Page 1 Lexmark C792 series Machine Type 5062-xxx • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PrintCryption and StapleSmart are trademarks of Lexmark International, Inc.
Page 3: Table Of Contents
5062 Table of contents Notices and safety information ......... . xiii Laser notice .
Page 4 5062 Print is too dark ..............2-32 Print is too light .
Page 5 5062 241.03, 242.03, 243.03, 244.03, 242.05, 243.05, 244.05, 245.05—Paper jam (550-sheet/2000-sheet input option) service check ............. 2-96 242.08, 243.08, 244.08, 245.08—Paper jam (550-sheet/2000-sheet input option) service check .
Page 6 5062 PRINT TESTS ..............3-13 Print Tests (input sources) .
Page 7 5062 Print Quality Pages ............. . 3-26 Reports .
Page 8 5062 Multipurpose feeder (MPF) cover removal ..........4-16 OP panel bezel removal .
Page 9 5062 Paper auto-size sensor removal ........... 4-113 Paper path redrive assembly with sensors removal .
Page 10 5062 2000-sheet high-capacity feeder pass thru sensor removal .......4-205 2000-sheet high-capacity feeder pick assembly removal ....... . .4-207 2000-sheet high-capacity feeder pick roll assembly removal .
Page 11 5062 Finisher or stacker top cover removal ..........4-267 Finisher stapler unit assembly removal .
Page 12 5062 Connectors ................5-2 System board .
Page 13: Notices And Safety Information
5062 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 I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Page 14 5062 stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1. Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
Page 15 5062 Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) - lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
Page 16 5062 Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
Page 17 5062 xvii Notices and safety information...
Page 18 5062 xviii Service Manual...
Page 19: Safety Information
5062 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.
Page 20 5062 Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
Page 21 5062 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 22: Preface
5062 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 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.
Page 23: Conventions
5062 Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. There are several types of caution statements: 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.
Page 24 5062 xxiv Service Manual...
Page 25: General Information
It prints both four-color and monochrome print jobs. The C792 represents the latest in Lexmark printer innovation, including a full-color eTask touch screen with improved messaging and animation, enhanced security features, remote operator panel access and control, customizable reports, and access to the growing list of downloadable and customizable solutions.
Page 26: Printer Configurations
If you purchased a multifunction printer (MFP) that scans, copies, and faxes, you may need additional furniture. For more information, see www.lexmark.com/multifunctionprinters. Some options may not be available for all models. Standard output bin...
Page 27: Options And Features
StapleSmart finisher or 5-bin mailbox (mailbox pictured) Options and features Lexmark C792 printers support only Lexmark C792 paper-handling options. These options are not compatible with any other Lexmark printer. Some of the following options are not available in every country or region.
Page 28: Printer Specifications
5062 • Firmware cards – Bar Code – PrintCryption • Printer hard disk • Lexmark Internal Solutions Ports (ISP) – RS-232-C Serial ISP – Parallel 1284-B ISP – MarkNet N8250 802.11 b/g/n Wireless ISP – MarkNet N8130 10/100 Fiber ISP –...
Page 29 5062 Operating clearances 152.4 mm (6 in.) Right 101.6 mm (4 in.) Front 609.6 mm (24 in.) Left 381 mm (15 in.) Rear 304.8 mm (12 in.) Allow additional clearance around the printer for adding options, such as additional input drawers, high-capacity output stacker, banner tray, StapleSmart finisher, or 5-bin mailbox.
Page 30: Duty Cycle
5062 – Maximum wet bulb temperature: 73° F (22.8° C) – Altitude: 10,000 ft. (0 to 3,048 meters) – Atmospheric pressure: 74.6 kPa • Power off – Temperature: 50 to 110° F (10 to 43.3° C) – Relative humidity: 8 to 80% –...
Page 31: Paper Sizes Supported By The Printer
5062 Memory configuration 512MB standard memory. Optional memory is available in 256MB, 512MB, and 1GB DIMM. There is only one DIMM slot available for optional memory. Supported paper sizes, types, and weights Paper sizes supported by the printer 550-sheet trays Optional Multipurpose Paper size...
Page 32: Paper Types And Weights Supported By The Printer
For more information, see the Card Stock & Label Guide available on the Lexmark Web site at http://support.lexmark.com. Use envelopes that lie flat when individually placed facedown on a table.
Page 33: Paper Types And Weights Supported By The Output Bins
(24 lb) xerographic, grain long paper. Business papers designed for general business use may also provide acceptable print quality. We recommend Lexmark part number 12A5950 letter-size glossy paper and Lexmark part number 12A5951 A4- size glossy paper. Always print several samples before buying large quantities of any type of media. When choosing any media, consider the weight, fiber content, and color.
Page 34: Paper Characteristics
Paper characteristics The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. For detailed information, see the Card Stock & Label Guide available on the Lexmark Web site at http:// support.lexmark.com. Weight The printer can automatically feed paper weights from 60 to 220 g/m (16 to 58 lb bond) grain long.
Page 35: Selecting Paper
5062 • Preprinted papers that require a registration (the precise print location on the page) greater than ±0.09 in., such as optical character recognition (OCR) forms. In some cases, registration can be adjusted with the software application to successfully print on these forms. •...
Page 36: Tools Required For Service
5062 Tools required for service Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964 1-12 Service Manual...
Page 37: Acronyms
5062 Acronyms ASIC Application-Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Cyan Cyclic Redundancy Check Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT...
Page 38 5062 1-14 Service Manual...
Page 39: Diagnostic Information
5062 2. Diagnostic information CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer. CAUTION The printer weight is greater than 32 kg (70 lb) and requires three or more trained personnel to lift it safely.
Page 40: Error Code Divisions
5062 Error code divisions Error codes identifications have changed for this product. The following chart identifies the new code numbers that should be consistent across product lines. Range Description Go to page… Text prompts User prompts without code numbers “User prompts” on page 2-41 0–99 User attendance messages “User attendance messages (0–99)”...
Page 41: Understanding Jam Numbers And Locations
5062 Paper jams Understanding jam numbers and locations When a jam occurs, a message indicating the jam location appears on the display. To resolve any paper jam message, you must clear all jammed paper from the paper path. Area Jam number What to do 200–203 Open the side door, and then remove the jammed...
Page 42: Paper Jam
5062 Area Jam number What to do Remove all paper from the multipurpose feeder, and “250 paper jam” on then remove the jammed paper. page 2-19 200 paper jam Open the left access door. Firmly grasp the jammed paper, and then gently pull it out. Note: Make sure all paper fragments are removed.
Page 43 5062 Error code Description Action 200.04 Input sensor flag broke early. • Clear away anything in the paper path that might cause the paper to jam. Possible cause: • Be sure the paper settings match the media. • Incorrect paper settings •...
Page 44 5062 Error code Description Action 200.35, Near narrow media sensor does not 1. Clear away anything in the paper path that might 200.37 break or breaks late. cause the paper to jam. 2. Be sure the paper settings match the media. •...
Page 45: Paper Jam
5062 Error code Description Action 200.48 Narrow media sensor is never made “200.43” on page 2-6. or is made late. 200.49 S1 sensor is made when printer tries • Clear away anything in the paper path that might to print from an idle state. cause the paper to jam.
Page 46 5062 Error code Description Action 201.03 Bubble sensor is never made or is • Clear away anything in the paper path that might made late. cause the paper to jam. • If clearing a paper jam does not fix the problem, Possible causes: go to “201.03, 201.05, 201.07, 201.08—Paper...
Page 47: 202-203 Paper Jams
5062 202–203 paper jams Paper jam in the standard exit bin: Firmly grasp the paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed. From the operator panel, touch Continue, jam cleared. Paper jam in the fuser: Open the left access door.
Page 48 5062 Additional checks—202–203 paper jams Error code Description Action 202.01 Exit sensor is made when printer tries • Check for anything in the paper path that might to print from an idle state. cause the paper to jam. • The fuser exit sensor may not be functioning Possible causes: properly.
Page 49 5062 Error code Description Action 202.33 Bin-full sensor is never made or is • Clear away anything in the paper path that might made late. cause the paper to jam. • If clearing a paper jam does not fix the problem, go to “Bin-full sensor service check”...
Page 50: 230-239 Paper Jams
5062 Error code Description Action 203.03 Redrive bubble sensor is never made • Clear away anything in the paper path that might or is made late. cause the paper to jam. • If clearing a paper jam does not fix the problem, Possible cause: Faulty redrive bubble go to “Redrive bubble sensor service check”...
Page 51 5062 Additional checks—230 paper jam Error code Description Action 231.01 D1 sensor is made when printer tries • Check for anything in the paper path that might to print from an idle state. cause the paper to jam. • The D1 sensor may not be functioning properly. Possible causes: Go to “D1 and D2 sensor service check”...
Page 52: 24X Paper Jam
5062 Error code Description Action 232.05, D2 sensor never broke. • Check for anything in the paper path that might 232.07 cause the paper to jam. Possible causes: • If clearing the jam does not solve the problem, • Damaged D2 sensor Faulty fuser go to “D1 and D2 sensor service check”...
Page 53 5062 Error code Description Action 241.03 While feeding from tray 2, the paper 1. Remove anything in the paper path. never reaches the next sensor. 2. Flex the media, and stack it flat in the tray. 3. Check if the jam clearance cover can close Possible causes: properly.
Page 54 5062 Error code Description Action 242.03 While feeding from tray 3, the paper 1. Remove anything in the paper path. never reaches the next sensor. 2. Flex the media, and stack it flat in the tray. 3. Check if the jam clearance cover can close Possible causes: properly.
Page 55 5062 Error code Description Action 243.05 While feeding from tray 3, the paper 1. Clear the paper path. took a long time to clear the pass thru 2. Make sure the paper setting match the media. sensor. 3. Check if the pick roll are worn out. Possible causes: •...
