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Few things are more frustrating than a printer breaking down when you need it most. Knowing how to handle routine maintenance can save businesses and consumers time and money, and keep them from waiting on someone else’s schedule.
Replacing the maintenance kit on your Xerox printer may sound complicated, but it’s simpler than you think. The kit contains parts that transfer toner to paper and guide sheets through the printer. These components wear down over time, so replacing them as needed helps preserve print quality, smooth paper feeding, and reliable performance.
At Strategic Technology Partners of Texas (STPT), we've serviced thousands of Xerox printers and handled maintenance-related repairs and replacements thousands of times. With more than 40 years in the printer industry, we know how important it is to keep your equipment running without unnecessary interruptions.
In this guide, Matthew from The Printing Workshop, a printer technician with several years of hands-on repair experience, will show you how to replace the maintenance kit on a Xerox VersaLink C500 or C505. You'll learn how to remove and install the second bias transfer roll, transfer belt assembly, and paper tray separator roll, along with the correct way to secure each component.
Table of Contents
- Quick Answer: How Do You Replace the Maintenance Kit?
- What Is a Printer Maintenance Kit?
- When Should You Replace the Maintenance Kit?
- How to Replace the Maintenance Kit
- Common Maintenance Kit Replacement Mistakes
- Quick Recap
- FAQ
- Keep Your Xerox VersaLink Printing Smoothly
Quick Answer: How Do You Replace the Maintenance Kit on a Xerox VersaLink C500 or C505?
To replace the maintenance kit on a Xerox VersaLink C500 or C505, start by replacing the second bias transfer roll (BTR) inside the rear door. Next, remove the waste toner container, unlock the drum assemblies, and replace the transfer belt behind the right-side cover. Finally, remove the paper tray and replace the separator roll assembly before reinstalling the tray.
The process involves three main components, so working through each replacement separately makes the job easier to manage.
What Is a Printer Maintenance Kit?
A printer maintenance kit contains replaceable components that help maintain print quality and reliable paper feeding as a printer ages.
The Xerox VersaLink C500/C505 maintenance kit replacement involves three components:
- Second bias transfer roll (BTR): Helps transfer the toner image onto the paper during printing.
- Transfer belt assembly: Helps move the toner image through the printer's imaging process before it is transferred to the paper.
- Paper tray separator roll assembly: Helps separate sheets during paper feeding so the printer doesn't pull multiple pages at once.
These components serve different purposes, but all experience wear through normal printing.
When Should You Replace the Maintenance Kit?
Replace the maintenance kit when your Xerox VersaLink C500 or C505 displays a maintenance alert or a technician identifies worn parts.
Worn transfer components or feed rollers may cause print-quality issues, jams, or multiple sheets feeding at once.
These symptoms can have other causes, so troubleshoot first if no maintenance alert appears.
How Do You Replace the Maintenance Kit on a Xerox VersaLink C500 or C505?
The maintenance kit replacement involves three parts. Matthew begins with the second BTR, moves on to the transfer belt assembly, and finishes with the paper tray separator roll.
Part 1: Replace the Second Bias Transfer Roll (BTR)
Step 1: Open the Rear Cover
Start by opening the rear cover of your Xerox VersaLink C500 or C505.
The second bias transfer roll is located directly on the rear door, near the top.
You'll notice two orange handles, one on each end of the assembly. These handles release the BTR from its position.
Step 2: Remove the Old Second BTR
Grab both ends of the second BTR and squeeze the orange handles.
While holding them, pull the assembly straight up and out of the rear door.
Once removed, set the old BTR aside and prepare the replacement.
Step 3: Align the New Second BTR
Before installing the replacement, look at the angle of the slots where the BTR fits.
Matthew points out that these slots aren't perfectly vertical. They're angled backward slightly.
Position the new BTR at the same angle as the slots rather than trying to insert it straight up and down.
This helps the assembly fit correctly into its guides.
