out Media level 3 Tray X present Tray 1 Yes Yes Yes Yes Tray 2 Yes Yes Yes Yes Tray 3 Yes Yes Yes Yes Tray 4 Yes Yes Yes Yes MP Feeder No Yes No No TFeed out Testing appears on the LCD with the sensor s current state Open or Closed Media out Testing appears on the LCD with the sensor s current state Open or Closed SMedia level Testing appears on the LCD with the sensor s current state Open or Closed Tray X present appears on the LCD with the sensor s current state Open or Closed After selecting a specific sensor you can manually toggle the sensor between its two values Open or Closed The LCD displays Open when the sensor is open and Closed when the sensor is closed If the wrong message is displayed then the sensor must be malfunctioning Press Stop to exit the test OUTPUT BIN TESTS Feed Tests output bins Use these tests to verify that media can be fed to a specific output bin Media is fed from the default input source to the selected output bin No information is printed on the media fed to the output bin because
376. power is turned off assembly Go to Upper printer engine card assembly removal on page 4 74 944 01 Sensor media level late error tray 4 Step Check Yes No 1 Check the media Go to step 2 Load media i properly Is media loaded in tray 4 properly 2 Check the sensor media level tray 4 for proper operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 4 5 Select Media level Does the display on the operator panel change every time the media tray is opened and closed Diagnostic information 2 89 5057 XXX Step Check Yes No 3 Check the sensor media level tray 4 for proper Replace the Replace the connection sensor media connection Is the above component properly connected level Go to Sensor media level removal on page 4 24 4 Check the media feed lift motor tray 4 for proper Go to step 6 Go to step 5 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Tray 4 media feed lift motor Warning The media tray must be opened before performing this test or paper jam may occur Does the above component operate properly 5 Check the media feed lift motor tray 4 for proper Replace the media Replace the connection feed lift motor connection
377. ppear on the LCD If required reset the values and submit Booklet 15 sheet Booklet 15 sheet values appear on the LCD If required reset the values and submit Booklet Fold Pos Fine Adj Booklet Staple Fold Fine Adjust values appear on the LCD If required reset the values and submit Booklet Staple Pos Fine Adj Booklet Staple Fold Fine Adjust values appear on the LCD If required reset the values and submit Finisher Config To perform Finisher Config e Select Finisher Config from the Diagnostics Menu Finisher Config values appear on the LCD If required reset the values and submit Exiting Diagnostics From Diagnostics menu select Back until Exit Diagnostics appears on the LCD Select Exit Diagnostics to perform a POR Diagnostic aids 3 23 5057 XXX Entering Configuration Menu Turn off the printer Turn on the printer POL Available menus Press and hold the Select d and Right Arrow buttons simultaneously Release the buttons after 10 seconds Maintenance Counter Value See Maintenance Counter Value on page 3 24 Reset Maintenance Counter See Reset Maintenance Counter on page 3 25 Black Only Mode See Black Only Mode on page 3 25 Print Quality Pages See Print Quality Pages Configuration Menu on page 3 25 Color Trapping See SIZE SENSING on page 3 25 SIZE SENSING Tray 1 Sensing Tray 2 Sensing Tray 3 Sensing S
378. problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Perform a POR Replace the RIP Problem solved Does the error occur when the power is turned off on card assembly Go to RIP card assembly removal on page 4 71 907 04 SOS internal error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Perform a POR Replace the RIP Problem solved Does the error occur when the power is turned off on card assembly Go to RIP card assembly removal on page 4 71 2 70 Printer Service Manual 907 05 Printhead control error 5057 XXX Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on panties If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Perform a POR Replace the RIP Problem solved Does the error occur when the power is turned off on card assembly Go to RIP card assembly removal on page 4 71 908 00 Waste toner full
379. r s serial number that was assigned by the manufacturer When you select this setting a replica of a keyboard appears on the LCD that enables you to edit the serial number Engine Setting 1 to 4 These settings are used by Engine code ECs to fix field problems Warning Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cannot be changed Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the manufacturer however you may need to reset Configuration ID 1 or Configuration ID 2 when you replace the printer engine card assembly This printer uses two Configuration IDs each of which consists of eight digits The first seven digits in each ID are hexadecimal numbers while the last digit is a checksum of the preceding seven hexadecimal digits Each ID can contain a combination of the digits 0 through 9 and the characters A to F 3 16 Printer Service Manual 5057 XXX If the printer s firmware detects that either of the printer s Configuration IDs has not been defined or is invalid then the following occurs 1 The firmware automatically uses the Configuration IDs defined for the printer s standard model 2 The Configuration ID setting is the only item that appears when you open the Diagnostics menu
380. r A 2 Remove the rear cover A Repair information 4 181 5057 XXX 1X 500 sheet drawer 1TM caster removal 1 Remove the media tray 2 assembly 2 Place the right side of the drawer down 3 Remove the three screws securing the caster A 4 Remove the caster A 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 1 Remove the media tray 2 assembly 2 Open the 1TM left door assembly 3 Release the harness from the clamp 4 Disconnect the connector from the media feed unit assembly A 5 Remove the two screws securing the media feed unit assembly A to the machine 6 Remove the media feed unit assembly A Connector 4 182 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM sensor tray 2 feed out removal 1 Open the 1TM left door assembly 2 Remove the two screws securing bracket A to the machine 3 Remove the bracket A 4 Disconnect the connector from the sensor tray 2 feed out B 5 Release the hooks securing the sensor tray 2 feed out B to the bracket B 6 Remove the sensor tray 2 feed out B Connector Hook Repair information 4 183 5057 XXX 1X 500 sheet drawer 1TM switch media size removal 1 Remove the media tray 2 assembly 2 Open the 1TM front door 3 Disconnect the connector from the switch media size A 4 Remove the screw securing the switch media size A 5 Remove the swit
381. r tray 1 feed out late jam feeding from tray 2 2 37 243 00 sensor tray 3 feed out late jam 2 38 243 01 sensor tray 2 feed out late jam feeding from tray 3 2 40 244 00 sensor tray 4 feed out late jam 2 42 244 01 sensor tray 3 feed out on jam feeding from tray 4 2 44 250 00 sensor registration late jam feeding from the Index l 1 5057 XXX MPF 2 46 841 00 image pipeline ASIC failure 2 56 849 00 hard drive failure 2 57 900 XX RIP card assembly software failure 2 57 903 00 RAM read write check failure 2 58 904 00 NVM data failure 2 61 905 00 NVM read write cannot be executed failure 2 67 907 00 RFID ASIC failure 2 69 908 00 PPM data failure 2 71 911 00 transport motor failure 2 72 918 00 exit 1 media shift HP failure 2 73 920 00 fuser unit assembly on time failure 2 74 924 00 pressure roll thermistor failure 2 78 925 00 fuser operating temperature failure 2 80 2 81 2 82 941 00 media tray 1 lift up no media tray failure 2 83 942 00 media tray 2 lift up no media tray failure 2 85 943 00 tray 3 lift up no tray failure 2 86 944 00 tray 4 lift up no tray failure 2 88 980 03 exit interface card assembly communication failure 2 92 error messages 2TM TTM left door assembly open 2 93 duplex left door assembly open 2 94 media size mismatch in width 2 95 no media in the select media tray 2 96 paper is installed short edge in the media paper tray 2 98 PC cartridge end of life 2 98 printer front door open 2 99 p
382. r Adjust Cycles Does the above test pass The sensor ATC setup is now complete Ensure that the photoconductor unit assemblies are installed before performing this test ATC VALUE CONVERSION CHART Bar code number last 2 digits Sensitivity gradient default value Standard TC output default value 00 526 169 01 572 166 02 617 162 03 663 158 04 708 154 05 753 150 06 799 146 07 844 142 08 889 138 09 934 134 10 526 171 11 572 168 12 617 164 13 663 160 14 708 156 15 753 152 16 799 148 17 844 144 18 889 140 19 934 136 20 527 174 21 572 169 4 200 Printer Service Manual 5057 XXX ATC VALUE CONVERSION CHART Bar code nom ber Sensitivity gradient default value Standard TC output default value last 2 digits 22 617 166 23 663 162 24 708 158 25 753 154 26 799 150 27 844 146 28 889 142 29 934 138 30 527 176 31 572 172 32 617 168 33 663 164 34 708 160 35 753 156 36 799 152 37 844 148 38 889 144 39 934 140 40 527 178 41 572 174 42 617 170 43 663 166 44 708 162 45 753 158 46 799 154 47 844 150 48 889 146 49 934 142 50 526 179 51 572 176 52 617 172 Repair information 4 201 5057 XXX ATC VALUE CONVERS
383. r agitator motor assembly 1 22 electrical components and controller 1 22 exit 1 18 1 19 functions of main components 1 6 bottom plate 1 7 1 45 end guide 1 7 media tray assembly 1 6 rear media guide 1 7 media size 1 9 media transport 1 4 media transport path 1 4 SFP sensors 1 6 media tray assembly 1 7 detection of media size 1 7 media feed unit assembly 1 7 media feed lift motor 1 8 sensor feed out 1 8 sensor media level 1 8 sensor media out 1 8 switch media size 1 8 1 38 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 printhead assembly 1 13 front thermistor 1 18 fuser exit sensor 1 18 heat roll 1 17 heater lamp 1 18 pressure belt 1 18 printhead shutter 1 16 rear thermistor 1 18 thermostat 1 18 registration 1 10 media transport roll assembly 1 10 registration clutch 1 10 registration roll assembly 1 10 sensor registration 1 10 sensor transparency detect 1 10 standard media exit roll assembly 1 19 duplex diverter gate 1 19 sensor standard bin full 1 19 standard media exit shift motor 1 19 transfer 1 11 2nd transfer roll assembly 1 12 2nd transfer roll retract motor 1 12 sensor 2nd transfer roll HP 1 13 transfer belt cleaning assembly 1 11 transfer belt drive motor assembly 1 11 transfer belt steering motor 1 12 transfer belt unit assembly 1 12 xerographic process during a print cycle 1 27 processor 1 1 R removals feed rol
384. r assembly removal on page 4 26 Remove the two screws securing the plate A to the registration transport roll assembly B Remove the plate A Remove the screw securing the sensor transparency detect C to the registration transport roll assembly B Remove the sensor transparency detect C Disconnect the connector from the sensor transparency detect C OMNONRWND 4 38 Printer Service Manual 5057 XXX Waste toner cartridge cover removal NOOB OND A Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Lower the waste toner cartridge cover A to its lower most position Remove the waste toner cartridge Remove the front left cover See Front left cover removal on page 4 9 Remove the C clip securing the waste toner cartridge cover A to the machine Move the waste toner cartridge cover A to the left Remove the waste toner cartridge cover A C clip Waste toner cartridge sensor assembly removal 0 JO Om P oi Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the screw securing the bracket A to the machine Remove the bracket A Disconnect the three connectors from the
