Service Manual
Page 4
... 1-29 Exposing process 1-31 Developing process 1-32 First transfer (drum) process 1-34 Belt discharge (erase lamp) process 1-35 Belt cleaning process 1-36 Details of the transfer system 1-38 Second transfer (paper) process 1-38 Transfer belt cleaning process 1-39 Details of the optical system ... symptom table 2-27 Printer service checks 2-29 901-Yellow developer clutch service check 2-29 902-Magenta developer clutch service check 2-31 903-Cyan developer clutch service check 2-33 904-Black developer clutch service check 2-35 905-Yellow toner retract solenoid service check 2-37...
... 1-29 Exposing process 1-31 Developing process 1-32 First transfer (drum) process 1-34 Belt discharge (erase lamp) process 1-35 Belt cleaning process 1-36 Details of the transfer system 1-38 Second transfer (paper) process 1-38 Transfer belt cleaning process 1-39 Details of the optical system ... symptom table 2-27 Printer service checks 2-29 901-Yellow developer clutch service check 2-29 902-Magenta developer clutch service check 2-31 903-Cyan developer clutch service check 2-33 904-Black developer clutch service check 2-35 905-Yellow toner retract solenoid service check 2-37...
Service Manual
Page 5
... service check 2-63 986-Duplex connection error 2 service check 2-64 990-Transfer belt unit service check 2-65 991-Transfer roller clutch service check 2-67 992-Transfer belt cleaning roller clutch service check . . . . 2-68 993-Fuser clutch service check 2-69 994-OPC belt marker sensor service check 2-70 995-...sensing service check 2-87 Printer no power service check 2-89 Toner feed service check 2-91 Toner low/empty service check 2-92 Transfer roller missing service check 2-93 Tray empty service check 2-95 Waste toner bottle service check 2-97 Waste toner feed service check 2-...
... service check 2-63 986-Duplex connection error 2 service check 2-64 990-Transfer belt unit service check 2-65 991-Transfer roller clutch service check 2-67 992-Transfer belt cleaning roller clutch service check . . . . 2-68 993-Fuser clutch service check 2-69 994-OPC belt marker sensor service check 2-70 995-...sensing service check 2-87 Printer no power service check 2-89 Toner feed service check 2-91 Toner low/empty service check 2-92 Transfer roller missing service check 2-93 Tray empty service check 2-95 Waste toner bottle service check 2-97 Waste toner feed service check 2-...
Service Manual
Page 86
... cartridge) charging unit. Go to "994-OPC belt marker sensor service check" on page 2-65. 991 Transfer roller clutch error Indicates a problem with HVPS charging voltage supplied to "990-Transfer belt unit service check" on page 2-70. 995 Charger HV unit error Indicates a problem with...power supply (HVPS) service check" on page 2-72. 996 LVPS error Go to "991-Transfer roller clutch service check" on page 2-74. 2-8 Service Manual Go to "992-Transfer belt cleaning roller clutch service check" on OPC belt (photodeveloper cartridge) is not being properly detected by marker sensor....
... cartridge) charging unit. Go to "994-OPC belt marker sensor service check" on page 2-65. 991 Transfer roller clutch error Indicates a problem with HVPS charging voltage supplied to "990-Transfer belt unit service check" on page 2-70. 995 Charger HV unit error Indicates a problem with...power supply (HVPS) service check" on page 2-72. 996 LVPS error Go to "991-Transfer roller clutch service check" on page 2-74. 2-8 Service Manual Go to "992-Transfer belt cleaning roller clutch service check" on OPC belt (photodeveloper cartridge) is not being properly detected by marker sensor....
Service Manual
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See "Print quality service checks" on page 2-85. See "Output tray full service check" on page 2-101. 5021-0XX Symptom The transfer roll is not transferring images or does not turn No power Waste toner feed problems Fans not working or making noise Print/image problems Printer does not stop when ... service check" on the I/O board are plugged into the correct position. 2-26 Service Manual Find the failing fan and follow the action suggested. Ensure developer clutch connectors (DCLK, DCLY, DCLM, DCLC) on page 2-89.