Step 4: Install and Secure the Second BTR
Lower the replacement BTR into position, following the angle of the slots.
Once it's aligned, use your thumbs to give the assembly a firm push until the orange handles click into place.
Matthew recommends giving the assembly a gentle wiggle afterward to confirm it's securely locked.
Close the rear cover to complete this part of the replacement.
Part 2: Replace the Transfer Belt Assembly
Step 5: Open the Right-Side and Rear Covers
To access the transfer belt, open the printer's right-side cover.
Then open the rear cover as well.
Both covers need to be open to provide access to the transfer belt assembly.
Step 6: Remove the Waste Toner Container
Inside the right-side cover, locate the waste toner container.
Carefully remove it and set it aside.
You'll reinstall this component after replacing the transfer belt.
Step 7: Unlock All Four Drum Assemblies
Before removing the transfer belt, you'll need to release the four drum assemblies.
Locate the orange latch handles for the drums.
Pull each orange handle downward to unlock its corresponding drum assembly.
Repeat this process until all four drums are unlatched.
You don't need to remove the drums completely. They simply need to be unlocked to allow the transfer belt to come out.
Step 8: Unlock the Transfer Belt Assembly
With the drums released, locate the transfer belt assembly.
You'll notice two orange locking mechanisms, one on each end.
Turn both orange locks inward to unlock the transfer belt.
Matthew notes that these locks can sometimes be a little difficult to turn, so apply steady pressure until they release.
Step 9: Remove the Old Transfer Belt
Grab the orange handle on the transfer belt and begin pulling the assembly straight out of the printer.
As you pull, the transfer belt will stop partway out. This is normal because an internal latch prevents it from sliding completely free.
To release that latch, grab the orange handle on top of the assembly and lift upward.
Once the internal latch releases, you can slide the transfer belt the rest of the way out.
Matthew explains that the assembly should be fairly well-balanced on the orange handle, making it easier to control during removal.
Step 10: Insert the New Transfer Belt Assembly
Take the replacement transfer belt and hold it by the orange handle.
Carefully position it inside the opening where the old assembly was removed.
Once the transfer belt is partially inserted, release the orange handle. This allows the internal latch to engage.
Continue sliding the assembly straight into the printer until it clicks into place.
Avoid forcing the transfer belt if it doesn't slide smoothly. Check its positioning before continuing.
Step 11: Relock the Transfer Belt
Once the new transfer belt is fully seated, return the two orange outer locks to their locked positions.
Turn both locks outward until they're straight up and down.
This secures the transfer belt assembly inside the printer.
Step 12: Relock All Four Drum Assemblies
Next, return to the four drum assemblies you unlocked earlier.
For each drum, use your thumb to push the assembly firmly into position.
Then lift its orange latch handle upward to lock it.
Repeat this process for all four drums, making sure each one is fully seated and secured.
Step 13: Reinstall the Waste Toner Container
Take the waste toner container you removed earlier.
You'll notice small alignment arrows on the container that correspond with gray troughs inside the printer.
Position the container so those alignment points fit into their guides.
Once aligned, roll the waste toner container upward and inward, then push until it clicks securely into place.
Step 14: Close the Printer Covers
After reinstalling the waste toner container, close the right-side cover first, followed by the rear cover.
The transfer belt portion of the replacement is now complete.
Part 3: Replace the Paper Tray Separator Roll
Step 15: Remove the Paper Tray
The final component is the separator roll assembly, which is located toward the back of the paper tray.
Start by pulling the paper tray completely out of the printer.
Once removed, look toward the rear of the tray for the orange and black separator roll assembly.
Step 16: Remove the Old Separator Roll
Locate the white release latch on the right side of the separator roll assembly.
Pull the white latch to the side to release the assembly.
Next, rotate the orange assembly upward and lift its left side out of the tray.
Once the left side is free, pull the entire separator roll assembly out.
Step 17: Position the New Separator Roll
Take the replacement separator roll assembly and locate the dowels on each side.