385. r denna del r 6ppnad och sp rren ar urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass I 1 I andra l nder uppfyller skrivaren kraven f r laserprodukter av Klass I enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid p 5 milliwatt som arbetar i v gl ngdsomr det 770 795 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass I niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse I 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt i samsvar med kravene i IEC 60825 1 Klasse laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Notices and safety information XVii 5057 XXX Av
386. r is turned off on a SC Go to Lower printer engine card assembly removal on page 4 77 911 01 Transfer belt drive motor cooling fan error Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Check the transfer belt drive motor cooling fan assembly for Replace the Replace the proper connection transfer belt drive connection Is the above component properly connected Ey ling fan Go to Transfer belt drive motor cooling fan removal on page 4 78 3 Perform a POR Replace the lower Problem solved Does the error occur when the power is turned off on o card Go to Lower printer engine card assembly removal on page 4 77 2 72 Printer Service Manual 911 02 Fuser cooling fan lock error 5057 XXX Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on panties If the problem remains go to step 2 2 Check the fuser cooling fan for proper operation Go to step 4 Go to step 3 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Fuser cooling fan Does the above component operate properly 3 Check the fuser cooling fan for proper connection Replace the
387. r on the LCD for selected tests Press Stop to stop the test PRINT TESTS To run the Print Tests 1 Select PRINT TESTS from the Diagnostics Menu 2 Select Input Source to verify that the printer can generate output from that source s media 3 Select Printing Quality Test Pages to view information about the printer s current settings and to test the printer s ability to generate quality output Input source Appears on the LCD Tray 1 Tray 1 Printing Tray 2 Tray 2 Printing Tray 3 Tray 3 Printing Tray 4 Tray 4 Printing MP Feeder MP Feeder Printing Printing Quality Test Pages Printing Quality Test Pages 4 Select Single or Continuous e f Single is selected a single page is printed f Continuous is selected printing continues until Stop is pressed to cancel the test If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope After a Single test has printed or a Continuous test canceled the LCD returns to the Input Source screen 3 6 Printer Service Manual 5057 XXX Input Source Print Test Regardless of the input source selected the printer always generates a simplex version of the Print Test page using its default resolution Print Quality Test Pages This setting enables you to view the values of a broad range of the device s setting
388. r panel assembly 7 4 40X4092 SFP RIP card assembly 7 39 40X4093 100K printer maintenance kit 220V 7 70 40X4098 Printer left door closed actuator 7 17 40X4102 SFP relocation kit 7 70 40X4103 TTM main cable assemlby 7 69 40X4108 3TM main cable assemlby 7 57 40X4109 1TM main cable assemlby 7 47 40X4111 Front left cover errr errr eee eee eee ee eee eee 7 4 40X4112 SFP relocation kit with options 7 70 40X4117 Front locking caster 7 47 7 57 7 69 40X4119 Tray module media transport roll assembly 7 45 7 55 7 65 40X4126 TTM tray lift idler pulley 7 63 40X4126 TTM tray lift pulley 7 62 40X4127 TTM tray lift idler pulley guide 7 62 7 63 40X4141 1TM left door assembly
389. r printer engine card assembly removal on page 4 74 Perform a print test Does the problem remain card assembly Go to RIP card assembly removal on page 4 71 Diagnostic information 2 115 5057 XXX Solid black Check the media path for foreign objects such as staples clips scraps of media Step Check Yes No 1 Check the four PC cartridges for proper installation Go to step 2 Correct and clean Check the PC cartridge connections contaminated Are the PC cartridge connections free of excess wear pins or replace and contamination the appropriate PC cartridge or connector 2 Check the charge roll HVPS card assembly connections Go to step 3 Replace the Is the above component properly connected connecHan 3 Replace the charge roll HVPS card assembly Go to Go to step 4 Problem solved page 4 100 Perform a print test Does the error continue 4 Check the upper printer engine card assembly on page 4 74 Perform a print test Does the error continue Charge roll HVPS card assembly removal on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal Replace the RIP card assembly Go to RIP card assembly removal on page 4 71 Problem solved 2 116 Printer Service Manual Vertical lines and bands process direction Leading edge e PAAR 5057 XXX
390. ra cd eee ee nite same EE EELER SIE Ee 2 107 K PC cartridge nearly exhausted asss a KE cantons te knakk Ek ee eee Re emake oom 2 108 K PE Carriage EE heueede seeing cede hes bieek arkene 2 108 Color toner cartridge nearly empty 0 20 c cece cece eee eee eee 2 109 Color toner CannhdGeGMPly EE EEN 2 110 Image Quality OUD sasaeessassesb kn AAA AAA AA 2 111 Printer Related Troubleshoonng corria det indians aker Sm bk dad coeur EE 2 111 image quality SYMONS area red eg eee Te PTE Re PRES a FA 2 111 mage Quality conri de KRAGE lek RO EE 2 112 Faini pint Low COnwast lt 024 c0cc aeeoanesdweesdbentadentdosstaneseaenns 2 112 SER FE EE PE reen EEE REE 2 114 SOA DIES ca a Se 2 116 Vertical lines and bands process direchon cece eee eee eee eee 2 117 Horizontal white stripes or bands side to side direction 2 ee eee eee 2 119 Veiiieal Stipes EEGENEN snoot re Ee y harmo nu 2 121 Horizontal stripes side to side direcion ERR SEELEN REES anda vekke 2 123 21100 Te EE aed AE ake ine ake A A A A e O 2 125 SEE EEE ER LER EEE EEE POE EN ida 2 127 HE de PEER IA AAA E es 2 128 Background AEE is AA 2 130 EE REESE EE ENE EE EE EE E T 2 132 Media damage EE 2 134 NOTISER saldo Gare 2 136 Fa Eee EE SEE EEE So ds A ER 2 137 EA Ge EEE VEE ede ND EE ED 2 138 geek Tee REE EE 2 139 EE 3 1 Accessing Service MENUS coca cece se Weeds be warms eee cece swede keeper DEG a 3 1 Diagnostics Menus sesionar seine ed kake MESES A eee skalke
391. racket A to the machine 3 Remove the bracket A 4 Disconnect the connector from the sensor tray 2 feed out B 5 Release the hooks securing the sensor tray 2 feed out B to the bracket B 6 Remove the sensor tray 2 feed out B Connector 4 158 Printer Service Manual 5057 XXX 3X 500 sheet drawer 3TM switch media size removal Note This removal procedure may be applied to media tray 2 3 and media tray 4 assemblies Remove the media tray 2 assembly Remove the media tray 3 assembly Remove the media tray 4 assembly Disconnect the connector from the appropriate switch media size A Remove the screw securing the appropriate switch media size A OO OO P Co b Remove the appropriate switch media size A Rear Connector NS LAA Repair information 4 159 5057 XXX 3X 500 sheet drawer 3TM media feed unit assembly removal tray 3 Remove the media tray 4 assembly Open the 3TM left door assembly Remove the two screws securing the two support straps A to the machine Release the harness from the clamp Disconnect the connector from the media feed unit assembly B Remove the two screws securing the media feed unit assembly B to the machine Remove the media feed unit assembly B NOOR GO M Boss Cc 4 160 Printer Service Manual 5057 XXX
392. ration IDs select Submit The printer validates both IDs If either ID is invalid the printer posts Invalid ID discards any changes and displays the original Configuration IDs If both IDs are valid the printer automatically returns to the PRINTER SETUP menu EVENT LOG The exact number of events recorded in the Event Log will vary since each event requires a different amount of storage space When the Event Log requires more space to record an event it overwrites the oldest currently logged event s and inserts the new event into the first log position Consecutive log entries may be identical if the same event occurred twice in a row The Event Log records the following types of events e All 9xx Service Errors e 2xx Paper Jams Maintenance Count Resets e NV Resets and various types of JFFS partition formats Select EVENT LOG from the Diagnostics Menu and the following options are displayed Display Log Print Log Clear Log Display the Event Log Note The displayed version of the Event Log shows only a subset of the information contained in the Diagnostics version of the printed Event Log For the most comprehensive information about each logged event print the Event Log See Print the Event Log on page 3 18 Select Display Log Diagnostic aids 3 17 5057 XXX Each logged event is identified by the text that appeared when the event occurred For instance if the log recorded a 900 Service Error the Display Log w
393. ration Menu 3 Press d to save the change Exiting Configuration Menu Press a or w until Exit Config Menu appears on the LCD Select Exit Config Menu Diagnostic aids 3 29 5057 XXX 3 30 Printer Service Manual 5057 XXX 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic ESD To prevent damage to ESD sensitive parts use the following instructions in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of
394. ray 3 assembly 2 Remove three screws securing the tray 3 front cover A to media tray 3 assembly B 3 Remove the tray 3 front cover A 4 Remove the four screws securing the bracket C to the media tray 3 assembly B 5 Remove the bracket C Repair information 4 117 5057 XXX 2000 sheet dual input TTM tray 3 rear cable assembly removal 1 2 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove the tray 3 front cover See 2000 sheet dual input TTM tray 3 front cover removal on page 4 117 Remove the E clip with a prying tool securing the front lift cable pulley A to the tray lift shaft assembly B Gently move the tray lift shaft assembly B toward the rear of the tray and detach the rear bushing C from the frame Note Do not remove the front lift cable pulley A or the front lift cables will become detached Move the rear portion of the tray lift shaft assembly B away from the frame 4 118 Printer Service Manual 5057 XXX 8 Move the rear lift cable pulley D toward the rear of the tray to release the two tray 3 rear cables E from the tray lift sh
395. ray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM media tray 4 assembly removal on page 4 116 Remove the tray 4 media transport assembly See 2000 sheet dual input TTM TTM tray 4 media transport assembly removal on page 4 121 Remove the media feed unit assembly See 2000 sheet dual input TTM media feed unit assembly 2 removal on page 4 130 2000 sheet dual input TTM media feed unit assembly removal tray 3 on page 4 130 or 2000 sheet dual input TTM media feed unit assembly removal tray 4 on page 4 125 Release the two bosses on the media out actuator A from the media feed unit assembly Remove the media out actuator A gt Lower view Repair information 4 137 5057 XXX 2000 sheet dual input TTM sensor media level removal 1 Remove the tray module left cover See 2000 sheet dual input TTM tray module left cover removal on page 4 112 2 Remove the media tray 3 assembly See 2000 sheet dual input TTM TTM media tray 3 assembly removal on page 4 117 3 Remove the media tray 4 assembly See 2000 sheet dual input TTM TTM