Page 56 5062 Error code Description Action 244.05 While feeding from tray 4, the paper 1. Clear the paper path. took a long time to clear the pass thru 2. Make sure the paper setting match the media. sensor. 3. Check if the pick roll are worn out. Possible causes: •...
Page 57: 250 Paper Jam
5062 Error code Description Action 245.05 While feeding from tray 5, the paper 1. Clear the paper path. took a long time to clear the pass thru 2. Make sure the paper setting match the media. sensor. 3. Check if the pick roll are worn out. Possible causes: •...
Page 58 5062 Additional checks—250 paper jam Error code Description Action 250.02 S1 sensor is made early with paper • Clear away anything in the paper path that might input from the MPF. cause the paper to jam. • If clearing the jam does not solve the problem, Possible causes: go to “241.02—Paper Jam error service...
Page 59: Print Quality
5062 Print quality Note: These symptoms may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge. Service tip: Before troubleshooting any print quality problems, do the following: Print a menu settings page, and then check the life status of all supplies.
Page 60: Background (Fog)
5062 Symptom Action Print is too light Go to “Print is too light” on page 2-32 Random marks Go to “Random marks” on page 2-33 Repeating defects Go to “Repeating defects” on page 2-34 Shadow images Go to “Shadow images” on page 2-35.
Page 61 5062 Additional checks—background Step Questions / actions Replace the print cartridge. Problem solved. Go to step 2. Does this fix the problem? Check the high voltage contact from the HVPS to the Replace the ITU Go to step 3. transfer module. See “ITU block assembly removal”...
Page 62: Blank Page
5062 Blank page Try one or more of the following: • MAKE SURE THERE IS NO PACKING MATERIAL LEFT ON THE PRINT CARTRIDGE Remove the print cartridge and make sure the packing material is properly removed. Reinstall the print cartridge. •...
Page 63: Blurred Or Fuzzy Print
5062 Blurred or fuzzy print Try one or more of the following: • CHECK THE EP DRIVE ASSEMBLY AND TRANSFER MODULE Blurred or fuzzy print is usually caused by a problem in the EP drive assembly or in the transfer module. Check the EP drive assembly and transfer module for correct operation.
Page 64: Colors Not Properly Aligned
5062 • For Windows users, specify the size from Print Properties. • For Macintosh users, specify the size from the Page Setup dialog. • RESEAT THE CARTRIDGES Colors not properly aligned ABCDE ABCDE ABCDE ABCDE Color has shifted outside of the appropriate area or has been superimposed over another color area. Try one or more of the following: •...
Page 65: Horizontal Banding
5062 Horizontal banding Leading edge Trailing edge Try one or more of the following: • MAKE SURE THERE IS NO DEFECTIVE PRINT CARTRIDGE Measure the distance between repeating bands. If the distance between bands either 37.7, 41.6 or 94.2 mm, then replace the defective print cartridge. •...
Page 66: Light Colored Line, White Line, Or Incorrectly Colored Line
5062 Additional checks—horizontal lines Step Questions / actions Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove obstacles or Check the media route for contamination or obstacles.
Page 67: Media Damage
5062 Media damage Leading edge Trailing edge Additional checks—media damage Step Questions / actions Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for missing printer foot. Is the setup surface normal? Check the media feed.
Page 68: Mottle (2-5Mm Speckles)
5062 Mottle (2–5mm speckles) Leading edge Trailing edge Keep running prints through, and the problem normally clears up. If the problem persists, replace the print cartridge causing the spots. Paper curl • CHECK THE PAPER TYPE AND WEIGHT SETTINGS Make sure the paper type and weight settings match the paper loaded in the tray: From the printer Paper menu, check the Paper Type and Paper Weight settings.
Page 69 5062 Make sure the paper type and weight settings match the paper loaded in the tray: From the printer Paper menu, check the Paper Type and Paper Weight settings. Before sending the job to print, specify the correct type settings from the computer: •...
Page 70: Print Is Too Dark
5062 Print is too dark Try one or more of the following: • LOAD PAPER FROM A FRESH PACKAGE The paper may have absorbed moisture due to high humidity. Store paper in its original wrapper until you use it. • AVOID TEXTURED PAPER WITH ROUGH FINISHES •...
Page 71: Random Marks
5062 • MAKE SURE THE PRINT CARTRIDGE IS NOT LOW ON TONER When a cartridge low message appears, make sure that toner is distributed evenly among all four print cartridges or whichever color has the shadow images: Remove the print cartridge. Warning: Be careful not to touch the photoconductor drum.
Page 72: Repeating Defects
5062 Repeating defects Print quality defect locator chart The printer has an internal copy of the defect locator chart under the Help Menu. From the home screen, navigate to: > Help > Print Defects Verify the proper image size by measuring any of the marks on the printed chart and comparing them to the corresponding measurement in the chart.
Page 73: Shadow Images
5062 Shadow images Leading edge Trailing edge Try one or more of the following: • CHECK THE PAPER TYPE AND WEIGHT SETTINGS Make sure the paper type and weight settings match the paper loaded in the tray or feeder: From the operator panel Paper menu, check the Paper Type and Paper Weight settings. Before sending the print job, specify the correct paper type setting: •...
Page 74: Skew
5062 Skew Leading edge Trailing edge Step Questions / actions Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for damaged printer caster. Is the setup surface normal? Properly load media into the media tray assembly and Go to step 3.
Page 75: Solid Color Or Black Pages
5062 Solid color or black pages • MAKE SURE THE PRINT CARTRIDGES ARE INSTALLED CORRECTLY, ARE NOT DEFECTIVE AND NOT LOW ON TONER Remove and reinstall the print cartridges. Service tip: A solid color page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
Page 76: Toner Rubs Off
5062 Toner rubs off Leading edge Trailing edge Try one or more of the following: • CHECK THE PAPER TYPE AND WEIGHT SETTINGS Make sure the paper type and weight settings match the paper loaded in the tray or feeder: From the operator panel Paper menu, check the Paper Type and Paper Weight settings.
Page 77: Transparency Print Quality Is Poor
5062 Transparency print quality is poor Try one or more of the following: • CHECK THE TRANSPARENCIES Use only transparencies that meet the printer specifications. • CHECK THE PAPER TYPE SETTINGS Make sure the paper type settings match the paper loaded in the tray or feeder: From the operator panel Paper menu, check the Paper Type setting.
Page 78: Vertical Lines
5062 Vertical lines Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free Go to step 3.
Page 79: User Messages
5062 User messages User prompts Error code Action Close Front Door Close the front door securely. If you continuously get this error, then either the 24 V interlock switch or the 5 V interlock switch is bad. See “Bubble sensor service check” on page 2-112 “Bubble sensor service check”...
Page 80 5062 Error code Action Load Manual <size> If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, pressing Select indicates to the printer it should search for a source with the proper size. Additional messages may include: •...
Page 81: User Attendance Messages (0-99)
5062 User attendance messages (0–99) Error code Action 31 Defective or Missing • Reseat the specified print cartridge. <color> Cartridge • Inspect the print cartridge contacts for damage/contamination. Replace the print cartridge if defective. • Inspect the XXXX cable connection. Properly connect the cable if it is not connected properly.
Page 82 5062 Error code Action 37 Insufficient memory, • The printer deleted some held jobs in order to process current jobs. Some Held Jobs Were • Select Continue to clear the message. Not Restored • If this does not fix the problem, replace the system board. See “System board removal”...
Page 83 5062 Error code Action 54 Serial option <x> • Make sure the serial link is set up correctly and the appropriate cable is in use. error • Make sure the serial interface parameters (protocol, baud, parity, and data bits) are set correctly on the printer and host computer.
Page 84 5062 Error code Action 58 Too Many Trays 1. Turn off and unplug the printer. Attached 2. Remove options until the supported number of options for that model. Models C734 supports three options and models C736 supports four options. 3. Plug in the printer, and turn it on. If this does not fix the problem, replace the system board.
Page 85 5062 Error code Action 80 Replace Fuser • Show Me, View Supplies, and Tell Me More displays additional information. • Replace the fuser. See “Fuser assembly removal” on page 4-58. Note: Be sure to reset the fuser count as instructed on the sheet. •...
Page 86 5062 Error code Action 82 Waste Toner Missing • Insert the waste toner box. • Check the cable in connector JBUMP1on the system board for defects and proper connection. If the cable wiring or the cable connection is defective, replace the bump multipurpose feeder/duplex motor assembly.
Page 87 5062 Error code Action 84 <color> PC Unit • Scroll down the operator panel to see if the printer is showing that all four of the PC units Missing are missing. If so, check the HVPS cable between the system board and the HVPS. Ensure that the cable is not plugged in backwards on the HVPS.
Page 88: Service Errors
5062 Service errors Printer hardware errors (100–199) Error code Description Action 110.xx An error has occurred in the • POR the printer. Printhead Error printhead. • If the error message persists, go to “110.xx— Printhead error service check” on page 2-57.
Page 89 5062 Error code Description Action 146.01–146.22 Tray 1 motor has failed. • POR the printer. Autocomp Motor Error • If the error message persists, go to “146.xx— Autocomp (tray 1) motor error service check” on page 2-72. 147.01–147.22 The staging motor has failed. •...
Page 90: Firmware And/Or System Electronics (900-999)
5062 Firmware and/or system electronics (900–999) Error code Description Action 900.00–900.99 An unrecoverable RIP software error • POR the printer. (except 900.05) occurred while an unknown process • If the error message persists, go to “900.xx— Software Error was running. Software error service check”...
Page 91 5062 Error code Description Action 938.21 A staging motor failure occurred. • POR the printer. Electronics Hardware • If the error message persists, go to “147.xx— Error Staging motor error service check” on page 2-73. 938.22 A printhead failure error occurred. •...
Page 92 5062 Error code Description Action 956.00–956.99 A processor failure has occurred. • POR the printer. System Card Failure • If the error message persists, go to “956.xx— System board failure service check” on page 2-109. 957.00–957.99 An ASIC failure has occurred. •...