Begin by inserting the right dowel into its position in the tray while holding the assembly upright.
Then lower the left dowel into its corresponding slot.
This positions the assembly so it can be secured correctly.
Step 18: Secure the Separator Roll Assembly
With both dowels positioned, slide the entire separator roll assembly to the left.
Next, rotate the assembly downward into the tray.
Give it a firm push until it latches back into place.
Make sure the assembly is seated securely before reinstalling the paper tray.
Step 19: Reinstall the Paper Tray
Slide the paper tray back into the printer.
Once the tray is fully installed, you've completed the physical maintenance kit replacement on your Xerox VersaLink C500 or C505.
Common Maintenance Kit Replacement Mistakes to Avoid
Installing the Second BTR at the Wrong Angle
The second BTR fits into slots that lean slightly backward. Make sure the replacement follows the same angle rather than attempting to insert it vertically.
Forgetting to Unlock All Four Drums
Before removing the transfer belt, all four drum assemblies need to be unlatched. Skipping one can prevent the transfer belt from coming out correctly.
Forcing the Transfer Belt Past Its Internal Latch
The transfer belt stops partway out during removal. Lift the orange handle on top to release the internal latch before pulling the assembly the rest of the way out.
Not Relocking the Drums or Transfer Belt
After installing the new transfer belt, make sure both outer locks are returned to their vertical positions and all four drum assemblies are secured.
Installing the Separator Roll Incorrectly
The right and left dowels must be positioned correctly before you slide the assembly to the left and rotate it downward into place.
Quick Recap: Replacing the Maintenance Kit
Replacing the maintenance kit on a Xerox VersaLink C500 or C505 involves three main steps.
First, replace the second BTR in the rear door, making sure it follows the angle of its slots and clicks securely into place.
Next, open the right-side and rear covers, remove the waste toner container, and unlock all four drums. Remove the old transfer belt, install the replacement, and secure the transfer belt locks before relocking the drums and reinstalling the waste toner container.
Finally, remove the paper tray and replace the separator roll assembly. Position both dowels correctly, slide the assembly to the left, rotate it downward until it latches, and reinstall the tray.
FAQ
What Is Included in the Xerox VersaLink C500/C505 Maintenance Kit Replacement?
Matthew's maintenance kit replacement procedure includes the second bias transfer roll (BTR), transfer belt assembly, and paper tray separator roll assembly.
Where Is the Second BTR Located?
The second bias transfer roll is located near the top of the printer's rear door. It is secured by two orange release handles.
Do You Need to Remove the Drums to Replace the Transfer Belt?
No. In Matthew's procedure, you only need to unlock all four drum assemblies before removing the transfer belt. The drums remain inside the printer.
Why Won't the Transfer Belt Come All the Way Out?
An internal latch stops the transfer belt partway through removal. Lift the orange handle on top of the assembly to release the latch, then slide the transfer belt the rest of the way out.
Where Is the Paper Tray Separator Roll Located?
The separator roll assembly is located toward the back of the paper tray. It is the orange and black component secured by a white latch on the right side.
Keep Your Xerox VersaLink Printing Reliably
The maintenance kit plays an important role in keeping your Xerox VersaLink C500 or C505 operating as intended.
Replacing the full kit involves more steps than changing toner or a waste toner container, but handling each component separately simplifies the process. Properly aligning the second BTR, securing the transfer belt, relocking the drums, and installing the separator roll helps prevent printer errors and interruptions.
At STPT, we've spent more than 40 years helping businesses maintain their Xerox equipment. If you're comfortable following these instructions, this replacement may be something you can handle yourself. However, if a component isn't fitting correctly or your printer continues experiencing problems afterward, contacting a qualified service technician is the better option.
For more step-by-step Xerox tutorials and practical printer maintenance tips, subscribe to The Printing Workshop on YouTube. Our experienced technicians share helpful guides to make maintaining your printers easier.