396. ray module left Does the display on the operator panel change every time the actuator on the above switch is operated 3 Check the switch tray module left door interlock for Replace the switch Replace the proper connection tray module left connection Is the above switch properly connected oe ED Go to 1X 500 sheet drawer 1TM switch tray module left door interlock removal on page 4 197 4 Perform a POR Replace the 1TM Problem solved Does the error continue when the power is turned off SE on assembly Go to 1X 500 sheet drawer 1TM 1TM controller card assembly removal on page 4 198 Go to 3X 500 sheet drawer 3TM 3TM controller card assembly removal on page 4 178 or Go to 2000 sheet dual input TTM TTM controller card assembly removal on page 4 152 Go to step 5 Diagnostic information 2 93 5057 XXX Step Check Yes No Perform a POR Does the error continue when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal Problem solved on page 4 74 Duplex left door assembly open Step Check Yes No 1 Check the duplex left door for proper operation Go to step 2 Replace the duplex Does the above component open and close properly unit assembly Go to Duplex unit assembly removal on page 4 10 2 Check the switch duplex le
397. re turning the screw Counter Clockwise EG Y Skew adjustment 10 Turn the screw CW 10 clicks EG Y Skew adjustment 10 Turn the screw CCW 10 clicks Printhead adjusting screw Have the appropriate printhead adjustment screw been adjusted Re perform step 1 If the test fails then replace the printhead See Printhead assembly removal on page 4 90 Once the printhead is replaced then re perform the entire RegCon procedure See Color registration RegCon on page 4 203 Go to step 7 4 212 Printer Service Manual 5057 XXX Step Check Yes No 5 Perform the In out skew setup printhead adjustment Go to the Center Adjust the e e setup rinthead 1 Enter the Diagnostics Menu adjustment screw 2 Select ENGINE ADJUST See Center then go to Center 3 Select RegCon adjust pase 4 215 setup 4 Select Control setup cycles i See Center 5 Select Cycle result values setup on page 4 215 Locate the following new values for the following settings Y Skew adjustment M Skew adjustment C Skew adjustment K Skew adjustment Turn the appropriate printhead adjustment screws located behind the waste toner cartridge the number of clicks rotation until a snap sound is heard and felt based on the above settings values require turning the screw Clockwise values require turning the screw Counter Clockwise EG Y Skew adjustment 10 Turn t
398. rea of the printer to make the sensor toggle between Open and Closed If the wrong message is displayed then the sensor must be malfunctioning Press Stop to cancel the test INPUT TRAY TESTS Feed Tests Use this test to observe the paper path of media as it passes through the printer No information is printed on the feed test pages since the laser is not engaged during this test You can perform the feed test using media from any installed input source All pages used during the feed test are dropped into the default output bin To run the Input Tray Tests 1 Select INPUT TRAY TESTS from the Diagnostics Menu 2 Select the input source Input source Appears on the LCD Tray 1 Tray 1 Feeding Tray 2 Tray 2 Feeding Tray 3 Tray 3 Feeding Tray 4 Tray 4 Feeding MP Feeder MP Feeder Feeding 3 Select either Single or Continuous e Single Feeds one sheet of media from the selected source Diagnostic aids 3 9 5057 XXX e Continuous Media continues feeding from the selected input source until Stop is pressed Sensor Test input tray This test is used to verify that a specific input tray s sensors are working correctly To run the Input Tray Sensor Test 1 Select INPUT TRAY TESTS from the Diagnostics Menu 2 Select Sensor Test After selecting Sensor Test the LCD displays each installed input source one source per line When you select an input source the LCD dis
399. removal akoONdD o 10 11 12 13 14 15 Remove the duplex unit assembly See Duplex unit assembly removal on page 4 10 Remove the fuser unit assembly See Duplex controller card assembly removal on page 4 14 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 82 Remove the CMYK transfer HVPS card assembly See CMYK transfer HVPS card assembly removal on page 4 90 Remove the K developer transport drive assembly See K developer transport drive motor assembly removal on page 4 92 Remove the E clip securing the shaft A to the K developer transport drive assembly B Remove the busing C Remove the shaft A Disconnect the connector from the K developer clutch D Remove the K developer clutch D Re Connector Clutch alignment boss alignment notch AC drive card bracket assembly r
400. removal on page 4 17 Repair information 4 19 5057 XXX 5 Remove the screw securing the bracket A to the standard media exit bin shift assembly 6 Remove the bracket A 7 Release the hooks securing the switch printer left door interlock B to the bracket A 8 Remove the switch printer left door interlock Hooks 4 20 Printer Service Manual 5057 XXX Sensor standard media bin full removal 1 OD OON DUH Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Warning Ensure that the rear left middle cover is removed before removing the rear left upper cover or damage will occur Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the rear left upper cover See Rear left upper cover removal on page 4 7 Remove the standard media exit bin full actuator See Standard media exit bin full actuator removal on page 4 18 Remove the screw securing the bracket A to the machine Remove the bracket A Release the hooks securing the sensor standard bin full B to the bracket A Remove the sensor standard bin full B Disconnect the connector from the sensor standard media bin full B B Media feed unit assembly 1 removal 1 2 3 4 5 Remove the media tray 1 Remove the printer left lower door assembly See Printer left lower door assembly removal on page 4 8
401. repeated while rotating the drum a two dimensional image is created The resolution in the scanning direction from right to left is determined by the rotational speed of the printhead motor depending on how quickly the laser is adjusted The resolution in the process direction from top to bottom is determined by the rotational speed of the printhead motor The higher the scanning speed becomes the sooner the scanning of the next row can be started General information 1 13 5057 XXX Conceptual diagram of an image created by scanning Paper Path 600 dots inch 1 14 Printer Service Manual ee Printhead 600 sc ans inch 5057 XXX Y Laser Path SC Sensor Polygon Mirror Y start of scan M Laser Path Polygon Mirror M start of scan General information 1 15 5057 XXX EN C drum C Laser Path Sensor C start of scan Polygon Mirror Corn drum K Laser Path Sensor K start of scan Polygon Mirror Printhead shutter The printhead shutter tightly covers the slit glass through which laser beams from the printhead pass to write the four drums To prevent the seal glass from becoming dirty the shutter stays closed except when laser beams are written onto the drums The printhead shutter motor assembly is used to prevent contamination from obstructing the printhead slit glasses The printhead shutters for yellow magenta cyan and black are opened or clo
402. rinter left door open 2 100 printer left lower door open 2 101 scheduled maintenance required 2 102 2 103 standard bin 1 full 2 103 toner cartridge RFID failure 2 103 toner cartridge set failure 2 104 ESD sensitive parts 4 1 exiting Configuration Menu 3 29 exiting Diagnostics Menu 3 23 l image quality trouble 2 111 blank print no print 2 114 faint print low contrast 2 112 image quality 2 112 solid black 2 116 troubleshooting 2 111 vertical blank lines white stripes in media transport direction 2 117 image quality troubles after image 2 128 background fog 2 130 horizontal band printheads out 2 119 horizontal stripes 2 123 media damage 2 134 no fuse 2 136 2 137 partial lack 2 125 skew 2 132 spots 2 127 vertical stripes 2 121 l 2 Printer Service Manual L lubrication specification 6 2 maintenance scheduled 6 2 memory 1 1 menus 2 140 models 1 1 O operator panel understanding 2 140 options and features description 1 2 P parts catalog miscellaneous 7 70 preventive maintenance 6 1 printer overview 1 2 basic model 1 2 configured model 1 3 printer technology 1 1 printer theory 1 4 control 1 25 fuser control 1 26 media size control 1 25 printhead control 1 25 drive 1 19 CMY developer drive motor assembly 1 21 CMY toner add motor assembly 1 21 CMYK PC cartridge drive motor assembly 1 20 K developer clutch 1 21 K developer transport drive motor assembly 1 19 MPF transport drive motor 1 19 waste tone
403. roll assembly Transfer belt Heat roll Pressure roll Fuser unit ASM r I I d Standard media 1 exit roll assembly 1 d d I I I I Standard media exit Duplex media transport roll ASM Duplex media Center transport roll ASM PRINT EXIT j 1 34 Printer Service Manual 5057 XXX Media transport path The following is a cross section of the printer and the tandem tray module showing the main components directly associated with the media path and transport Upper media e transport roll assembl Finisher media entrance H y Bridge unit assembly roll assembly included with finisher Upper media exit Standard media exit roll assembly roll assembly Bridge unit bin exit roll assembly o 3 VU Buffer roll assembly E See 9 Media eject qR ee roll assembly q O oR e Q Q o Q 2 Fuser O Duplex media 0 Q Lower media exit transport roll roll assembl assembly o 2nd transfer roll assembly y Q OO Q A e Booklet media uer D O Registration roll assembly tra sport roll assembly MPF pick roll A O O A a Media t t roll bl Tray 1 O Bookletmedia eca anspore rar assanmoy y L entrance roll assembly O Booklet maker bit 3 Tray 2 optional Booklet media LA exit roll assembly Tray module transport Tray 3
404. roller card assembly Go to Duplex controller card assembly removal on page 4 14 Go to step 12 Problem solved 12 Perform a 2 sided print test Does the error remain Replace the lower printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 Problem solved 231 01 Sensor registration late jam duplex media feed Are the duplex unit assembly rolls free of excess wear and contamination Step Check Yes No 1 Check the media position Remove the media Go to step 2 Does the media remain in standard media exit 2 Check the duplex unit assembly rolls Go to step 3 Clean or replace the duplex unit assembly Go to Duplex unit assembly removal on page 4 10 2 32 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the sensor registration for proper operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TESTS 3 Select Media Path 4 Select Registration Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor registration for proper connection Replace the sensor Replace the Is the above component properly connected registration connecuon Go to Sensor registration removal on page 4 37 5 Check the duplex diverter gate solenoid for
405. s and to test the device s ability to generate acceptable printed output The printer automatically generates a Print Quality Test page in English and an Entire printable area of the page is solid dark blue Entire printable area of the page is solid dark magenta Entire printable area of the page is solid dark yellow Entire printable area of the page is solid dark black Entire printable area of the page is solid light blue Entire printable area of the page is solid pink Entire printable area of the page is solid light yellow 8 Entire printable area of the page is solid gray NOP Oh The device always uses the media that is currently installed in Tray 1 to print this report Once started printing cannot be canceled and all key presses are ignored until printing completes The test pages are always simplexed regardless of the value of the duplex setting HARDWARE TESTS Select the following Hardware Tests from this menu e Panel Test Button Test DRAM Test e CACHE Test Panel Test This test automatically toggles all pixels on the LCD through every contrast level beginning with the darkest to the brightest This test shows non functioning pixels as blank spaces during the darkest contrast This test continues until you press Stop O then the LCD returns to HARDWARE TESTS Button Test The Button Test is used to verify the operation of each button on the operator panel To perform the Button Test 1 Select HARDWARE TEST