See "Print quality service checks" on page 2-85. See "Output tray full service check" on page 2-101. 5021-0XX Symptom The transfer roll is not transferring images or does not turn No power Waste toner feed problems Fans not working or making noise Print/image problems Printer does not stop when ... service check" on the I/O board are plugged into the correct position. 2-26 Service Manual Find the failing fan and follow the action suggested. Ensure developer clutch connectors (DCLK, DCLY, DCLM, DCLC) on page 2-89.
Service Manual
Page 145
... and 8 (cable) to connector that attaches to step 2. Disconnect transfer roller clutch from step 3. If Disconnect cable from problem DCN10 on I /O board shield. See "Engine controller board. 991-Transfer roller clutch service check 5021-0XX Step Questions / actions Yes No 1 Turn... printer off and remove Go to transfer roller clutch. See "Right cover removal" on page 4-70. See "Clutch removal" on transfer roller clutch. Does resistance measure between two...
... and 8 (cable) to connector that attaches to step 2. Disconnect transfer roller clutch from step 3. If Disconnect cable from problem DCN10 on I /O board shield. See "Engine controller board. 991-Transfer roller clutch service check 5021-0XX Step Questions / actions Yes No 1 Turn... printer off and remove Go to transfer roller clutch. See "Right cover removal" on page 4-70. See "Clutch removal" on transfer roller clutch. Does resistance measure between two...
Service Manual
Page 146
..." See "Engine on page 4-55. 5021-0XX 992-Transfer belt cleaning roller clutch service check Step Questions / actions Yes No 1 Turn printer off and remove Go to controller remove shield. persists, go to cleaning roller clutch. Ensure that connects I2CN on on page 4-55 for ...steps to step 2. See "Engine controller board. engine controller board to board removal" remove I/O board shield. See "Cleaning roller clutch removal" on I /O board shield. Replace I /O board removal" board. If Disconnect cable from problem DCN10 on page 4-36. 2 Remove I /O ...
..." See "Engine on page 4-55. 5021-0XX 992-Transfer belt cleaning roller clutch service check Step Questions / actions Yes No 1 Turn printer off and remove Go to controller remove shield. persists, go to cleaning roller clutch. Ensure that connects I2CN on on page 4-55 for ...steps to step 2. See "Engine controller board. engine controller board to board removal" remove I/O board shield. See "Cleaning roller clutch removal" on I /O board shield. Replace I /O board removal" board. If Disconnect cable from problem DCN10 on page 4-36. 2 Remove I /O ...
Service Manual
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... printer) cleaning roller for overflow. for damage. "Waste toner auger removal" on page 4-73. 6 Inspect waste toner feeder Replace waste Problem solved. clutch. service check" on page 4-42. 2-98 Service Manual toner feeder removal" on page 2-97. 4 Check waste toner auger Replace waste Go to ... Is waste toner See "Waste feeder damaged? for damage. 5021-0XX Waste toner feed service check Step Questions / actions Yes No 1 Is transfer belt unit cleaning Go to step 4. Go to step 3. 3 Check waste toner bottle Go to "Waste Go to step 2. Is waste toner...
... printer) cleaning roller for overflow. for damage. "Waste toner auger removal" on page 4-73. 6 Inspect waste toner feeder Replace waste Problem solved. clutch. service check" on page 4-42. 2-98 Service Manual toner feeder removal" on page 2-97. 4 Check waste toner auger Replace waste Go to ... Is waste toner See "Waste feeder damaged? for damage. 5021-0XX Waste toner feed service check Step Questions / actions Yes No 1 Is transfer belt unit cleaning Go to step 4. Go to step 3. 3 Check waste toner bottle Go to "Waste Go to step 2. Is waste toner...