Page 93 5062 Error code Description Action 990.05 Service Tray2 An input option error has occurred. Go to “990.05—POST error (550-sheet input option) service check” on page 2-111. 991.00–991.99 The specified device has detected an • POR the printer. <device> Error error. •...
Page 94: Symptoms
5062 Symptoms Symptom table—base printer Symptom Action Dead printer Go to “Dead printer service check” on page 2-117. Tray linking will not work. Go to “Tray linking service check” on page 2-139. Paper pick mechanism—pick arm is stuck Go to “Pick arm stuck down service check”...
Page 95: Service Checks
5062 Service checks 110.xx—Printhead error service check Step Questions / actions View the Event Log: Replace the printhead. See Go to step 2. “Printhead removal, 1. Turn off the printer, press and hold 3 and 6 installation, and and turn on the printer. alignment”...
Page 96: 120.Xx-Motor (Fuser) Error Service Check
5062 Step Questions / actions Measure the resistance across fuse F13 on Replace the system board. Go to step 5. the system board. “System board removal” on page 4-142. Is the fuse blown? Perform the printhead verification to check Replace the printhead. See Replace the system board.
Page 97 5062 Step Questions / actions Remove the rear cover. See “Rear cover Go to step 4. Reseat the cable. removal” on page 4-18. Check the BLDE Y & Fuser cable (B) for proper connection to the fuser motor. Is the cable properly connected? Is the BLDE Y &...
Page 98: 121.Xx-Fuser Error Service Check
5062 121.xx—Fuser error service check Step Questions / actions Replace the fuser. See “Fuser assembly Problem solved. Go to step 2. removal” on page 4-58. Does the error clear? Open the system board shield. Check the Go to step 3. Reseat the cable.
Page 99 5062 Step Questions / actions Check the cable on the LVPS for damage. Replace the Fuser and Go to step 6. system card LVPS cable. Is the cable damaged? “Fuser system card and LVPS cable removal” on page 4-63. Open the left access door, remove the two Go to step 7.
Page 100: 125.Xx/145.Xx-Itu Error Service Check
5062 125.xx/145.xx—ITU error service check Step Questions / actions Replace the ITU assembly. See “ITU Problem solved. Go to step 2. assembly removal” on page 4-72. Does the error clear? Turn the printer off, open the system board Go to step 3. Reseat the cable.
Page 101: 126.Xx-Lvps Error Service Check
5062 126.xx—LVPS error service check Step Questions / actions Ask the customer if they’re having any Do nothing. Go to step 2. problem with their power lines, e.g., power outages or power failures. Is the customer having power line problems? Turn the printer off, open the system board Go to step 2.
Page 102: 133.Xx-Cartridge Sensor Error Service Check
5062 133.xx—Cartridge sensor error service check Step Questions / actions Turn the printer off and open the system Go to step 2. Reseat the cable. board shield. Check the cables in the indicated connectors for proper connection to the system board. The cables are interchangeable on the terminals, so check all four cables for any 133.xx error.
Page 103 5062 Step Questions / actions Check the cables in connectors JCMKM1 and Replace the cable. Go to step 3. JCMCY1 for damage, and then remove all four cartridges and check the other ends of the cables connected to the sensors on the memory blocks.
Page 104: 141.Xx-Black Cartridge Motor Error Service Check
5062 141.xx—Black cartridge motor error service check Step Questions / actions Turn the printer off, open the system board Go to step 2. Reseat the cable. shield, and remove the connector shield. Check the cable in the connector JKI1 (BLDC K &...
Page 105: 142.Xx-Cyan Cartridge Motor Error Service Check
5062 Step Questions / actions Remove the system board cage. See Go to step 5. Reseat the cable. “System board cage with board removal” on page 4-145. Check the cable connected to the black cartridge motor. Is the cable connected properly Replace the EP drive assembly.
Page 106 5062 Step Questions / actions Check the cable for damage. Replace the BLDC C&M Go to step 3. cable. See “EP drive Is the cable damaged? assembly removal” on page 4-54. Measure the resistance across the fuse F4 on Replace the system board. Go to step 4.
Page 107: 143.Xx-Magenta Cartridge Motor Error Service Check
5062 143.xx—Magenta cartridge motor error service check Step Questions / actions Turn the printer off, open the system board Go to step 2. Reseat the cable. shield, and remove the connector shield. Check the cable in the connector JCM1 (BLDC C&M cable) for proper connection to the system board.
Page 108: 144.Xx-Yellow Cartridge Motor Error Service Check
5062 Step Questions / actions Remove the system board cage. See Go to step 5. Reseat the cable. “System board cage with board removal” on page 4-145. Check the cable connected to the magenta cartridge motor. Is the cable connected properly Replace the EP drive assembly.
Page 109 5062 Step Questions / actions Check the cable for damage. Replace the BLDC Y & Go to step 3. Fuser cable. See “EP Is the cable damaged? drive assembly removal” on page 4-54. Measure the resistance across the fuse F1 on Replace the system board.
Page 110: 146.Xx-Autocomp (Tray 1) Motor Error Service Check
5062 146.xx—Autocomp (tray 1) motor error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JTRAY1 (A) for proper connection to the system board.
Page 111: 147.Xx-Staging Motor Error Service Check
5062 147.xx—Staging motor error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JSTAG1 (staging motor cable) for proper connection to the system board. Is the cable properly connected? Check the cable for damage.
Page 112: 149.Xx-Paper Path Redrive Motor Error Service Check
5062 149.xx—Paper path redrive motor error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JRDR1 for proper connection to the system board.
Page 113 5062 Step Questions / actions Turn the printer off, and open the system Go to step 3. Reseat the cable. board shield. Check the cable in connector JDUPL1 (Duplex motor cable) for proper connection to the system board. Is the cable properly connected? Check the cable for damage.
Page 114: 151.Xx-Itu Motor Error Service Check
5062 151.xx—ITU motor error service check Step Questions / actions Turn the printer off, open the system board Go to step 2. Reseat the cable. shield, and remove the connector shield. Check the cable in connector JKI1 (BLDC K & ITU cable) for proper connection to the system board.
Page 115: 171.Xx-Main Fan Error Service Check
5062 171.xx—Main fan error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JM1 for proper connection to the system board. Is the cable properly connected? Replace the main fan.
Page 116: 173.Xx-Blower Fan Error Service Check
5062 173.xx—Blower fan error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JBLW1 (blower & right side waste cable) for proper connection to the system board.
Page 117: 200.02-Paper Jam Error Service Check
5062 200.02—Paper Jam error service check Step Questions / actions Open the left access door. Check the input Replace the input sensor. Go to step 2. flag (A) for damage. “Sensor (input, S1, narrow media, near narrow media) removal” on page 4-133.
Page 118: 200.03, 200.08-Paper Jam Error Service Check
5062 200.03, 200.08—Paper Jam error service check Step Questions / actions Remove the input tray. Replace the pick tires. See Go to step 2. “Pick rolls removal” on page 4-118. Are the pick tires worn? Open the left access door. Check the input Replace the input sensor.
Page 119: 200.05, 200.07-Paper Jam Error Service Check
5062 Step Questions / actions Check the cable in connector JPP2 for any Replace the paper path Go to step 6. other damage. cable. See “Paper path cables” on page 7-35. Is the cable damaged? Remove the staging deflector assembly. See Go to step 7.
Page 120: 200.32-Paper Jam Error Service Check
5062 Step Questions / actions Remove the staging deflector assembly. See Go to step 6. Reseat the cable. “Staging deflector assembly removal” on page 4-135. Is the cable connected correctly? Replace the input sensor. See “Sensor Replace the System Board. Problem solved.
Page 121 5062 Step Questions / actions Remove the staging deflector assembly. See Reseat the sensor and add Contact your next level of “Staging deflector assembly removal” on a sensor retainer. See support. page 4-135.. “Sensor (input, S1, narrow media, near narrow media) removal” on page 4-133.
Page 122: 200.33, 200.38-Paper Jam Error Service Check
5062 200.33, 200.38—Paper Jam error service check Step Questions / actions Remove the input tray. Replace the pick tires. See Go to step 2. “Pick rolls removal” on page 4-118. Are the pick tires worn? Open the left access door. Check the near Replace the near narrow Go to step 3.
Page 123: 200.35, 200.37-Paper Jam Error Service Check
5062 Step Questions / actions Check the cable in connector JPP2 for any Replace the paper path Go to step 6. other damage. cable. See “Paper path cables” on page 7-35. Is the cable damaged? Remove the staging deflector assembly. See Go to step 7.
Page 124 5062 Step Questions / actions Remove the staging deflector assembly. See Go to step 6. Reseat the cable. “Staging deflector assembly removal” on page 4-135. Is the cable connected correctly? Replace the near narrow media sensor. See Replace the System Board. Problem solved.
Page 125: 200.42-Paper Jam Error Service Check
5062 200.42—Paper Jam error service check Step Questions / actions Open the left access door. Check the narrow Replace the narrow media Go to step 2. media flag (C) for damage. sensor. See “Sensor (input, S1, narrow media, near narrow media) removal”...
Page 126: 200.43, 200.48-Paper Jam Error Service Check
5062 200.43, 200.48—Paper Jam error service check Step Questions / actions Remove the input tray. Replace the pick tires. See Go to step 2. “Pick rolls removal” on page 4-118. Are the pick tires worn? Open the left access door. Check the narrow Replace the narrow media Go to step 3.
Page 127: 200.45, 200.47-Paper Jam Error Service Check
5062 Step Questions / actions Check the cable in connector JPP2 for any Replace the paper path Go to step 6. other damage. cable. See “Paper path cables” on page 7-35. Is the cable damaged? Remove the staging deflector assembly. See Go to step 7.
Page 128: Paper Jam Error Service Check
5062 Step Questions / actions Remove the staging deflector assembly. See Go to step 6. Reseat the cable. “Staging deflector assembly removal” on page 4-135. Is the cable connected correctly? Replace the near narrow media sensor. See Replace the system board. Problem solved.