406. s in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries PCLO 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 expense P N 12G9765 5057 XXX Notices and safety information 0 0 c cece eee eee XV ES EEE ceed Pade EEE esse Ree Redd EN xv See OE EE nec xxi EEE NE AE eea xxiv CONVENON S seric cacccaaedcxet cess SARA e ARA xxiv General information aaaeeeaa akakaa AEAEE EEEE EEEE EEEE EEEE Errr 1 1 PIO teen erer rosa eer Ee 1 1 EEE EEN 1 1 MEMON TN aa re re ec ree eee ea 1 1 PCOUSICS c66h cc iat tea cede ee bekker hen ES 1 1 E
407. s securing the sensor MPF media out B to the upper frame cover A Remove the sensor MPF media out B B LI Hooks e SC Connector a r MPF pick roll assembly removal 1 2 3 4 5 6 Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the three screws securing the MPF pinch roll assembly A to the MPF feed unit assembly B Remove the MPF pinch roll assembly A Release the two hooks of the two feed shaft cores B and move them both outwards in the directions in the arrows Note When removing the MPF feed roll assembly C do not touch the rubber surface Remove the two MPF feed roll assemblies C by moving them outward in the direction of the arrows and lifting upwards Repair information 4 107 5057 XXX Replacement note When replacing the MPF feed roll assemblies C do not touch the rubber surface Replacement note When replacing the MPF feed roll assemblies C ensure that the directional arrow is properly aligned 4 108 Printer Service Manual 5057 XXX Media feed lift motor removal 8 Remove the printer left lower door assembly See Printer left lower door assembly removal on page 4 8 1 Remove the media feed unit assembly See Media feed un
408. sed simultaneously by the printhead shutter motor assembly 1 16 Printer Service Manual 5057 XXX Fuser Pressure belt Thumb screws Heat roll The heat roll is a hollow metal tube with a coated surface This tube is heated by the inner heater lamp The heat is applied to the media passing between the heat roll and pressure roll fusing the toner on the media General information 1 17 5057 XXX Pressure belt The pressure belt is used to apply pressure to the media surface for fusing Pressure is applied to the media between the pressure belt and heat roll pressing the melted toner against the media Heater lamps Beak Ke thermister ES Thermistat ewe Front thermister Heater lamp The heater lamp is a quartz glass tube containing a heater coil A terminal is mounted to the end of the heater rod via a harness Two heater lamps are used the main heater lamp to heat the entire heat roll and the sub heater lamp to heat the central portion of the heat roll Thermostat If the heat roll temperature exceeds the preset temperature the thermostat cuts off the circuits of the main heater lamp and sub heater lamp Front thermistor The front thermistor monitors the surface temperature of the media feed portion of the heat roll to control on off of the main heater lamp and sub heater lamp Rear thermistor The rear thermistor monitors the surface temperature at the rear side of the heat roll to switc
409. sfer belt unit assembly contains the four 1st transfer rolls these 1st transfer rolls are referred to as the CMYK transfer rolls The CMYK transfer rolls are positively charged to remove the developed toner image from the four drums The negatively charged toner image is attracted by positive charges on the surface of the transfer belt Thus the toner image is transferred from the drum surface to the transfer belt surface During black K only operation the CMY transfer rolls are retracted to reduce wear on the transfer belt surface and CMY drums Transfer belt steering motor This motor is used to ensure that the transfer belt is properly tracking If the transfer belt starts to track off center then the transfer belt steering motor will activate to keep the transfer belt centered and tracking properly 2nd transfer roll assembly The 2nd transfer roll assembly applies positive charges to the rear surface of the media when the media passes between the 2nd transfer roll assembly and the transfer belt The negatively charged toner image is attracted by positive charges on the surface of the media Thus the toner image is transferred from the transfer belt surface to the media surface 2nd transfer roll retract motor The 2nd transfer roll retract motor is used to retract the 2nd transfer roll assembly when printing processes are not occurring 1 12 Printer Service Manual 5057 XXX Sensor 2nd transfer roll HP The sensor 2nd transfer ro
410. sor duplex wait Duplex media transport roll assembly 1 58 Printer Service Manual 5057 XXX Tools required for service Flat blade screwdriver 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade Needle nose pliers Diagonal side cutters Spring hook Analog or digital multi meter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 5 5 mm hexdriver magnetic Color toner vacuum Fine incremental ruler General information 1 59 5057 XXX Acronyms 1TM 3TM AC ADF APS ASIC ATC CRU CSU CCW CW DC DIMM DRAM EDO EP EPROM ESD FRU GB GFI HCF HVPS LASER LCD LD LED LEF LVPS MPF MS NVM NVRAM OEM OPT PC PEL POR POST PPM PSC PSD PWM RFID RIP ROM RPM SDRAM SEF SIMM SOS 1 Tray Module 3 Tray Module Alternating Current Automatic Document Feeder Automatic Paper Size Application Specific Integrated Circuit Automatic Toner Control Customer Replaceable Unit Customer Setup Counterclockwise Clockwise Direct Current Dual Inline Memory Module Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable Programmable Read only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte Ground Fault Interrupter High Capacity Feeder High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Las
411. sor media level late error tray 1 Step Check Yes No 1 Check the media Go to step 2 Load media i j properly Is media loaded in tray 1 properly 2 Check the sensor media level tray 1 for proper operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 1 5 Select Media level Does the display on the operator panel change every time the media tray is opened and closed 3 Check the sensor media level tray 1 for proper Replace the Replace the connection sensor media connection Is the above component properly connected level Go to Sensor media level removal on page 4 24 4 Check the media feed lift motor tray 1 for proper Go to step 6 Go to step 5 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Tray 1 media feed lift motor Warning The media tray must be opened before performing this test or paper jam may occur Does the above component operate properly 5 Check the media feed lift motor tray 1 for proper Replace the media Replace the connection feed lift motor connection Is the above component properly connected Go to Media feed lift motor removal on page 4 109 6 Perform a POR Replace the upper Problem solved Does the error continue when the power
412. sor Test output bin on page 3 11 FINISHER TESTS Staple Test See Staple Test on page 3 11 Hole Punch Test See Hole Punch Test on page 3 12 Feed Tests See Feed Tests Finisher on page 3 12 Sensor Tests See Sensor Test Finisher on page 3 12 BASE SENSOR TESTS See BASE SENSOR TEST on page 3 14 Cover and Door Devices Exit Level Media Path Transfer Belt PRINTER SETUP Defaults See Defaults on page 3 16 PAGE COUNTS See Prt Color Pg Count on page 3 16 Serial Number See Serial Number on page 3 16 Engine Setting 1 to 4 See Engine Setting 1 to 4 on page 3 16 Model Name See Model Name on page 3 16 Configuration ID See Configuration ID on page 3 16 EVENT LOG Display Log See Display the Event Log on page 3 17 Print Log See Print the Event Log on page 3 18 Clear Log See Clear the Event Log on page 3 18 Trans Belt Fail Clear Trans Belt HP Fail Clear See Trans Belt HP Fail Clear on page 3 18 Fuser Temp Fail Clear Fuser Temp Fail Clear See Fuser Temp Fail Clear on page 3 19 ATC SENSOR FAILURE CLEAR See ATC SENSOR FAILURE CLEAR on page 3 19 Y Channel 925 00 M Channel 925 01 3 4 Printer Service Manual 5057 XXX C Channel 925 02
413. spect MEDIA FEED UNIT ALL Feed Roll Inspect Replace Verify page count before replacing Pick Roll Inspect Replace Verify page count before replacing Separation Roll Inspect Replace Verify page count before replacing MPF pick roll Inspect Clean Water or alcohol Media Transport Roll Assembly Clean Water or alcohol Sensor registration Clean Brush or blower brush Sensor tray 1 feed out Clean Brush or blower brush Sensor tray 2 feed out Clean Brush or blower brush Sensor tray 3 feed out Clean Brush or blower brush Sensor tray 4 feed out Clean Brush or blower brush PRINTHEAD Printhead slit glass 4 Clean Clean Printhead cleaning tool Preventive maintenance 6 1 5057 XXX LEXMARK C930 C935 SERVICE EVERY EVERY wens CALL DEVELOPER UNITS Transfer Developer unit 4 Replace C developer carrier Replace M developer carrier Replace Y developer carrier Replace K developer carrier Replace TRANSFER ROLL 2nd Transfer Roll assembly Inspect Replace TRANSFER BELT UNIT Transfer belt unit assembly Inspect Replace Damp cloth Transfer belt cleaning assembly Replace FUSER UNIT Fuser Unit Inspect Replace Sensor fuser exit Clean Blower brush DUPLEX Duplex Media Transport Roll 2 Clean Water or alcohol Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other
414. ssembly Tab K 2 Rotate the gears in the assembly to evenly distribute the carrier B Warning Ensure that the two seals are properly positioned in the assembly before replacing the top cover A or spillage may occur which may lead to print quality problems ao Replace the top cover A Perform the ATC sensor setup and adjustment Go to Sensor ATC setup on page 4 199 5 Perform the color registration RegCon setup and adjustment Go to Color registration RegCon on page 4 203 4 56 Printer Service Manual 5057 XXX Photoconductor PC unit assembly removal Warning Ensure that all four PC cartridges are concealed from all sources of light or damage will occur Note This procedure can be applied to either the C M Y or K PC unit assemblies 1 Open the printer front door assembly 2 Press the button on the transfer belt lift latch A 3 Raise the transfer belt lift latch A to its upper most position 4 Lower the transfer belt lift handle B to its lower most position Button Repair information 4 57 5057 XXX 5 Pull the appropriate PC unit assembly C from the machine NG Note When the PC unit assembly C is removed ensure that it is stored in the position as shown in the graphic below PALE ASSL L CAPSS SPIT 4 58 Printer Service Manual 5057 XXX Replacement warning When replacing the PC unit assembly C ensure that the rai
415. ssembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Disconnect the connector from the MPF feed unit assembly A Detach the frame clamp from the machine Remove the two screws securing the MPF feed unit assembly A to the machine Remove the MPF feed unit assembly A oarhwon Connector Frame clamp 4 8 Printer Service Manual 5057 XXX Front left cover removal 1 Open the printer front door assembly 2 Remove the two screws securing the front left cover A to the machine 3 Move the front left cover A up and pull out 4 Remove the front left cover A Duplex media inverter assembly removal 1 Open the printer left door assembly 2 Remove the E clip securing the fuser exit roll assembly A to the machine 3 Remove the bushing B 4 Remove the fuser exit roll assembly A 5 Remove the two screws securing the duplex media inverter assembly C 6 Remove the duplex media inverter assembly C Repair information 4 9 5057 XXX Duplex unit assembly removal 1 Remove the two screws securing the duplex unit assembly A to the printer left door assembly B 2 Gently pull the duplex unit assembly A from the printer left door assembly B Note When removing the duplex unit assembly A the plastic panel C may become detached 3 Remove the duplex unit assembly
416. ssory 2 AN i Ge 8 gt 2 E g i ajo JO LO st 0 5 3 i BE i J410 To Upper printer engine card ASM P410 ra x TO 24V LVPS P505 1 SS El ZS 9 Eu as i Ko as 3 5 a g x J l oe PSW TO 24V LVPS P505 2 Rb S al 5 GER BER 3 i P41 T d ASM 41 x 5 H 3 DE o z 2 i z E Outlet i BEBE a d SEEEEEEEE 0 To lower printer engine car J410 D SI 3 z z g s s 25 i D Z TARRE sale olde Ze S Zee ase BET zer aye z HE zs 3 al dl a da Sl ga REA Eggs 2 za Meee ada dd 3338 3383 ES DE 22832933 J410 To P410 Upper printer engine card ASM 2888 Sat Si si si Si Si ei 0 oo o bg 5 5 sis E e te EF 4 A A A d EE Common GND D Ye o ll 153 3 res Sale Tajo o S TN N a N Al ei be 8 1 Ei y gt a 5 24V LVPS card 3 amp E BIS 18 lE AC IN Noise Filt P50 assembly el E g El g El gl a S a 5 GFI olse Filter gs 222 2 ie 0 o MOT ON L monan Jm O Tre Poemas NG Fs P l 5V LVPS 5V LVPS 5V LVPS 5 Seen SC i SSES SCH V y bigs a Pig EN 5 P39 SA card assembly card assembly card assembly o 2 Verse emm nd a E D MOT CLK I _ gt _z3 gt Hr AAA AAA ed OF EOI EY RP PB ANIOS non tofu HL EE T dn Ne FS48 D 2 5VDC To Metal E o Printer Frame al g ch peeks e 1 MOT K FAIL ER S A d UU y x PLY D i E 8 e A Lower printer engine card assembly 3 uorsaseesos q 8 3 3 Al d i 4 MOT K SPEED 2 7 2
417. standard bin first then it feeds a separate piece of media to each output bin installed While this test runs A11 Bin Test Feeding appears on the LCD The test is continuous until Stop Gi is pressed If a test is canceled All Bin Test Canceled appears on the LCD and feeds any remaining media in the paper path to the appropriate output destination Sensor Test output bin This test is used to verify that a specific output bin s sensors are working correctly To run the Output Bin Sensor Test 1 Select OUTPUT BIN TESTS from the Diagnostics Menu 2 Select Sensor Test 3 Select Standard Bin 4 Select Standard bin full 1 Select OUTPUT BIN TESTS from the Diagnostics Menu 2 Select Sensor Test 3 Select Finisher Standard Bin 4 Select Finisher upper media bin full 1 Select OUTPUT BIN TESTS from the Diagnostics Menu 2 Select Sensor Test 3 Select Finisher Bin 1 4 Select Stacker bin level 1 Stacker bin level 2 or Booklet bin media present XXXXXXXXXX Testing appears on the LCD and XXXXXXXXXX Open or Closed You can manually toggle the sensor between its two values Open or Closed The LCD displays Open when the sensor is open and Closed when the sensor is closed If the wrong message is displayed then the sensor must be malfunctioning Press Stop to exit the test FINISHER TESTS Staple Test This test is used to verify the functioning of the finisher s staple mechanism Diagnostic aids 3 1
418. ste mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria XXI Printer Service Manual Informacio de Seguretat A re 5057 XXX La seguretat d aquest producte es basa en
419. stration transport roll assembly Go to step 3 Clean or replace Is the above component free of excess wear and al contamination assembly Go to Registration transport roll assembly removal on page 4 36 3 Check the sensor registration for proper operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Media Path 4 Select Registration Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 4 Check the sensor registration for proper connection Replace the Replace the Is the above component properly connected e connection Go to Sensor registration removal on page 4 37 5 Check the transport roll MPF drive motor assembly for Go to step 7 Go to step 6 proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select MPF transport drive motor Does the above component operate properly 6 Check the MPF transport drive motor assembly for proper Replace the MPF Replace the connection transport drive connection Is the above component properly connected motor assembly Go to MPF transport drive motor assembly removal on page 4 101 5057 XXX Step Check Yes No 7 Check the Repl
420. t open and close properly assembly Go to Printer left door assembly removal on page 4 26 3 Check the sensor printer left door interlock for operation Go to step 5 Go to step 4 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Cover and Door 4 Select Door A left side Does the display on the operator panel change every time the actuator on the above switch is operated 4 Check the switch printer left door interlock for proper Replace the switch Replace the connection printer left door connection interlock Is the above component properly connected Go to Switch printer left door interlock removal on page 4 19 5 Perform a print test Replace the upper Problem solved Does the error continue when the power is turned off on e dig card Go to Upper printer engine card assembly removal on page 4 74 2 100 Printer Service Manual Transfer belt access door open 5057 XXX Step Check Yes No 1 Check the transfer belt access door for proper operation Go to step 2 Replace the Does the above component open and close properly SA Ke Go to Printer left door damper removal on page 4 29 2 Check the switch transfer belt access door interlock for Go to step 4 Go to step 3 operation 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Cover and Door 4 Select Door A left side Does the display on the operator p
421. talled specification black toner cartridge specification black toner cartridge Incorrect lt color gt toner cartridge error Step Check Yes No 1 Check the lt color gt toner cartridge for correct specification Install a new Reinstall the according to product make and model correct _ correct Is the correct specification lt color gt toner cartridge installed erence passe cartridge cartridge Diagnostic information 2 49 5057 XXX Tray 1 media size mismatch error Step Check Yes No 1 Check the media tray assembly 1 side guide Go to step 2 Properly set the Is the above component set properly A bl olde guide 2 Check the media tray assembly 1 end guide Go to step 3 Properly set the Is the above component set properly de guide 3 Check the media tray assembly for damage Replace the media Go to step 4 Is the above component damaged tray assembly 4 Check the switch media size for proper connection Replace the switch Replace the Is the above component properly connected media size ib 5 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on a card Go to Upper printer engine card assembly removal on page 4 74 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly remov
422. ted removes any residual DC charge that was left from the previous print cycle General information 1 31 5057 XXX At the beginning of each individual printer cycle the Printhead scans the surface of the drum further discharging any residual DC charge that may be left on the drum Erase lamp LED a ITAN Ground Auto density sensing Image density sensor assembly The image density sensor assembly uses a reflection type sensor that detects a pre placed toner patch and image on the transfer belt and outputs pulses when the central line of the patch image aligns with the central line of the detector The sensor outputs pulses at the timing the patch image passes the sensor Therefore observing changes of intervals at which pulses are output leads to color mis registration detection If no color mis registration occurs pulses are output at regular intervals 1 32 Printer Service Manual 5057 XXX TTM theory Front General information 1 33 5057 XXX Media transport Media transport path Media is supplied from tray 2 tray 3 or tray 4 and is transported to the printer along the media transport path shown below Tray 2 Tray 3 Tray 4 Pick roll Pick roll Pick roll Separation roll Separation roll Separation roll Feed roll Feed roll Feed roll Tray module media Transport roll ASM y Media transport roll ASM y Registration roll ASM h 2nd transfer
423. tep 10 Go to step 9 Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select Registrat clutch Does the above component make an audible clicking sound when activated 9 Check the registration clutch for proper connection Replace the Replace the Is the registration clutch properly connected registration clutch connection Go to Registration clutch removal on page 4 37 10 Check the Replace the K developer transport drive motor Go to step 12 Go to step 11 assembly for proper operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select K developer transport drive motor Does the above component operate properly 11 Check the K developer transport drive motor assembly for Replace the K Replace the proper connection developer connection transport drive Is the above component properly connected motorassembly Go to K developer transport drive motor assembly removal on page 4 92 5057 XXX Step Check Yes No 12 Perform a print test Does the error continue Replace the lower printer engine card assembly Go to Lower printer engine card assembly Problem solved
424. tep 2 1 Enter the Diagnostics Menu edge learn test 2 Select ENGINE ADJUST a gg 3 Select RegCon adjust age 4 206 4 Select Control Sensor Cycle pag Does the above test pass 2 Check the upper printer engine card assembly connections Replace the upper Replace the rinter engine card connection Is the above component properly connected ee See Upper printer engine card assembly removal on page 4 74 3 Re perform the Measurement cycle test again Perform the Belt Contact next level Does the above test pass edge learn test See Belt edge learn test on page 4 206 of support Repair information 4 205 5057 XXX Belt edge learn test Step Check Yes No 1 Perform the Belt edge learn test Perform Skew Go to step 2 1 Enter the Diagnostics Menu setup 2 Select ENGINE ADJUST SC eg fine 3 Select RegCon adjust 4 206 4 Select Belt edge learn pa taus Does the above test pass 2 Replace the transfer belt unit assembly Perform Skew Contact next level See Transfer belt unit assembly removal on setup of support page 4 16 See Skew fine Does the error continue ng Skew fine setup Step Check Yes No 1 Perform the Skew fine setup Go to step 2 Go to step 3 1 Enter the Diagnostics Menu 2 Select ENGINE ADJUST 3 Select RegCon adjust 4 Select Control setup cycles 5 Select Skew fine setup Does the above test
425. tep 2 Replace the Does the above component open and close properly eg door Go to Printer front door assembly removal on page 4 3 2 Check the switch printer front door interlock for operation Go to step 4 Go to step 3 1 Enter the Diagnostics Menu 2 Select BASE SENSOR TEST 3 Select Cover and Door 4 Select Door J printer front Does the display on the operator panel change every time the actuator on the above switch is operated 3 Check the switch printer front door interlock for proper Replace the switch Replace the connection printer front door connection interlock Is the above component properly connected Go to Switch printer front door interlock removal on page 4 66 4 Perform a POR Replace the upper Problem solved Does the error continue when the power is turned off on GEN card Go to Upper printer engine card assembly removal on page 4 74 Diagnostic information 2 99 5057 XXX Printer left door open Step Check Yes No 1 Check the printer left door closed actuator located on the Go to step 2 Replace the rear of the printer left door assembly for damage printer left door Is the above component as shown in the graphic below 40x0408 T free of damage ae Printer left door closed actuator 2 Check the printer left door for proper operation Go to step 3 Replace the D the ab t naci rober printer left door oes the above componen