Service Manual
Page 189
... service check 5021-0XX Mixed color image appears. Replace transfer belt unit cleaning roller clutch. Replace toner retract system. Problem area 1 Toner cartridge 2 Transfer roller clutch 3 Transfer belt unit cleaning roller clutch 4 Toner retract system Action Ensure toner cartridge moves in... question with one of resistance. See "Cleaning roller clutch removal" on page 4-36. Diagnostic information ...
... service check 5021-0XX Mixed color image appears. Replace transfer belt unit cleaning roller clutch. Replace toner retract system. Problem area 1 Toner cartridge 2 Transfer roller clutch 3 Transfer belt unit cleaning roller clutch 4 Toner retract system Action Ensure toner cartridge moves in... question with one of resistance. See "Cleaning roller clutch removal" on page 4-36. Diagnostic information ...
Service Manual
Page 199
Remove and reinstall transfer roller. See "Clutch removal" on page 4-8. See "Transfer roller removal" on page 4-40. Replace faulty transfer roller clutch. Diagnostic information 2-121 Ensure spring contact on left side (looking from front of image. White band service check 5021-0XX Horizontal white banding creates missing portion of printer) is not making proper contact with high voltage spring contact. Problem area 1 Transfer roller 2 Transfer roller clutch Action • Transfer roller bias pole is not damaged. • Replace faulty transfer roller.
Remove and reinstall transfer roller. See "Clutch removal" on page 4-8. See "Transfer roller removal" on page 4-40. Replace faulty transfer roller clutch. Diagnostic information 2-121 Ensure spring contact on left side (looking from front of image. White band service check 5021-0XX Horizontal white banding creates missing portion of printer) is not making proper contact with high voltage spring contact. Problem area 1 Transfer roller 2 Transfer roller clutch Action • Transfer roller bias pole is not damaged. • Replace faulty transfer roller.
Service Manual
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See "Right cover removal" on page 4-6. 2. Remove right cover. Using a flat tip tool, pry and remove cleaning roller clutch gear from inside of printer. 4-36 Service Manual 5021-0XX Cleaning roller clutch removal 1. See "Transfer belt cleaning roller removal" on page 4-22. 3. Remove transfer belt cleaning roller.
See "Right cover removal" on page 4-6. 2. Remove right cover. Using a flat tip tool, pry and remove cleaning roller clutch gear from inside of printer. 4-36 Service Manual 5021-0XX Cleaning roller clutch removal 1. See "Transfer belt cleaning roller removal" on page 4-22. 3. Remove transfer belt cleaning roller.
Service Manual
Page 270
Slide clutch away from clutch (B). 4. Remove right cover. Remove clip from printer to the fuser clutch, transfer roller clutch, registration clutch, and the paper feed clutch. 1. See "Right cover removal" on page 4-22. 2. 5021-0XX Clutch removal Note: This procedure applies to remove. 4-40 Service Manual Disconnect clutch cable (A). 3.
Slide clutch away from clutch (B). 4. Remove right cover. Remove clip from printer to the fuser clutch, transfer roller clutch, registration clutch, and the paper feed clutch. 1. See "Right cover removal" on page 4-22. 2. 5021-0XX Clutch removal Note: This procedure applies to remove. 4-40 Service Manual Disconnect clutch cable (A). 3.
Service Manual
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... to the waste toner feeder you do not have to printer. Remove fuser clutch. Remove transfer roller clutch. Note: If you are removed at the first of this procedure because the main drive gear assembly FRU does not include the clutches. 3. See "Clutch removal" on page 4-38. A Repair information 4-41 See "Toner sensor (sender) removal...
... to the waste toner feeder you do not have to printer. Remove fuser clutch. Remove transfer roller clutch. Note: If you are removed at the first of this procedure because the main drive gear assembly FRU does not include the clutches. 3. See "Clutch removal" on page 4-38. A Repair information 4-41 See "Toner sensor (sender) removal...
Service Manual
Page 313
... fuser unit to main gear unit at the time of transfer belt. Locations and connectors 5-9 Solenoid/clutch locations Cleaning roller clutch Toner retract solenoid 5021-0XX Fuser clutch Transfer roller clutch Left side (shown with all boards removed) Registration clutch Paper feed clutch Developer clutches Name Code Function Paper feed clutch PCLU Feeds paper by coupling feed roller to main...