Page 129 5062 Step Questions / actions Open the left access door, remove the two Go to step 5. Reseat the cable. screws (A), and pull out the fuser autoconnect enough to check the cable for proper connection. Is the cable connected correctly? Check the cable for damage.
Page 130: 202.32-Paper Jam Error Service Check
5062 202.32—Paper Jam error service check Step Questions / actions Is the bin-full flag damaged? Replace the bin-full flag. Go to step 2. “Bin-full flag removal” on page 4-36. Remove the top cover assembly. Reseat the sensor. Contact your next level of support.
Page 131: 241.02-Paper Jam Error Service Check
5062 241.02—Paper Jam error service check Step Questions / actions Open the left access door. Check the S1 Replace the S1 sensor. Go to step 2. sensor flag (B) for damage. “Sensor (input, S1, narrow media, near narrow media) removal” on page 4-133.
Page 132: Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check
5062 242.01, 243.01, 244.01, 245.01 —Paper Jam (550-sheet/2000-sheet input option) service check Step Questions / actions Check for any obstruction on the paper path. Go to step 2. Clear paper path for obstructions. Is the paper path free of obstruction? Check if the jam clearance cover can close Go to step 3.
Page 133 5062 Step Questions / actions For 550-sheet input option: For 550-sheet input option: Problem solved. Replace the 550-sheet Replace the controller card assembly. See drawer assembly. See “550-sheet tray controller card assembly “550-sheet drawer removal” on page 4-156. assembly removal” on page 4-155.
Page 134: Option) Service Check
5062 241.03, 242.03, 243.03, 244.03, 242.05, 243.05, 244.05, 245.05—Paper jam (550-sheet/ 2000-sheet input option) service check Step Questions / actions Check for any obstruction on the paper path. Go to step 2. Clear paper path for obstructions. Is the paper path free of obstruction? 1.
Page 135 5062 Step Questions / actions Check the pick roll assembly for Go to step 5. For 550-sheet input option: contamination and wear. Replace the pick roll assembly. See “550-sheet Is the above component free of excess tray pick roll assembly wear and contamination? removal”...
Page 136: Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check
5062 242.08, 243.08, 244.08, 245.08—Paper jam (550-sheet/2000-sheet input option) service check Step Questions / actions Check for any obstruction on the paper path. Go to step 2. Clear paper path for obstructions. Is the paper path free of obstruction? 1. Check if the jam clearance cover can Go to step 3.
Page 137 5062 Step Questions / actions 1. Bring the printer up in Diagnostics menu Go to step 5. Problem solved. (turn off the printer, press and hold 3 and 6, turn on the printer, and hold the buttons until the splash screen appears). 2.
Page 138: 250.21, 250.22-Mpf Motor Error Service Check
5062 250.21, 250.22—MPF motor error service check Step Questions / actions Open the left access door. Go to step 3. Go to step 2. Does the MPF wheels turn freely? Remove the LVPS fan shield. See “LVPS exit Replace the MPF pick Replace the MPF paper duct removal”...
Page 139 5062 Step Questions / actions Remove the input tray. Go to step 6. Reseat the cable. Is the input tray cable connected correctly? Remove the LVPS. See “Low-voltage power Replace the MPF drive Go to step 7. supply (LVPS) removal” on page 4-82.
Page 140: 900.Xx-Software Error Service Check
5062 900.xx—Software error service check Step Questions / actions Replace the system board. Go to step 2. 1. Turn the printer off. “System board 2. Remove the following: removal” on page 4-142. • All communication cables • Any memory options 3.
Page 141: 938.16-Mpf Paper Out Sensor Error Service Check
5062 938.16—MPF paper out sensor error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JMPF1(MPF sensor cable) for proper connection to the system board. Is the cable properly connected? Check the cable in the JMPF1(MPF sensor Replace the MPF sensor...
Page 142: 938.18-Waste Toner Sensor Error Service Check
5062 938.18—Waste toner sensor error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JWTB1 for proper connection to the system board.
Page 143: 938.19-Waste Toner Full Sensor Error Service Check
5062 938.19—Waste toner full sensor error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JWTBF1 for proper connection to the system board.
Page 144: 938.27, 938.29, 938.30-Weather Station Error Service Check
5062 938.27, 938.29, 938.30—Weather station error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JFSRD1 for proper connection to the system board.
Page 145: 938.28-Remote Weather Station Error Service Check
5062 938.28—Remote weather station error service check Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector JCCT2 (weather station compensation thermistor) for proper connection to the system board.
Page 146: 950.00-950.29-Eprom Mismatch Failure
5062 950.00–950.29—EPROM mismatch failure Warning: When replacing any of the following components, replace only one component at a time or the printer will be rendered inoperable: • System board • OP panel UICC card Replace the required component, bring the printer up in Diagnostics mode (see “Diagnostics menu”...
Page 147: 956.Xx-System Board Failure Service Check
5062 956.xx—System board failure service check Step Questions / actions Turn the printer off, and open the system Replace the system board. Reseat the cable. board shield. “System board removal” on page 4-142. Check the cable in connector J3 (system board fan connector) for proper connection to the system board.
Page 148 5062 Step Questions / actions Replace the 2000-sheet high-capacity feeder Go to step 5. Problem solved. jam door clearance sensor. See “2000-sheet high-capacity feeder jam door clearance sensor removal” on page 4-188. Does the problem persist? Replace the 2000-sheet high-capacity feeder Go to step 6.
Page 149: 990.05-Post Error (550-Sheet Input Option) Service Check
5062 990.05—POST error (550-sheet input option) service check Step Questions / actions Be sure that the following connectors are Go to step 2. Properly connect all properly connected on the 550-sheet connectors. controller card and on the other end. • Paper level sensor connector •...
Page 150: Bubble Sensor Service Check
5062 Bubble sensor service check Step Questions / actions Open the left access door, and check the Replace the damaged Go to step 2. fuser bubble sensor flag. sensor. See “Sensor (D1, D2, and fuser bubble) removal” on page 4-132. Is the bubble sensor flag damaged? Open the system board shield.
Page 151 5062 Step Questions / actions Remove the duplex cable cover. Go to step 5. Reseat the cable. A (88A0323) Check the cable for proper connection. Is the cable connected correctly? Check the cable for damage. Replace the duplexer Go to step 6. cable.
Page 152: D1 And D2 Sensor Service Check
5062 Step Questions / actions Replace the duplex assembly. See “Duplex Problem solved. Replace the system board. assembly removal” on page 4-51. “System board removal” on page 4-142. Is the problem fixed? D1 and D2 sensor service check Step Questions / actions Open the left access door, and open the Replace the damaged Go to step 2.
Page 153 5062 Step Questions / actions Open the system board shield. Check the Go step 3. Reseat the cable. cable in connector JDP1 for proper connection to the system card. Is the cable properly connected? Check the cable for damage. Replace the duplexer Go step 4.
Page 154 5062 Step Questions / actions Remove the duplex cable cover. Go to step 5. Reseat the cable. A (88A0323) Check the cable for proper connection. Is the cable connected correctly? Check the cable for damage. Replace the duplexer Go to step 6. cable.
Page 155: Dead Printer Service Check
5062 Dead printer service check A dead printer is a condition where the display is blank, the LED on the operator panel is off, no fans turn, no motors turn, and the fuser lamp does not come on. If a 550-sheet option assembly is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, replace the 550-sheet option assembly.
Page 156: Double Feed (550-Sheet/2000-Sheet Input Option) Service Check
5062 Double feed (550-sheet/2000-sheet input option) service check Step Questions / actions Check if the media supported and Go to step 3. Replace the media. environmental specification are supported by this machine. See “Environment” on page 1-5 “Supported paper sizes, types, and weights”...
Page 157 5062 Step Questions / actions 1. Check the media trays for mechanical Replace the whole input For 550-sheet input option: damage. option. Replace the media tray assembly. See “550-sheet 2. Check the media restrains. media tray assembly 3. Check for wears on the dams (for 2000- removal”...
Page 158: Input Option Not Detected (550-Sheet/2000-Sheet Input Option) Service Check
5062 Input option not detected (550-sheet/2000-sheet input option) service check Step Questions / actions Check the autoconnect connector for any Go step 3. For 550-sheet input option: damage. Replace the drawer assembly. See “550-sheet drawer assembly removal” on page 4-155. Is the autoconnect connector not damaged? For 2000-sheet input...
Page 159: Input, S1, Narrow Media, And Near Narrow Media Sensor Service Check
5062 Input, S1, narrow media, and near narrow media sensor service check Step Questions / actions Open the left access door. Check the sensor Replace the input sensor. Go to step 2. flag for damage. “Sensor (input, S1, narrow media, near narrow media) removal”...
Page 160 5062 Step Questions / actions Remove the staging deflector assembly, and Go to step 5. Reseat the cable. check the sensor cable connection. See “Staging deflector assembly removal” on page 4-135. A—Input sensor B—S1 sensor C—Narrow media sensor D—Near narrow media sensor Is the cable properly connected? Replace the sensor.
Page 161: Jam Clearance Cover Open (550-Sheet/2000-Sheet Input Option) Service Check
5062 Jam clearance cover open (550-sheet/2000-sheet input option) service check Step Questions / actions Go to step 2. For 550-sheet input option: 1. Check if the jam clearance cover can close properly. Replace the drawer assembly. See “550-sheet 2. Check if the jam clearance cover friction drawer assembly lock is not retracted.
Page 162 5062 Step Questions / actions 1. POR the printer. Go to step 4. For 550-sheet input option: Replace the drawer 2. Bring the printer up in Diagnostics menu assembly. See “550-sheet (turn off the printer, press and hold 3 and drawer assembly 6, turn on the printer, and hold the buttons removal”...