426. than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Scheduled maintenance The LCD displays 80 scheduled maintenance at each 100K and 600K page count interval It is necessary to replace the appropriate maintenance kit at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 40X4031 1 00K Maintenance Kit 110 V 40X4093 1 00K Maintenance Kit 220 V 40X4032 600K Maintenance Kit 110 amp 220 V The ADF requires scheduled maintenance at each 150K page count interval It is necessary to replace the feed pick roll assembly and the separation guide assembly at this interval to maintain ADF media feed reliability The parts are available as a maintenance kit with the following part number 6 2 Printer Service Manual 5057 XXX After replacing the kit the maintenance count must be reset to zero to clear the 80 scheduled maintenance message To reset the maintenance count Turn off the printer Press and hold the 2 and 6 buttons simultaneously Turn on the printer Release the buttons after 10 seconds The Configuration Menu appears on the LCD Tou
427. that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor tests 4 Select Transfer belt steering motor Does the above component operate properly 5 Check the transfer belt steering motor for proper Replace the Replace the connection transfer belt connection Is the above component properly connected steering motor Go to Go to Transfer belt steering motor removal on page 4 61 6 Perform a POR Replace the lower Problem solved Does the error occur when the power is turned off on SA al ESTA Go to Lower printer engine card assembly removal on page 4 77 904 02 Sensor transfer belt edge failure Step Check Yes No 1 Check the transfer belt unit assembly for proper installation Go to step 2 Re install the Is the above component properly installed deeg unit 2 Check the transfer belt unit assembly for damage Go to step 3 Replace the transfer belt unit eee component free of damage to the frame and assembly 2 62 Printer Service Manual 5057 XXX Step Check Yes No 3 Check the transfer belt steering motor assembly for proper Go to step 5 Go to step 4 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor tests 4 Select Transfer belt steer
428. the drum discharges the surface charge Charge roll Ground Drum Surface Drum Surface Photoconductive Image Voltage Surface T VDC value Conductive Tube Ground The charge roll is a conductive roll that is positioned slightly above the surface of the drum The HVPS supplies the charge roll with two voltages a negative DC charge voltage and an AC discharge voltage that is used for electrically cleaning the drum Charge roll Ground Drum Surface Drum Surface Photoconductive Image Voltage Surface T VDC value Conductive Tub 1 28 Printer Service Manual 5057 XXX Exposure The Printhead generates a beam of laser light Image data received from the RIP card assembly modulates this beam turning it on and off according to image information that is received from the host computer and software Through the use of a series of rotating and stationary mirrors within the Printhead the beam scans the negative charged drum surface Whenever the print controller sends a command to print a black pixel the laser switches on long enough to shine onto the drum at a single pixel point That point is now discharged and slightly less negative than the surrounding negative charge The less negative areas are considered positive This discharge no discharge process creates an invisible electrostatic image on the surface of the drum This image is called a latent image Modulated Laser Beam Printhead
429. the hard drive B Repair information 4 71 5057 XXX Warning Do not drop the hard drive or damage will occur Upper printer engine card bracket assembly removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the right cover assembly See Right cover assembly removal on page 4 4 Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the RIP card assembly See RIP card assembly removal on page 4 71 Remove the controller box top cover assembly See RIP card cooling fan cover assembly removal on page 4 67 Remove the switch main power See Switch main power removal on page 4 69 Remove the controller box assembly See Controller box assembly removal on page 4 68 Disconnect the thirteen connectors from the upper printer engine card assembly A Release the harnesses from the clamps Remove the four screws securing the upper printer engine card bracket assembly A to the machine Note When removing the upper printer engine card bracket assembly A the upper printer engine card assembly B and the lower printer engine card assembly C will become detached akon A SOON OD 11 Lift the upper printer engine card bracket assembly A 4 72 Printer Service Manual 5057 XXX 12 Remove the upper printer engine card bracket assembly A Connector Replacement warning Ensure that t
430. the media out actuator A from the media feed unit assembly 3 Remove the media out actuator A Lower view Repair information 4 187 5057 XXX 1X 500 sheet drawer 1TM sensor media level removal 1 Remove the media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 182 2 Disconnect the connector from the sensor media level A 3 Release the hooks securing the sensor media level A to the media feed unit assembly 4 Remove the sensor media level A HA eg 4 188 Printer Service Manual 5057 XXX 1X 500 sheet drawer 1TM sensor media out removal k M RO al Remove the media feed unit assembly See 1X 500 sheet drawer 1TM media feed unit assembly removal tray 2 on page 4 182 Remove the media out actuator See 1X 500 sheet drawer 1TM media out actuator removal on page 4 187 Disconnect the connector from the sensor media out A Release the hooks securing the sensor media out A to the media feed unit assembly Remove the sensor media out A FG LF AS O Hooks Lower view Repair information 4 189 5057 XXX 1X 500 sheet drawer 1TM feed roll re
431. the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 82 Remove the CMYK transfer HVPS card assembly See CMYK transfer HVPS card assembly removal on page 4 90 Remove the screw securing the bracket A to the machine Remove the bracket A Disconnect the four connectors from the K developer transport drive motor assembly B Release the harnesses from the clamps Release the frame clamp from the K developer transport drive motor assembly B Remove the five screws securing the K developer transport drive motor assembly B to the machine Warning The K developer transport drive motor assembly B may be difficult to remove ensure that none of the harnesses become damaged 4 92 Printer Service Manual 5057 XXX 16 Gently remove the K developer transport drive motor assembly A Repair information 4 93 4 94 5057 XXX K developer clutch
432. the tray 3 and the tray 4 media assemblies Remove the tray 3 lift gear or the tray 3 lift gear assembly See 2000 sheet dual input TTM tray 3 lift gear assembly removal on page 4 149 or 2000 sheet dual input TTM tray 4 lift gear assembly removal on page 4 149 2 Remove the tray lift coupling assembly A from the machine Remove the bushing B from the tray lift coupling assembly A 4 Remove the gear C from the tray lift coupling assembly A ao 2000 sheet dual input TTM tray module drive motor assembly removal 1 Remove the rear cover See 2000 sheet dual input TTM rear cover removal on page 4 113 2 Disconnect the connector from the tray module drive motor A 3 Remove the three screws securing the tray module drive motor A to the machine 4 150 Printer Service Manual 5057 XXX 4 Remove the tray module drive motor A Repair information 4 151 5057 XXX 2000 sheet dual input TTM TTM tray 4 transport motor removal 1 Remove the rear cover See 2000 sheet dual input TTM rear cover removal on page 4 113 2 Disconnect the connector from the TTM tray 4 transport motor A 3 Release the harness from the clamp 4 Remove the two screws securing the TTM tray 4 transport motor A to the machine 5 Remove the TTM transport drive motor A Connector em 2000 sheet dual input TTM TTM controller card ass
433. to step 4 Is the above component damaged tray assembly 4 Check the switch media size for proper connection Replace the switch Replace the Is the above component properly connected media size connection 5 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on ee eae Go to Upper printer engine card assembly removal on page 4 74 6 Perform a POR Replace the RIP Problem solved Does the error remain when the power is turned off on card assembly again Go to RIP card assembly removal on page 4 71 Diagnostic information 2 51 5057 XXX Tray 4 media size mismatch error Step Check Yes No 1 Check the media tray assembly 4 side guide Go to step 2 Properly set the Is the above component set properly A bl olde guide 2 Check the media tray assembly 4 end guide Go to step 3 Properly set the Is the above component set properly ieee ier guide 3 Check the media tray assembly for damage Replace the media Go to step 4 Is the above component damaged tray assembly 4 Check the switch media size for proper connection Replace the switch Replace the Is the above component properly connected media size ib 5 Perform a POR Replace the upper Problem solved Does the error remain when the power is turned off on a card Go to Upper printer engine card assembly removal on page 4 74 6 Perform a
434. toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the inner cover assembly See Inner cover removal on page 4 42 Disconnect the connector transfer belt steering motor A Remove the three screws securing the transfer belt steering belt motor A to the machine Remove the transfer belt steering motor A CMY erase lamp assembly removal A sch ao PONS Ch OO oo oO JO Warning Ensure the transfer belt unit assembly is removed or damage will occur Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the sensor waste toner cartridge full See Sensor waste toner cartridge full removal on page 4 40 Remove the inner cover See Inner cover removal on page 4 42 Raise the transfer belt lift handle A to its upper most position Disconnect the connector from
435. tons simultaneously 3 Turn on the printer 4 Release the buttons after 10 seconds 2 2 Printer Service Manual Error code table 5057 XXX Error code or oes x message Error contents Description Action 200 00 Sensor registration late jam The media is late reaching the sensor registration within the specified time after being fed from any Paper jam given media tray Go to 200 00 Sensor registration late jam on page 2 20 200 01 Sensor registration lag jam The media reached the sensor registration but did Paper jam not clear it within the specified time Go to 200 01 Sensor registration lag jam on page 2 21 200 02 Sensor static jam Media remains in the areas shown on the operator Paper jam panel after power on Go to 200 02 Sensor static jam on page 2 23 200 03 Sensor media on belt late The media is late reaching the sensor media on Paper iam jam belt within the specified time after reaching the per sensor registration Go to 200 03 Sensor media on belt late jam on page 2 24 201 00 Sensor fuser exit late jam The media is late reaching the sensor fuser exit i within the specified time after reaching the sensor Paper jam registration Go to 201 00 Sensor fuser exit late jam on page 2 25 202 00 Sensor fuser exit lag jam The media reached the sensor fuser exit but did Paper jam not clear it within the specified time Go to 202 00