... fuser unit to main gear unit at the time of transfer belt. Locations and connectors 5-9 Solenoid/clutch locations Cleaning roller clutch Toner retract solenoid 5021-0XX Fuser clutch Transfer roller clutch Left side (shown with all boards removed) Registration clutch Paper feed clutch Developer clutches Name Code Function Paper feed clutch PCLU Feeds paper by coupling feed roller to main...
Service Manual
Page 314
TRCL Cam action clutch that rotates, allowing transfer roller to release from transfer belt onto paper during second transfer process. 5-10 Service Manual 5021-0XX Name Toner retract solenoid Transfer roller clutch Code Function DSL (Y,M,C,K) Places selected toner cartridge in development position during second transfer. The transfer roller touching the back of paper causes toner to press against the back of paper during development phase.
TRCL Cam action clutch that rotates, allowing transfer roller to release from transfer belt onto paper during second transfer process. 5-10 Service Manual 5021-0XX Name Toner retract solenoid Transfer roller clutch Code Function DSL (Y,M,C,K) Places selected toner cartridge in development position during second transfer. The transfer roller touching the back of paper causes toner to press against the back of paper during development phase.
Service Manual
Page 317
Symbol TH TNK TPD TTR TRCM Part name Themistor Toner key sensor Toner empty sensor Transfer cam clutch 5021-0XX Locations and connectors 5-13
Symbol TH TNK TPD TTR TRCM Part name Themistor Toner key sensor Toner empty sensor Transfer cam clutch 5021-0XX Locations and connectors 5-13
Service Manual
Page 342
... N/A 2 NC N/A Cleaning roller solenoid 3 +24V-1DF3 no number 4 FBCLON-N no number Fuser clutch 5 +24V-1DF3 no number 6 FUCLON-N no number Transfer roller clutch 7 +24V-1DF3 no number 8 TRSLON-N no number Registration clutch 9 +24V-1DF3 no number 10 RECLON-N no number Paper feed clutch 11 +24V-1DF3 no number 12 PKCLU1ON-N no number Waste toner sensor...
... N/A 2 NC N/A Cleaning roller solenoid 3 +24V-1DF3 no number 4 FBCLON-N no number Fuser clutch 5 +24V-1DF3 no number 6 FUCLON-N no number Transfer roller clutch 7 +24V-1DF3 no number 8 TRSLON-N no number Registration clutch 9 +24V-1DF3 no number 10 RECLON-N no number Paper feed clutch 11 +24V-1DF3 no number 12 PKCLU1ON-N no number Waste toner sensor...
Service Manual
Page 365
... 56P1622 56P1621 56P1623 56P1620 56P1624 56P1626 56P1619 56P1628 56P1629 56P1681 56P1631 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 14 56P1627 1 5021-0XX Description Gear assembly, main drive Clutch, fuser Packet, parts P/N 56P1662 Clutch, registration Clutch, transfer roller Clutch, paper feed Clutch, cleaning roller Waste toner feeder Motor assembly, main Drive assembly, developer Assembly, waste toner holder Assembly, interlock switch Sensor, toner, sender...
... 56P1622 56P1621 56P1623 56P1620 56P1624 56P1626 56P1619 56P1628 56P1629 56P1681 56P1631 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 14 56P1627 1 5021-0XX Description Gear assembly, main drive Clutch, fuser Packet, parts P/N 56P1662 Clutch, registration Clutch, transfer roller Clutch, paper feed Clutch, cleaning roller Waste toner feeder Motor assembly, main Drive assembly, developer Assembly, waste toner holder Assembly, interlock switch Sensor, toner, sender...