Page 163: Media Size Error (550-Sheet/2000-Sheet Input Option) Service Check
5062 Media size error (550-sheet/2000-sheet input option) service check. Step Questions / actions Is the media tray inserted properly? Go to step 2. Insert the media tray properly. Check for any obstructions between the Go to step 3. Clear any obstructions. media size actuator and the input option finger size sensor.
Page 164: Media Tray Missing (550-Sheet Input Option) Service Check
5062 Media tray missing (550-sheet input option) service check Step Questions / actions Be sure that the 550-sheet tray pick assembly Go to step 2. Properly install the 550- is inserted to the correct hole and slot during sheet tray pick assembly. installation.
Page 165: Media Tray Missing (2000-Sheet Input Option) Service Check
5062 Step Questions / actions Check for any damage or obstruction on the Replace the 550-sheet Clear any obstructions. tray slides assembly. drawer assembly. See “550-sheet drawer assembly removal” on page 4-155. Is the 550-sheet drawer assembly free of damage or obstruction? Media tray missing (2000-sheet input option) service check Step Questions / actions...
Page 166 5062 Step Questions / actions Check if the pick arm assembly is not hanging Go to step 5. Go to step 6. down. Is the pick arm hanging? Press the actuator assembly (B) to lock the Go to step 6. Problem solved.
Page 167: Networking Service Check
Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Step...
Page 168 5062 Step Questions / actions Try using a different ethernet cable. Problem solved. Go to step 14. Did this remedy the situation? Have the network administrator check the Replace the system board. Contact the network network drop for activity. “System board administrator.
Page 169: Bin-Full Sensor Service Check
5062 Bin-full sensor service check Step Questions / actions Is the bin-full flag damaged? Replace the bin-full flag. Go to step 2. “Bin-full flag removal” on page 4-36. Turn the printer off, and open the system Go to step 3. Reseat the cable.
Page 170: Pick Arm Stuck Down Service Check
5062 Pick arm stuck down service check Step Questions / actions With the assembly still in the printer, push up Problem solved. Replace the paper pick on the bar on the bottom of the pick arm to mechanism assembly. See raise the arm, and then pull the larger latch in “Paper pick mechanism the back forward to lock it in place.
Page 171: Redrive Bubble Sensor Service Check
5062 Redrive bubble sensor service check Step Questions / actions Open the left access door, and remove the Replace the paper path Go to step 2. fuser. Check the redrive bubble sensor flag for redrive assembly. See damage. “Paper path redrive assembly with sensors removal”...
Page 172: Skew (550-Sheet Input Option) Service Check
5062 Skew (550-sheet input option) service check Step Questions / actions Go to “Skew” on Go to step 2. 1. Bring the printer up in Diagnostics menu (turn off the printer, press and hold 3 and page 2-36. 6, turn on the printer, and hold the buttons until the splash screen appears).
Page 173: Skew (2000-Sheet Input Option) Service Check
5062 Step Questions / actions 1. Check the 550-sheet tray drive assembly Replace the 550-sheet tray Replace the 550-sheet for damage. drive assembly. See “550- input option. sheet tray drive assembly 2. Check the 550-sheet tray drive assembly removal” on page 4-159.
Page 174 5062 Step Questions / actions Check if there’s a contact between the rollers Go to step 6. Replace the 2000-sheet of the 2000-sheet high-capacity feeder drive high-capacity feeder drive assembly and if the jam clearance cover is assembly. See “2000- properly closed.
Page 175: Tray Empty (2000-Sheet Input Option) Service Check
5062 Tray empty (2000-sheet input option) service check Step Questions / actions Check if the paper level flag on the 2000- Go to step 2. Replace the 2000-sheet sheet high-capacity feeder pick assembly can high-capacity feeder pick freely move. assembly. See the installation note of “2000- sheet high-capacity...
Page 176 5062 Step Questions / actions Check if the lift drive coupling gear is Replace the 2000-sheet Go to step 5. damaged. high-capacity feeder lift drive motor assembly. See “2000-sheet high- capacity feeder lift drive motor assembly removal” on page 4-201. Is the lift drive coupling gear damaged? Check if the 2000-sheet high-capacity feeder Go to step 6.
Page 177: Tray Jam Indicator (550-Sheet/2000-Sheet Input Option) Service Check
5062 Tray jam indicator (550-sheet/2000-sheet input option) service check Step Questions / actions 1. POR the machine. Go to step 2. Problem solved. 2. Simulate a paper jam by obstructing the pass thru sensor. 3. Turn on machine. Does the problem persist? Be sure that JM LD (Jam clearance cover Go to step 3.
Page 178 5062 2-140 Service Manual...
Page 179: Diagnostic Aids
5062 3. Diagnostic aids This chapter provides basic information to help you navigate the printer menus and explains the tests and procedures used to identify printer failures and verify repairs have corrected the problem. Understanding the operator panel and menus Operator panel Item Description...
Page 180: Understanding The Home Screen
5062 Understanding the home screen Buttons appearing on the home screen may vary depending on home screen customization settings. Item Description Change Language Allows you to change the primary language and reports on the display, and will remain in effect until changed Bookmarks Allows you to create, organize, and save a set of bookmarks (URLs) into a tree view of folders and file links...
Page 181 5062 Button Function Delete folder Deletes a print job Drag print jobs to the folder to delete them. Left arrow Scrolls left Right arrow Scrolls right Right scroll increase Increases a value Left scroll decrease Decreases a value Scrolls down Down arrow Accept/Submit Saves a setting...
Page 182: Other Touch-Screen Icons
5062 Other touch-screen icons Icon Function Exit Exits from the current screen to the home screen Unselected radio Indicates that an item is not selected button Selected radio button Indicates a selection Index Displays information about the key functions of the printer, including instructions on how to operate it Search Lets you search for files and menus...
Page 183: Administrative Menus
5062 Administrative menus Press to enter the Administrative menus. Some menu items may not be available based on the printer model or the options installed. Supplies Menu Paper Menu Reports Settings Cyan Cartridge Default Source Menu Settings Page General Settings Magenta Cartridge Paper Size/Type Device Statistics...
Page 184: Accessing Service Menus
5062 Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics menu 1. Turn off the printer. The Diagnostics menu group contains the settings and 2. Press and hold 3 and 6. operations used while manufacturing and servicing the printer.
Page 185: Diagnostics Menu
5062 Diagnostics menu To run the printer diagnostic tests described in this chapter, enter Diagnostics mode. Turn off the printer. Press and hold 3 and 6. Turn on the printer. Hold the buttons until the splash screen appears. Diagnostics menus Dual Diode Adjust “DUAL DIODE ADJUST”...
Page 186 5062 Multi-Purpose Feeder Print Quality Pages “Print Quality Pages” on page 3-13 HARDWARE TESTS Panel Test “Panel Test” on page 3-13. Button Test “Button Test” on page 3-14. DRAM Test “DRAM Test” on page 3-14. Serial Wrap 1 (if installed) “Serial Wrap Test”...
Page 187: Exiting The Diagnostics Mode
5062 Par 1 Strobe Adj (if installed) “Par 1 Strobe Adj” on page 3-23. EP SETUP EP Defaults “EP Defaults” on page 3-23. Fuser Temp “Fuser Temp” on page 3-23. DC Charge Adjust “DC Charge Adjustment” on page 3-23. Dev Bias Adj “Dev Bias Adj”...
Page 188: Alignment Menu
5062 Retain this page to determine the changes you need to make to the margins settings. The diamonds in the margins should touch the margins of the page. 2. To change the value of any of the margin settings: Select the margin you want to change. Touch (-) to decrease the value or (+) to increase the value.
Page 189: Adjusting Linearity
5062 The printer prints the test page from the default paper source, however if the default source only supports envelopes, then the page prints from Tray 1. Print on A4 or letter paper for best results. Determine which settings to change and follow the instructions on the printed sheets to determine the adjustment.
Page 190: Drift Sensors
5062 Drift Sensors This check is used to display the status of the thermal system used to compensate for printhead drift. To perform the test: From the Diagnostics menu, navigate to: Alignment Menu > Drift Sensors Select a color to test. Test results: Value: Description:...
Page 191: Auto Detect
5062 Auto Detect This test initiates an automatic component detect process. Auto Detect should be used after you replace the system board. PRINT TESTS Print Tests (input sources) This test determines if the printer can print on media from any of the paper input sources. Each of the installed sources is available within the Print Tests menu.
Page 192: Button Test
5062 Button Test This test verifies the operator panel button function. To run the Button Test: From the Diagnostics menu, navigate to: HARDWARE TESTS > Button Test With no buttons pressed, a pattern matching the operator panel buttons is displayed. Press each operator panel button one at a time, and an “X”...
Page 193: Serial Wrap Test
5062 Serial Wrap Test Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. To run the Serial Wrap Test: Disconnect the serial interface cable, and install the wrap plug. From the Diagnostics menu, navigate to: HARDWARE TESTS >...
Page 194: Usb Hs Test Mode
5062 USB HS Test Mode 1. From the Diagnostics menu, navigate to: HARDWARE TESTS > USB HS Test Mode 2. Select the desired Port. 3. Select the desired Test. Ports Tests Port 0 Test J Port 1 Test K Port 2 Test SEO NAK Port 3 Test Packet...
Page 195: Input Tray Tests
5062 INPUT TRAY TESTS Feed Test This test feeds blank pages through the paper path. Note: This test can run using any of the paper or envelope sizes supported by the printer. The pages are placed in the default output bin; however, the Feed Test menu lets you select the input source. From the Diagnostics menu, navigate to: INPUT TRAY TESTS >...
Page 196: Output Bin Tests
5062 OUTPUT BIN TESTS Feed Test Note: If the “Configure Bins” printer setting is link rather than mailbox, the printer selects its own internal bin linking regardless of which output bin is selected for the feed test. This test verifies that media can be fed to a specific output bin. No information is printed on the media because the printhead is not turned on during this test.