436. tract HP Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked 3 Check the sensor 2nd transfer roll HP for proper Replace the Replace the connection sensor 2nd connection 9 transfer roll retract Is the above component properly connected HP Go to Sensor 2nd transfer roll retract HP removal on page 4 34 4 Check the 2nd transfer roll retract motor for proper Go to step 6 Skip to step 5 operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer motor tests 4 Select 2nd transfer roll retract motor Does the above component operate properly 5 Check the 2nd transfer roll retract motor for proper Replace the 2nd Replace the connection transfer roll retract connection Is the above component properly connected motor Go to 6 Perform a print test Replace the lower Problem solved Does the error continue Au cera Go to Lower printer engine card assembly removal on page 4 77 7 Perform a POR Replace the lower Problem solved Does the error occur when the power is turned off on printer engine card assembly Go to Lower printer engine card assembly removal on page 4 77 Diagnostic information 2 65 5057 XXX 904 05 Sensor CMY transfer roll retract HP late error belt
437. tration WW Registration roll assembly Sensor registration MPF a GG Functions of main components When the duplex is installed to the left of the printer duplex double sided printing is available with the printer The following outlines the functions of the main components of the duplex Switch duplex left door interlock The switch left door interlock detects open close of the left door Sensor duplex wait The sensor duplex wait detects whether media is remaining in the duplex Duplex media transport roll assembly The two duplex media transport roll assemblies and the duplex media center transport roll assembly re feeds the media printed on the front side through the duplex to print on the rear side General information 1 57 5057 XXX Duplex controller card assembly The duplex controller card assembly that contains a CPU controls media feed in the duplex upon receiving a command from the upper printer engine card assembly and sensor switch information Duplex drive motor The duplex drive motor transmits driving force to the two duplex media transport roll assemblies and the duplex media center transport roll assembly middle that feeds media Inverter forward clutch Standard media exit roll assembly Inverter reverse clutch fra Le Duplex Q diverter gate re Duplex drive motor Ne a Duplex diverter solenoid NE SJ Switch duplex left RE P door interlock Sen
438. tridge empty on page 2 110 900 xx RIP card assembly software A error has occurred in the RIP card assembly Service RIP error software software Goto 900 XX RIP card assembly software error on page 2 57 901 xx RIP card assembly software A error has occurred in the RIP card assembly Service engine error error software Go to 900 XX RIP card assembly software error on page 2 57 903 00 Service motor error K developer transport drive motor error K developer transport drive motor error does not rotate at the specified speed Go to 903 00 K developer transport drive assembly motor error on page 2 58 903 01 Service motor error K PC drive motor error The K PC cartridge drive motor does not rotate at the specified speed Go to 903 01 K PC drive motor error on page 2 59 903 02 Service motor error CMY PC drive motor error The CMY PC cartridge drive motor does not rotate at the specified speed Go to 903 02 CMY PC drive motor error on page 2 59 903 03 Service motor error Developer drive motor error The developer drive motor does not rotate at the specified speed Go to 903 03 Developer drive motor error on page 2 60 904 00 Service transfer belt Sensor transfer belt HP late error The sensor transfer belt HP does not detect the transfer belt home position in the specified time or the transfer belt is damaged
439. ts and four developer Go to step 6 Problem solved carriers Go to Developer unit assembly removal on page 4 53 and Developer carrier removal and replacement on page 4 54 Does the problem remain 6 Check the developer transfer roll HVPS card assembly Go to step 7 Problem solved 2 130 Printer Service Manual 5057 XXX Step Check Yes No 7 Check the printhead assembly Go to step 8 Problem solved Replace the printhead assembly Go to Printhead assembly removal on page 4 90 Does the error continue 8 Check the upper printer engine card assembly Replace the RIP Problem solved Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Perform a print test Does the error continue card assembly Go to RIP card assembly removal on page 4 71 Diagnostic information 2 131 5057 XXX Skew The printed image is not paralleled with both sides of the media Leading edge Trailing edge Step Check Yes No 1 Check printer installation placement Go to step 2 Correct the a 2 installation Check the installation surface for irregularities placement Check for damaged printer caster Is the setup surface normal 2 Properly load media into the media tray assembly and Go to step 3 Problem solved ensure all guides are set correctly Properly install the media tray assemb
440. ty information XV 5057 XXX Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses re ne todas las condiciones expuestas en la norma IEC 60825 1 para productos l ser de Clase 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declarac o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamentac o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe lllb 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre
441. u deerme ceases 2 67 905 02 Marking device Xerographics error 2 68 905 03 Marking device Other error ooooocoocnccncn eee eee eee eee eee 2 68 905 04 Marking device paper handling error 2 68 905 05 Marking device other2 error EE niaka 2 68 907 00 Printhead polygon mirror motor error 2 69 907 01 SOS internal error cis A EE EE gr TEMES Sail 2 69 90702 SOS internal EE 2 69 907 03 SOS Internal error asides sd wai raske eed Hodes Reeds KORE ORE RS RES EERE 2 70 907 04 SOS internal error oir a EEN oa we pee ewe stale EE 2 70 907 05 Printhead control erg caiciserde re E sek ER bre einen ema ES 2 71 BOR 00 Waste There catacdasicad tessa dekk ae bos in 2 71 911 00 24V LVPS cooling fan error EEN EEN ices iv een EE E ew ereee enke dekk EE ER 2 72 911 01 Transfer belt drive motor cooling fan error 2 72 911 02 Fuser cooling Tan lock GffOFr sicoxiscininiancas rr ska ve n ka mad AA 2 73 918 00 Standard media exit shift error ocio ce ceed ae eed ee heder wat eee sand die ee 2 73 920 00 Fuser main lamp overheat error EE 2 74 920 01 Front thermistor disconnection error 2 74 920 02 Fuser sub lamp overheat error 2 75 920 03 Rear thermistor disconnection error 2 75 920 04 Main lamp warm up error 2 76 920 05 Main lamp on time error 0 cee cece AAAA RNO ANOR ERRERA 2 77 920 06 Sub lamp warm up failure 2 77 920 07 Sub lamp on time error NEEN ERENNERT bees baked 2 78 924 00 Yellow toner RFID commu
442. uch the rubber surface of the feed roll B Replacement note Before reinstalling do not touch the rubber surface of the separation roll B 4 104 Printer Service Manual 5057 XXX Sensor RFID toner cartridge removal OO PS Go b 0 Y 0 Note This removal applies to the sensor RFID K toner cartridge RFID C toner cartridge RFID M toner cartridge and RFID Y toner cartridge Remove the top cover assembly See Top cover assembly removal on page 4 4 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Remove the inner cover See Inner cover removal on page 4 42 Remove the three CMY toner add assemblies See CMY toner add assembly removal on page 4 46 Remove the K toner add assembly See K toner add assembly removal on page 4 48 Remove the main power switch actuator See Main power switch actuator removal on page 4 88 10 11 12 13 Remove the CMYK toner add motor assembly See CMYK toner add motor assembly removal on page 4 89 Release the hooks securing the appropriate sensor RFID toner c
443. uring the bracket B to the machine Remove the bracket B Disconnect the two connectors from the switch TTM left door interlock C Remove the two screws securing the switch TTM left door interlock C to the bracket B Remove the switch TTM left door interlock C NOOR GO M 4 148 Printer Service Manual 5057 XXX 2000 sheet dual input TTM tray 3 lift gear assembly removal 1 Remove the rear cover See 2000 sheet dual input TTM rear cover removal on page 4 113 2 Pull the tray 3 media assembly out of the machine 3 Remove the two screws securing the tray 3 lift gear assembly A to the machine Note When removing the tray 3 lift gear assembly A the tray lift coupling assembly B my become detached 4 Remove the tray 3 lift gear assembly A 2000 sheet dual input TTM tray 4 lift gear assembly removal 1 Remove the rear cover See 2000 sheet dual input TTM rear cover removal on page 4 113 2 Pull the media tray 4 out of the machine 3 Remove the two screws securing the tray 4 lift gear assembly A from the machine Note When removing the tray 4 lift gear assembly A the tray lift coupling assembly B may become detached 4 Remove the tray 4 lift gear assembly A Repair information 4 149 5057 XXX 2000 sheet dual input TTM tray lift coupling assembly removal Note This procedure can be applied to both
444. uring the registration clutch A to the registration transport roll assembly B Remove the registration clutch A Replacement note Before reinstalling ensure that the notch on the registration clutch A is placed over the boss on the registration transport roll assembly B Sensor registration removal D JO Om P Co b Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the printer left door assembly See Printer left door assembly removal on page 4 26 Remove the two screws securing the plate A to the registration transport roll assembly B Remove the plate A Remove the screw securing the sensor registration C to the registration transport roll assembly B Remove the sensor registration C Repair information 4 37 5057 XXX 9 Disconnect the connector from the sensor registration C Sensor transparency detect removal Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 8 Remove the printer left door assembly See Printer left doo
445. val on page 4 97 Remove the developer transfer roll HVPS card assembly See Developer transfer roll HVPS card assembly removal on page 4 99 Remove the lower printer engine card bracket assembly See Lower printer engine card bracket assembly removal on page 4 76 Remove the 5V HVPS card bracket assembly See 5V LVPS card bracket assembly removal on page 4 83 Remove the four screws securing appropriate 5V LVPS card assembly A to the 5V HVPS card bracket assembly Remove the appropriate 5V LVPS card assembly A Connectors 24V LVPS cooling fan removal po oof Go Remove the rear cover assembly See Rear cover assembly removal on page 4 5 Remove the rear upper cooling fan bracket assembly See Rear upper cooling fan bracket assembly removal on page 4 97 Remove the rear left middle cover See Rear left middle cover removal on page 4 6 Remove the 24V LVPS card bracket assembly See 24V LVPS card bracket assembly removal on page 4 82 Disconnect the connector from the 24V LVPS cooling fan A Remove the two screws securing the 24V LVPS cooling fan A to the 24V LVPS card bracket assembly B 4 84 Printer Service Manual 7 5057 XXX Remove the 24V LVPS cooling fan A Connector Replacement warning When replacing the 24V LVPS cooling fan A ensure that the label is facing up Rear lower cooling