Service Manual
Page 377
... tests 3-7 printer setup 3-16 restore EP factory defaults 3-20 ROM memory test 3-10 serial number 3-17 serial wrap test 3-11 setting configuration ID 3-17 first transfer (drum) process 1-34 fusing process 1-46 fusing unit 1-44 I interface control 1-51 interface connection 1-51 interface type 1-51 L laser drive control circuit 1-50 locations 5-1 boards... and motors 5-7 high voltage supply board 5-18 I/O board 5-17 interlock switches 5-8 low voltage power supply board 5-18 options 5-3 printer 5-1 printer cables 5-19 sensors 5-4 solenoids and clutches 5-9 I-1
... tests 3-7 printer setup 3-16 restore EP factory defaults 3-20 ROM memory test 3-10 serial number 3-17 serial wrap test 3-11 setting configuration ID 3-17 first transfer (drum) process 1-34 fusing process 1-46 fusing unit 1-44 I interface control 1-51 interface connection 1-51 interface type 1-51 L laser drive control circuit 1-50 locations 5-1 boards... and motors 5-7 high voltage supply board 5-18 I/O board 5-17 interlock switches 5-8 low voltage power supply board 5-18 options 5-3 printer 5-1 printer cables 5-19 sensors 5-4 solenoids and clutches 5-9 I-1
Service Manual
Page 378
... belt cleaning process 1-36 belt discharge (erase lamp) process 1-35 charging process 1-29 developing process 1-32 exposing process 1-31 first transfer (drum) process 1-34 printer identification 1-17 printer setup parallel strobe adjustment 3-18 serial number 3-17 setting configuration ID 3-17 setting ...the page count 3-16 viewing page count 3-16 R removals bracket assembly 4-45 cleaning roller clutch 4-36 cleaning roller cover 4-6 covers 4-17 developer drive assembly 4-32 developer motor 4-31 duplex unit assembly 4-13 I-2 Service Manual engine...
... belt cleaning process 1-36 belt discharge (erase lamp) process 1-35 charging process 1-29 developing process 1-32 exposing process 1-31 first transfer (drum) process 1-34 printer identification 1-17 printer setup parallel strobe adjustment 3-18 serial number 3-17 setting configuration ID 3-17 setting ...the page count 3-16 viewing page count 3-16 R removals bracket assembly 4-45 cleaning roller clutch 4-36 cleaning roller cover 4-6 covers 4-17 developer drive assembly 4-32 developer motor 4-31 duplex unit assembly 4-13 I-2 Service Manual engine...
Service Manual
Page 382
...7-5 56P1617 Board, I/O 7-15 56P1618 Cover, I/O board 7-15 56P1619 Motor assembly, main 7-9 56P1620 Clutch, paper feed 7-9 56P1621 Clutch, registration 7-9 56P1622 Clutch, fuser 7-9 56P1623 Clutch, transfer roller 7-9 56P1624 Clutch, cleaning roller 7-9 56P1625 Gear assembly, main drive 7-9 56P1626 Waste toner feeder 7-9 56P1627 Motor, developer..., paper feed 7-11 56P1656 Pad, seperator 7-11 56P1657 Lamp, erase 7-7 56P1659 Rear cover assembly 7-5 56P1660 Transfer roller assembly 7-3 56P1661 Parts packet, harness 7-19 56P1662 Parts packet, screw 7-19 56P1663 Assembly, duplex unit...
...7-5 56P1617 Board, I/O 7-15 56P1618 Cover, I/O board 7-15 56P1619 Motor assembly, main 7-9 56P1620 Clutch, paper feed 7-9 56P1621 Clutch, registration 7-9 56P1622 Clutch, fuser 7-9 56P1623 Clutch, transfer roller 7-9 56P1624 Clutch, cleaning roller 7-9 56P1625 Gear assembly, main drive 7-9 56P1626 Waste toner feeder 7-9 56P1627 Motor, developer..., paper feed 7-11 56P1656 Pad, seperator 7-11 56P1657 Lamp, erase 7-7 56P1659 Rear cover assembly 7-5 56P1660 Transfer roller assembly 7-3 56P1661 Parts packet, harness 7-19 56P1662 Parts packet, screw 7-19 56P1663 Assembly, duplex unit...