Page 197: Diverter Test
5062 Horizontal High Capacity Standard Sensor Transport Unit Output 5-bin Mailbox output bin (HTU) Stacker Media In Puncher Top Position Mailbox Empty This sensor toggles between empty and not empty. This sensor toggles between near fulland not near full. This sensor toggles between full and not full. This sensor toggles between covered and not covered.
Page 198: Finisher Sensor Test
5062 The printer feeds a single blank sheet of media from the default source to a default finisher output bin.You can also specify which bin to test by using the Output Bin feed tests (see “Feed Test” on page 3-18). This test cannot be canceled or terminated once the test has begun.
Page 199: Device Tests
5062 CAUTION These sensors are near high voltage terminals to the print cartridge. Use a nonconducting item to toggle these switches and not your hand. To run the Base Sensor Test. From the Diagnostics menu, select BASE SENSOR TEST. A list of the sensors appears, with the status of each sensor after the sensor name. Manually toggle the sensors to verify that each sensor switches from open to closed.
Page 200: Printer Setup
5062 PRINTER SETUP Defaults This setting is used by the printer to determine whether US or non-US factory defaults should be selected. The following printer settings have different US and non-US values: Printer default values US value Non-US value Paper Sizes setting in the General Settings menu U.S.
Page 201: Reset Color Calibration
5062 To set the configuration ID: From the Diagnostics menu, navigate to: Printer Setup > Configuration ID Enter the Configuration ID 1. Touch the Configuration ID 2 value to select it, and then enter the new Configuration ID Touch to save and validate the new IDs. If either ID is invalid, then the printer discards the changes and returns to the original IDs.
Page 202: Event Log
5062 EVENT LOG Display Log Display Log shows the message that appeared on the operator panel for each event in the log, starting with the most recent. Use the touch-screen arrows to scroll through the log entries. To see more in-depth information about each event, print the event log using the Print Log menu item.
Page 203: Configuration Menu
5062 Configuration Menu The Configuration Menu contains a set of menus, settings, and operations which are infrequently used by a user. Generally, the options made available in this menu are used to configure a printer for operation. Note: An asterisk (*) in the value list in the following menus indicates the default value. Entering the Configuration Menu Turn off the printer.
Page 204: Exiting The Configuration Menu
5062 Configuration Menu Key Repeat Initial “Key Repeat Initial Delay” on page 3-29. Delay Key Repeat Rate “Key Repeat Rate” on page 3-29. Clear Custom Status “Clear Custom Status” on page 3-29. USB Speed “USB Speed” on page 3-29. Exit Config Menu Exiting the Configuration Menu Select EXIT Config Menu to exit the Configuration Menu and return to normal mode.
Page 205: Size Sensing
5062 SIZE SENSING Automatic size sensing can be disabled or enabled in this menu. Only paper sources that support Auto Size Sensing are displayed. Select SIZE SENSING from the Configuration menu. Select a tray. Only those trays with size sensing appear. Select Auto to turn size sensing on for that tray, or select Off to disable size sensing.
Page 206: Auto Align Adj
5062 Auto Align Adj The printer automatically runs a Toner Patch Sensing (TPS) diagnostic after certain key events. If necessary, the printer will automatically adjust the alignment. If Auto Align Adj is set to Off, then the diagnostic still runs, but the printer will not use the resulting data to automatically adjust alignment.
Page 207: Wipe Disk
5062 Wipe Disk This setting performs a wipe of the printer hard disk, erasing all data. Warning: Wipe Disk deletes all data on the printer hard disk, including downloaded fonts, macros, and held jobs. Do not initiate a disk wipe if you have information on the printer that you want to save. •...
Page 208: Theory Of Operation
5062 Theory of operation Paper path, transport components In order for an image to be printed, the paper or specialty media has to be moved from an input source (such as a tray) into the printer and eventually exit into an output source. The most important component in this process is this paper itself.
Page 209: Transport Components
5062 Transport components The paper is fed from the tray into the printer by a pick roll and sent to two sets of feed rollers which time the paper to enter the EP process at just the right moment. The feed rollers push the paper to the transfer roll (ITU) where the image is transferred to the page.
Page 210: Print Engine Theory
5062 Print engine theory Electrophotographic Process (EP Process) The method that all laser and LED printers use to print is called the electrophotographic process. These machines use differences in charge to manipulate and move toner from the print cartridge to the printed page. Even though the basic EP process is the same for every laser and LED printer, the specifics for each printer are different.
Page 211: Step 1: Charge
5062 Step 1: Charge During the charge step, voltage is sent from the HVPS to the charge roller beside each of the four photoconductors. In this printer, the charge roller is part of the photoconductor unit in the print cartridges. The charge roller puts a uniform negative charge over the entire surface of the photoconductor to prepare it for the laser beam.
Page 212: Step 2: Expose
5062 Step 2: Expose During the expose step, the laser fires a focused beam of light at the surface of each photoconductor and writes an invisible image, called a latent image or electrostatic image, for each color. The laser beam actually discharges the surface only where the beam hits the photoconductor. This creates a difference in charge potential between the exposed area and the rest of the photoconductor surface.
Page 213: Step 3: Develop
5062 Step 3: Develop Once the laser exposes the photoconductor, the HVPS sends charge to the developer roll. For each color, the print cartridge engages the photoconductor so it is in contact with the surface. Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser, the toner will attract to the photoconductor only where the laser exposed the surface.
Page 214: Step 4A: First Transfer
5062 Step 4a: First transfer When the latent images are developed on each Photoconductor, the HVPS sends voltage to the 1st Transfer Rollers inside the ITU. The charge difference between the developed toner image on the Photoconductor surface and the 1st Transfer Roller causes the images to transfer to the surface of the ITU belt for each color.
Page 215: Step 4B: Second Transfer
5062 Step 4b: Second transfer Once the four planes of color are transferred to the transfer belt from the photoconductors, the image is carried toward the transfer roll, which is also part of the ITU. Based on the speed of the transfer belt, the proper time to send the signal to pick the paper from an input source is determined.
Page 216: Step 5: Fuse
5062 Step 5: Fuse Once the image has been fully transferred to the paper, the transfer roll helps move the paper into the fuser area. The fuser applies heat and pressure to the page to melt the tiny toner particles and bond them permanently to the paper.
Page 217: Step 6: Clean/Erase
5062 Step 6: Clean/Erase There are two main cleaning processes that take place during the EP Process. One process cleans the transfer belt, and the other cleans the photoconductors. Transfer Unit Clean Once the toner image on the transfer belt has been transferred to the page, the transfer belt rotates around and is cleaned by the cleaning blade (G).
Page 218: Printhead Verification
5062 Printhead verification You can verify that the printhead is the failing FRU by following this procedure: Turn the printer off, and remove the power cord from the outlet. Remove all cords and cables from the printer before beginning. Place the printer on a corner of a work area so the front and back can be accessed. CAUTION—POTENTIAL INJURY: The printer weight is greater than 32 kg (70 lb) and requires three or more trained personnel to lift it safely.
Page 219 5062 Swing the shield open about an inch, and then slide the shield to the left to remove it. Carefully unplug the printhead video cables (B) and the printhead motor cable (C) from the system board, and carefully connect the printhead video and motor cables from the new printhead to the system board. Note: Use the packaging that came with the printhead FRU to prop up the printhead.
Page 220 5062 3-42 Service Manual...
Page 221: Repair Information
5062 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 discharge (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: •...
Page 222: Arrangement Of Removals In This Chapter
5062 Screws and fasteners Screw and fastener part numbers appear with the graphic callouts. See “Screw and retainer identification table” on page 7-38 for descriptions and actual-size illustrations of the screws. Arrangement of removals in this chapter The removals in this chapter are arranged by area of the printer: “Base printer cover removals”...
Page 223 5062 Use a flat-blade screwdriver to carefully pry up the front access door pivot, and lift the pivot enough to remove the door. Repair information...
Page 224: Left Access Door Assembly Removal
5062 Left access door assembly removal “Left and rear covers” on page 7-5 for the part number. Open the left access door assembly. Remove the three screws (A) from the cable cover, and remove the cable cover. A (88A0323) Service Manual...
Page 225 5062 Lift the locking tabs (B) on the connectors to disconnect the two cables. Remove the cables from the cable retainers (C). Close the left access door. Open the multipurpose feeder. Repair information...
Page 226 5062 Slide the paper guide all the way to the left. Carefully use a flat-blade screwdriver to lift the multipurpose feeder inner cover, and remove. Note: Be careful not to scratch or mar the cover. Note: Using a flat-blade screwdriver, pry out the back pin (D) far enough to be able to grasp the ends. D (10J2832) Service Manual...
Page 227 5062 Open the left access cover slightly, grasp one of the pins, and move the left access door back and forth gently while pulling the pin out. This aligns the holes, so the pins come out easily. Remove the other pin (E) in the same manner. See steps and 8.
Page 228 5062 Open the left access door all the way, and disconnect the rear piston by pulling apart the clamps (F) from the tabs. Remove the E-clip (G) from the front piston. G (1126829) Service Manual...
Page 229 5062 While holding the front piston, pull out the pin (H) to disconnect the piston from the printer. Note: The piston is under pressure from the spring. Hold the piston firmly as you remove the post. Lift the door up slightly and out to remove it. Installation: Place the MPF cover on the bottom of the left cover, and hold it in place while you put the assembly into place.
Page 230: Left Cover Removal
5062 Left cover removal Lower left cover removal “Left and rear covers” on page 7-5 for the part numbers. Remove the rear cover. See “Rear cover removal” on page 4-18. Use a flat-blade screwdriver to disconnect the cable from the low-voltage power supply. Open the MPF door enough to remove the screw (A) from the lower left cover under it.
Page 231 5062 Open the left access door, and remove two screws (B) from the top and middle of the left cover. B (88A0323) Open the standard media tray, and remove the screw (C) from the front of the printer. C (88A0323) 4-11 Repair information...
Page 232 5062 Lift the top cover enough to free the top of the left cover. Close the left access door, and use a flat-blade screwdriver to pop out the front of the lower left cover. 4-12 Service Manual...