446. values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select to submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select y to submit the changes Registration values appear on the LCD If required reset the values and Select t
447. ve the Go to step 2 Is there a media jam in the fuser unit assembly megia 2 Check the fuser unit assembly for proper installation Go to step 3 Install the fuser Is the fuser unit assembly installed properly unit assembly y propery properly 3 Check the fuser unit assembly for proper connection Go to step 4 Repair the Is the above component properly connected connection 4 Perform a print test Replace the fuser Problem solved Does the error continue unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 5 5 Perform a POR Replace the AC Problem solved F drive card bracket Does the error occur when the power is turned off on assembly Go to AC drive card bracket assembly removal on page 4 95 920 06 Sub lamp warm up failure Step Check Yes No 1 Check the fuser unit assembly for a media jam Remove the Go to step 2 Is there a media jam in the fuser unit assembly media 2 Check the fuser unit assembly for proper installation Go to step 3 Install the fuser Is the fuser unit assembly installed properly unit assembly y propery s properly 3 Check the fuser unit assembly for proper connection Go to step 4 Repair the Is the above component properly connected connector 4 Perform a print test Replace the fuser Problem solved Does the error continue unit assembly Go to Fuser unit assembly removal on page 4 15 Go to step 5 Diagnostic information 2 77 5057 XXX
448. ve the right cover assembly See Right cover assembly removal on page 4 4 Disconnect the two connectors from the printhead assembly A Release the two frame clamps from the machine Release the harness from the clamps Remove the two screws securing the printhead assembly A to the machine 4 90 Printer Service Manual 5057 XXX 9 Gently pull the printhead assembly A from the machine Connectors Replacement warning When replacing the printhead assembly perform the color registration RegCon setup and adjustment See Color registration RegCon on page 4 203 Repair information 4 91 5057 XXX Transfer belt waste toner auger assembly removal 1 2 3 4 5 Remove the transfer belt unit assembly See Transfer belt unit assembly removal on page 4 16 Remove the two screws securing the transfer belt waste toner auger assembly A Detach the bushing B from the transfer belt waste toner auger assembly A Move the transfer belt waste toner auger assembly A toward the rear of the machine Remove the transfer belt waste toner auger assembly A from the machine K developer transport drive motor assembly removal D OO SS GO M 10 11 12 13 14 15 Remove the duplex unit assembly See Duplex unit assembly removal on page 4 10 Remove the fuser unit assembly See Duplex controller card assembly removal on page 4 14 Remove
449. waste toner cartridge sensor assembly B Remove the harness from the clamps Remove the waste toner cartridge sensor assembly B NN Repair information 4 39 5057 XXX SCH Connectors Sensor waste toner cartridge full removal op 1 Remove the printer front door assembly See Printer front door assembly removal on page 4 3 2 Remove the front left cover See Front left cover removal on page 4 9 3 4 Remove the waste toner cartridge sensor assembly See Wasie toner cartridge sensor assembly removal on Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 page 4 39 Disconnect the connector from the sensor waste toner cartridge full A Release the hooks securing the sensor waste toner cartridge full A to the assembly Remove the sensor waste toner cartridge full A Connectors 4 40 Printer Service Manual 5057 XXX Switch waste toner cartridge interlock removal 1 2 3 4 al Remove the printer front door assembly See Printer front door assembly removal on page 4 3 Remove the front left cover See Front left cover removal on page 4 9 Remove the waste toner cartridge cover See Waste toner cartridge cover removal on page 4 39 Remove the waste toner cartridge sensor assembly See Waste toner cartridge sensor assembly removal on page 4 39 Release the hooks securing the switc
450. wer 1TM media feed unit assembly removal tray 2 4 182 1X 500 sheet drawer 1TM sensor tray 2 feed out removal oo ooooomoomo o 4 183 1X 500 sheet drawer 1TM switch media size removal 4 184 1X 500 sheet drawer 1TM media feed lift motor removal ooooooooomomo 4 185 1X 500 sheet drawer 1TM one way clutch gear assembly removal 4 185 1X 500 sheet drawer 1TM media out actuator removal oooooooooommmmmoo 4 187 1X 500 sheet drawer 1TM sensor media level removal 4 188 1X 500 sheet drawer 1TM sensor media out removal 00 00 eee eee eee eee 4 189 1X 500 sheet drawer 1TM feed roll removal 00 cece eee eee eee 4 190 1X 500 sheet drawer 1TM feed roll one way clutch removal oooooooooooo 4 191 1X 500 sheet drawer 1TM one way 22 tooth removal 000 eee eee eee eee 4 192 1X 500 sheet drawer 1TM separation roll one way friction clutch removal 4 193 1X 500 sheet drawer 1TM separation roll removal 4 194 1X 500 sheet drawer 1TM pick roll removal 000 e eee eee eee 4 195 1X 500 sheet drawer 1TM tray module left door assembly removal 4 196 1X 500 sheet drawer 1TM switch tray module left door interlock removal 4 197 1X 500 sheet drawer 1TM tray module drive motor assembly removal 4 198 1X 500 s
451. y Developer transport drive motor assembly MPF transport drive motor assembly CMYK PC cartridge drive motor assembly Transfer belt drive motor assembly 7 6 MFP Service Manual 5057 XXX Assembly 5 ID sensor and transfer belt steering Asm Part FRUs Units Describti n index number mach FRU P 1 40X3674 1 1 Image density sensor assembly 2 40X3673 1 1 Transfer belt steering motor Parts catalog 7 7 5057 XXX Assembly 6 Media tray Asm Part FRUs Units d s index number mach FRU Description 1 40X3677 2 1 Switch media size 2 40X3676 8 1 Media tray slide 3 40X3678 3 6 Media tray assembly kit e Media tray assembly e 1 label e 2 label e 3 label e 4 label e Instruction label 4 40X3675 2 1 Media tray catch 7 8 MFP Service Manual 5057 XXX Assembly 7 Printer left lower door and media feed unit Asm Part FRUs Units Description index number mach FRU 1 40X3679 4 1 Media feed unit assembly 2 40X3688 30 1 Sensor printer left lower door interlock 3 40X0613 1 1 Hinge pin 4 40X3680 1 1 Printer left lower door assembly this comes assembled 5 40X3681 1 1 Sensor tray 1 feed out 6 40X3682 2 1 Magnetic catch Parts catalog 7 9 5057 XXX Assembly 8 Media feed unit 7 10 MFP Service Manual 5057 XXX Assembly 8 Media feed unit Asm Part FRUs Units Description index
452. y removal on page 4 74 2 108 Printer Service Manual Color toner cartridge nearly empty 5057 XXX Step Check Yes No 1 Check the appropriate toner cartridge Go to step 2 Replace the toner Does the appropriate toner cartridge contain toner cartridge 2 Check the appropriate toner cartridge for proper installation Go to step 3 Reinstall the Is the appropriate above component properly installed SE tong 3 Check the gear rotation in the appropriate toner add Go to step 4 Replace the assembly appropriate toner Does the gear located at the lower part of the above add assembly component rotate smoothly Go to CMY toner add assembly removal on page 4 46 or K toner add assembly removal on page 4 48 4 Check the appropriate toner add assembly chute for Go to step 5 Clean any clogging obstructions Is the chute located at the lower part of the above component free of clogs and obstructions 5 Check the appropriate segment of the CMYK toner add Go to step 7 Go to step 6 motor assembly for operation Caution When performing motor tests ensure that all cover and door interlock switches are overridden Warning Only perform this test in segments of three seconds or less or toner spill will occur 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 Select C M Y or K toner add motor Does the above component operate properly 6
453. y removal on page 4 89 2 78 Printer Service Manual 5057 XXX Step Check Yes No Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved 924 01 Magenta toner RFID communication error Step Check Yes No Check the M toner cartridge Is the M toner cartridge properly installed Go to step 2 Reinstall the M toner cartridge Check the sensor M toner RFID for proper connection Is the above component properly connected Replace the CMYK toner add motor assembly Go to CMYK toner add motor assembly removal on page 4 89 Replace the connection Perform a POR Does the error occur when the power is turned off on Replace the upper printer engine card assembly Go to Upper printer engine card assembly removal on page 4 74 Problem solved 924 02 Cyan toner RFID communication error Step Check Yes No Check the C toner cartridge Is the C toner cartridge properly installed Go to step 2 Reinstall the C toner cartridge Check the sensor C toner RFID for proper connection Is the above component properly connected Replace the CMYK toner add motor assembly Go to CMYK toner add motor ass
454. y which contains a CPU controls media feed in the tandem tray module upon receiving a command from the upper printer engine card assembly and sensor switch information f Tray module Switch tray module interlock drive motor 3TM controller card assembly Sensor tray 2 feed out Switch Sensor media size tray 3 feed out Sensor tray 4 feed out General information 1 47 5057 XXX Switch media size The following table gives on off states of the switches on the switch media size corresponding to the media sizes of the media tray assembly Note The switches media size are denoted by S W1 and S W3 respectively from the left side Analog switch Media Size S W1 S W3 Of B5L 7 25 x 10 5 L Off E 1 48 Printer Service Manual 5057 XXX 1TM theory General information 1 49 5057 XXX Media transport Media transport path Media is supplied from tray 3 or tray 4 and is transported to the printer along the media transport path shown below Tray 2 Tray 3 Tray 4 Pick roll Pick roll Pick roll Separation roll Separation roll Separation roll Feed roll Feed roll Feed roll Tray module media Transport roll ASM y Media transport roll ASM y Registration roll ASM h 2nd transfer roll assembly Transfer belt Heat roll Pressure roll Fuser unit ASM r
455. y 4 media type mismatch The sensor transparency detect did not detect Incorrect paper error transparency media type check Go to Tray 4 media type mismatch error on tray 4 page 2 55 Diagnostic information 2 7 5057 XXX SSES Error contents Description Action message 80 100K maintenance required Service is required to maintain printer performance Scheduled Go to 100K maintenance required on maintenance page 2 102 100K kit 80 600K maintenance required Service is required to maintain printer performance Scheduled Go to 600K maintenance required on maintenance page 2 102 600K kit 82 Waste toner cartridge full Replace the waste toner cartridge Replace waste Go to Waste toner cartridge full on page 2 104 toner 82 Waste toner cartridge not Reinstall the waste toner cartridge Waste toner detected Go to Waste toner cartridge not detected on missing page 2 105 82 Waste toner cartridge nearly Waste toner cartridge is nearing the replacement Waste toner full interval nearly full Go to Waste toner cartridge nearly full on page 2 106 84 Color PC cartridge not A color PC cartridge is not installed or not installed color PC unit detected properly missing Go to Color PC cartridge not detected on page 2 106 849 00 Hard drive configuration ID The device does not have a hard drive installed mismatch even though its

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