Page 233 5062 Use a flat-blade screwdriver to free the latches in the middle of the cover. Open the left access door, and disconnect the rear piston by pulling apart the clamps (F) from the tabs. Slide the left cover over the piston arm to remove the left cover and lower left cover together. Note: If you are removing the left cover to access another part, then leave the left cover attached to the lower left cover.
Page 234 5062 Slide the lower left cover down to remove it from the left cover. 4-14 Service Manual...
Page 235: Lower Frame Cable Cover Removal
5062 Lower frame cable cover removal “Front” on page 7-7 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-72. Remove the screw (A). A (88A0323) Slide the cover toward the rear of the printer, and lift to remove it. 4-15 Repair information...
Page 236: Multipurpose Feeder (Mpf) Cover Removal
5062 Multipurpose feeder (MPF) cover removal “Left and rear covers” on page 7-5 for the part number. Remove the left access door assembly. See “Left access door assembly removal” on page 4-4. Separate the MPF from the left access door assembly. 4-16 Service Manual...
Page 237: Op Panel Bezel Removal
5062 OP panel bezel removal “Top, right, and front covers” on page 7-3 for the part number. Remove the logo panel. See “Logo panel removal” on page 4-81. Use a flat-blade screwdriver to pry up the three tabs (A), and then remove the bezel. Note: Three bezels are in the FRU.
Page 238: Rear Cover Removal
5062 Remove the two screws (A) on the right side. A (88A0323) Lift and slide the cover toward the right of the printer to unlatch the tabs on the right edge, and remove the cover. Rear cover removal “Left and rear covers” on page 7-5 for the part number.
Page 239 5062 Remove the three screws (A) and the two screws (B). A (88A0323) B (88A0212) A (88A0323) 4-19 Repair information...
Page 240 5062 Push in the indicated areas of the right side and left side covers, and pull out the rear cover tabs. Note: On the right cover side, start with the top tab. On the left cover side, start with the bottom tab. Remove the rear cover.
Page 241: Rear Upper Cover Removal
5062 Rear upper cover removal “Left and rear covers” on page 7-5 for the part number. Open the system board shield door, and remove the two screws (A) and the one screw (B). B (88A0212) A (88A0323) Pull toward the rear, and lift the corner off the rear upper cover post. 4-21 Repair information...
Page 242 5062 Separate the system board shield door from the rear upper cover. 4-22 Service Manual...
Page 243: Right Cover Removal
5062 Right cover removal “Top, right, and front covers” on page 7-3 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-142. Remove the rear cover. See “Rear cover removal” on page 4-18. Remove the top cap cover.
Page 244 5062 Remove the screw (B). B (88A0212) Remove the four screws (C). C (88A0323) 4-24 Service Manual...
Page 245 5062 Pull the tabs (D) away from the pins, and then pull out and down on the rear of the right cover to remove it. 4-25 Repair information...
Page 246: System Board Shield Door Removal
5062 System board shield door removal To remove the system board shield door, remove the rear upper cover. See “Rear upper cover removal” on page 4-21. System board shield removal “Left and rear covers” on page 7-5 for the part number. Open the system board shield door, and remove the two screws (A) on the system board shield.
Page 247: Top Cap Cover Removal
5062 Swing the shield open about an inch, and slide the shield to the left to remove the shield. Top cap cover removal “Top, right, and front covers” on page 7-3 for the part number. Squeeze the cover and rock it back to disengage the latches. 4-27 Repair information...
Page 248: Top Cover Removal
5062 With the cover tilted back, and pull up to remove it. Top cover removal “Top, right, and front covers” on page 7-3 for the part number. Remove the printhead access cover. See “Printhead access cover removal” on page 4-17. Remove the rear cover.
Page 249 5062 Remove three screws on the front (B). B (88A0323) Open the left access door, and remove the screw (C). C (88A0323) 4-29 Repair information...
Page 250 5062 On the top, remove two metal screws (D). D (88A0212) On the right side, remove two screws (E) and one screw (F). F (88A0212) E (88A0323) 4-30 Service Manual...
Page 251 5062 Pull the tabs away from the pins, and lift the top cover. Clip the cable tie (G), and disconnect the cable (H) from the bin-full sensor. 4-31 Repair information...
Page 252: Waste Toner Left Cover Removal
5062 Remove the top cover. Note: If you are removing the top cover to replace the cover or the cables tied to it, then clip the four cable ties and remove the operator panel and sensor cables. If you are replacing the cover, then also disconnect the output option cable from JOOPT1 on the system board.
Page 253 5062 Remove the eight screws (A) from the waste toner left cover. (88A0323) A A (88A0323) 4-33 Repair information...
Page 254: Waste Toner Sensor Cover Removal
5062 Pinch the release tab (D) and disconnect the beacon cable. Waste toner sensor cover removal Remove the waste toner container. See “Waste toner container removal” on page 4-147. Remove the screw (A) to remove the cover. A (88A0323) 4-34 Service Manual...
Page 255: Base Printer Removals
5062 Base printer removals ACM bias spring removal “Left” on page 7-11 for the part number. Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on page 4-116. Remove the screw (A) to remove the spring. A (88A0323) 4-35 Repair information...
Page 256: Bin-Full Flag Removal
5062 Bin-full flag removal “Top, right, and front covers” on page 7-3 for the part number. Pull the flag forward out of the clips. Rotate the flag, and pull to remove it. 4-36 Service Manual...
Page 257: Bin-Full Sensor Removal
5062 Bin-full sensor removal “Sensors parts packet, including” on page 7-7 for the part number. Remove the top cover. See “Top cover removal” on page 4-28. Press in the tabs to remove the sensor from under the top cover. Cartridge blower assembly removal “Front”...
Page 258 5062 Remove the screw (A) in the top cover. A (88A0323) 4-38 Service Manual...
Page 259 5062 Lift the blower assembly slightly up and to the left to free the bottom. Flex the top cover up, and rotate the blower assembly to the right to free the hook at the top. 4-39 Repair information...
Page 260 5062 Press the release tab (B) to disconnect the cable from the assembly. 4-40 Service Manual...
Page 261: Cartridge Contact Block Assembly Removal
5062 Cartridge contact block assembly removal “Front (continued)” on page 7-9 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-147. Remove the print cartridges. Remove the three screws (A) from the cartridge contact block assembly. A (88A0212) Remove the assembly.
Page 262: Cartridge Memory Block Removal
5062 Installation note: Be sure to line up the notches in the HVPS board with the ridges on the cartridge contact block assembly. Cartridge memory block removal “Front (continued)” on page 7-9 for the part number. Remove the ITU assembly. See “ITU assembly removal”...
Page 263 5062 Disconnect the cable (A, B, C, or D) for the memory block you want to remove. The terminals are interchangeable, so trace the cable back from the memory block to locate the correct connector. Note: To easily route the new cable to the system board, tie a string (at least twelve inches long) to the end of the cable you disconnect from the system board.
Page 264 5062 From the memory block you are removing, press the lever (E) to access the sensor, push the right side of the sensor to remove it, and then disconnect the cable from the sensor. Remove the two screws (F), and pull to remove the memory block. As you pull the cable through, be sure to leave the string in the path from the memory block to the system board.
Page 265: Cartridge Metering Cable Removal
5062 Installation notes: Attach the memory block and tie the string to its cable. Connect the sensor cable to the sensor, and then attach the sensor to the memory block. From the rear of the printer, pull the string to feed the memory block cable through the frame to the system board.
Page 266 5062 Disconnect the cyan & yellow cable (C) or the black & magenta cable (D) from the system board, and then pull the cable out of the printer. Installation notes: Connect the cable to the system board. Tie the correct strings to the sensor ends of the cable. From the inside of the printer, pull the strings to feed the sensor cables through to the memory blocks.
Page 267: Cartridge Rail Removal
5062 Cartridge rail removal “Front” on page 7-7 for the part number. Remove the print cartridges. Remove the screw (A) from the rail you want to remove. A (88A0212) Slide the rail forward and drop it down to remove it. 4-47 Repair information...
Page 268 5062 Installation notes: Insert the tab on the rail into the slot (B) in the back, and then lift and slide the rail into the notches (C) on the top. Apply the correct color label to new rail. 4-48 Service Manual...
Page 269: Datum Bell Crank Removal
5062 Datum bell crank removal “Left” on page 7-11 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-72. Remove the fuser. See “Fuser assembly removal” on page 4-58. Front crank Remove the waste toner left cover. See “Waste toner left cover removal”...
Page 270 5062 Rear crank Remove the left cover. See “Left cover removal” on page 4-10. Remove two screws (B) and the four screws (C) to remove the rear fuser guide. C (88A0212) B (10J1046) Remove the E-clip (D). Unhook the spring (E), and pull to remove the bell crank. D (1126830) 4-50 Service Manual...
Page 271: Duplex Assembly Removal
5062 Duplex assembly removal “Left and rear covers” on page 7-5 for the part number. Remove the left access door assembly. See “Left access door assembly removal” on page 4-4. Remove the screw (A) that secures the duplex assembly to the left access cover. A (88A0425) Lift the duplex assembly from the left access door.
Page 272 5062 Installation notes: If you are replacing the duplex drive belt, then carefully check the routing as you install the new belt. Align the edge (A) of the duplex assembly under the back edge of the left access door assembly. 4-52 Service Manual...
Page 273 5062 Align the top edge of the duplex assembly with the post, and then replace the screw. 4-53 Repair information...
Page 274: Ep Drive Assembly Removal
5062 EP drive assembly removal “Rear” on page 7-15 for the part number. Remove the system board cage with board. See “System board cage with board removal” on page 4-145. Disconnect the cable (A) from the fuser motor. Note: If you are replacing the cables, remove the toroids from the old cables and use cable ties to attach the toroids to the new cables.
Page 275 5062 Push the assembly up and pull to remove it. 4-55 Repair information...
Page 276: Exit Cooling Duct Removal
5062 Exit cooling duct removal “Rear” on page 7-15 for the part number. Remove the system board cage with board. See “System board cage with board removal” on page 4-145. Remove the main fan. See “Main fan removal” on page 4-88.
Page 277: Front Access Door Beacon Removal
5062 Front access door beacon removal “Waste toner left cover with beacon” on page 7-3 for the part number. Remove the waste toner left cover. See “Waste toner left cover removal” on page 4-32. Remove the two screws (A) from the beacon cover, and then lift off the cover. Carefully pull the cable through the holes (B) to remove it.
Page 278: Fuser Assembly Removal
5062 • Be sure the beacon LED extends through the opening in the waste toner left cover before attaching the beacon cover screws. Fuser assembly removal CAUTION Be sure the fuser assembly has cooled before you remove it. “Left” on page 7-11 for the part numbers.
Page 279 5062 Pull down the two fuser latches (A). Pull to remove the fuser assembly. 4-59 Repair information...
Page 280 5062 Installation note: After inserting the fuser assembly, push up the handles and then push up the tab under the right handle. 4-60 Service Manual...
Page 281: Fuser Drive Assembly Removal
5062 Fuser drive assembly removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-18. Remove the fuser assembly. See “Fuser assembly removal” on page 4-58. Remove the E-clip (A) and the washer under it from the fuser gears, and then slide the gears off the post. A (1126829) 4-61 Repair information...
Page 282 5062 Disconnect the cable (B) from the fuser motor. Remove the three screws (C). C (88A0212) Remove the fuser drive assembly. Installation note: Be sure to apply grease to the gear and post using the instruction sheet and two kinds of grease that came with the fuser drive assembly.
Page 283: Fuser System Card And Lvps Cable Removal
5062 Fuser system card and LVPS cable removal “Left (continued)” on page 7-13 for the part number. Remove the ITU. See “ITU assembly removal” on page 4-72. Remove the fuser. See “Fuser assembly removal” on page 4-58. Remove the waste toner left cover. See “Waste toner left cover removal”...
Page 284 5062 Remove two screws (C), and then remove the cable end and support guide from the frame. Note: If you are just testing the cable as part of a service check, then stop here. Remove the OP panel. See “Operator panel (OP) assembly removal” on page 4-105.
Page 285 5062 Clip all cable ties securing the cable. Remove the system board shield. See “System board shield removal” on page 4-26. Disconnect the fuser system card cable (D) from the system board. 4-65 Repair information...
Page 286: Fuser Thermistor Removal
5062 Push in the tab (E) to disconnect the cable from the LVPS, and remove the cable. Fuser thermistor removal “Fuser thermal guide assembly” on page 7-37 for the part number. Remove the fuser. See “Fuser assembly removal” on page 4-58.
Page 287: High-Voltage Power Supply (Hvps) Board Removal
5062 High-voltage power supply (HVPS) board removal “Front” on page 7-7 for the part number. Remove the ITU block assembly. See “ITU block assembly removal” on page 4-76. Remove the rear cover. See “Rear cover removal” on page 4-18. Remove the two screws (A) to remove the connector shield from the system board. A (88A0232) Disconnect the HVPS cable (B) from the system board.
Page 288 5062 Remove three screws (C), and then pull out the cartridge contact block assembly. C (88A0212) Remove the screw (D) from the center of the plate over the HVPS. D (88A0121) Pull the HVPS board forward. 4-68 Service Manual...
Page 289 5062 Disconnect the cable from the HVPS board. Pull the board all the way out of the printer. Note: If you are replacing only the HVPS cable, then stop here. Remove the screw (E) and three screws (F) from the bottom of the board to remove the metal post (G) and the plastic contact bracket (H).
Page 290 5062 Installation notes: • Be sure the HVPS cable sits in the groove under the HVPS board. • Be sure the ITU block assembly sits flat before attaching the three screws to reinstall it. 4-70 Service Manual...
Page 291: Host Usb Cable Removal
5062 Host USB cable removal “Front host USB cable” on page 7-36 for the part number. Remove the operator panel assembly. See “Operator panel (OP) assembly removal” on page 4-105. Remove two screws (A) from the USB cable. A (88A0323) Disconnect the cable from the UICC card to remove it.
Page 292: Itu Assembly Removal
5062 Disconnect the cable (B) from the sensor, and remove three screws (C). C (88A0323) A (88A0323) Disconnect the cable from the system board (JCVR1). Route the cable through the printer to remove the assembly. Clip and remove cable ties as needed. Note: Observe the cable routing for reinstallation.
Page 293 5062 Grasp the ITU handle (A), and carefully slide the ITU assembly from the printer. Warning: Be careful to support the ITU as you remove it to avoid damaging the components on the left access door. 4-73 Repair information...
Page 294: Itu Autoconnect Removal
5062 ITU autoconnect removal “Left” on page 7-11 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-18. Remove the right cover. See “Right cover removal” on page 4-23. Remove the ITU assembly. See “ITU assembly removal” on page 4-72.
Page 295 5062 Clip the cable tie and remove the toroid. Note: Be sure to replace the toroid during reinstallation. From the right side and back of the printer, remove four screws (C). 4-75 Repair information...
Page 296: Itu Block Assembly Removal
5062 Pull to remove the autoconnect. ITU block assembly removal “Front” on page 7-7 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-72. Remove the three screws (A) from the ITU block assembly. A (88A0323) 4-76 Service Manual...
Page 297 5062 Pull up to remove the assembly. Installation note: Be sure the ITU block assembly sits flat before attaching the three screws to reinstall it. 4-77 Repair information...
Page 298: Left Access Door Piston Removal
5062 Left access door piston removal “Left (continued)” on page 7-13 for the part number. Open the left access door assembly. Front piston Remove the E-clip (G) from the front piston. G (1126829) 4-78 Service Manual...
Page 299 5062 Remove the post (H) from the piston where it attaches to the printer. Note: The piston is under pressure from the spring. Hold the piston firmly as you remove the post. Remove the E-clip (I) and post (J) from the other end to remove the piston. I (1126830) 4-79 Repair information...
Page 300 5062 Rear piston Disconnect the piston by pulling apart the clamps (F) from the tabs. Remove the E-clip (G) and post (H) from the piston where it attaches to the printer. G (1126830) 4-80 Service Manual...
Page 301: Logo Panel Removal
5062 Remove the E-clip (I) and post (J) from the other end to remove the piston. I (1126827) Logo panel removal “Top, right, and front covers” on page 7-3 for the part number. Open the front access door. Remove the three screws (A). A (88A0323) 4-81 Repair information...
Page 302: Low-Voltage Power Supply (Lvps) Removal
5062 Rotate the panel up and pull to remove it. Low-voltage power supply (LVPS) removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-18. Push the release (A) to disconnect the power cable (B) and the fuser cable (C). 4-82 Service Manual...
Page 303 5062 Remove two screws (D) to remove the connector shield from the system board. D(88A0232) Disconnect the LVPS cables (E) from the system board. 4-83 Repair information...
Page 304 5062 Disconnect the thermistor cable from the system board. Remove the three screws (F) and the two screws (G). G (88A0323) F (88A0212) Remove the LVPS. 4-84 Service Manual...
Page 305: Lvps Exit Duct Removal
5062 Installation note: If you are replacing the LVPS FRU, then clip the cable tie to remove the thermistor from the old LVPS, and then attach the thermistor to the replacement LVPS with a new cable tie (10B1648). LVPS exit duct removal “Rear”...
Page 306: Lvps Fan Removal
5062 Remove two screws (B). B (88A0323) LVPS fan removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-18. Disconnect the fan cable (A) from the system board. 4-86 Service Manual...
Page 307 5062 Push in to open the cable clip (B) behind the system board shield. Feed the cable through the slot in the system board cage and the clip. Remove the two screws (C). C (10B1580) 4-87 Repair information...
Page 308: Main Fan Removal
5062 Feed the cable through the slot in the fan housing (D) as you remove the fan. Main fan removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-18. Disconnect the fan cable (A) from the system board. 4-88 Service Manual...
Page 309: Media Tray Rail Removal
5062 Remove the screws (B). B (10B1580) Feed the cable through the slot in the system board cage, and remove the fan. Media tray rail removal “Front (continued)” on page 7-9 for the part number. Remove the standard media tray. See “Standard media tray removal”...
Page 310 5062 Remove the screw (A) on the bottom of the printer and the screw (B) on the front. B (88A0323) A (10J1046) 4-90 Service Manual...
Page 311 5062 Lift the rail out of the printer. Right rail Remove the screw (C) to release the tension on the right side cover. C (88A0323) 4-91 Repair information...
Page 312 5062 Shut the front access door. Gently lay the printer on its back. Remove the screw (D) on the bottom of the printer, and the screw (E) and screw (F) on the front of the printer. E (88A0323) F (88A0212) D (10J1046) 4-92 Service Manual...
Page 313 5062 Pull aside the right side cover. Pull up and to the left to remove the rail from the printer. 4-93 Repair information...
Page 314: Mpf Breakaway Assemblies Removal
5062 Installation note: Be sure to align the rails with the slots in the back of the printer to slide them into place, and then fit them over the pins on the front of the printer. MPF breakaway assemblies removal “Left”...
Page 315 5062 Remove seven screws (A) and two screws (B), and remove the bottom plate. B (10J1046) B (10J1046) A (88A0323) Note: If you are replacing the input option cable, then push it up through the frame, and then stand the printer back up to remove the cable.
Page 316 5062 Front breakaway assembly Remove two screws (E). E (88A0323) Using a flat-blade screwdriver, pry out the top, and then pull to remove the assembly. 4-96 Service Manual...
Page 317: Mpf Paper Pick Assembly Removal (Including The Mpf Ratchet Collar And Mpf Drive Pulley)
5062 MPF paper pick assembly removal (including the MPF ratchet collar and MPF drive pulley) “Left and rear covers” on page 7-5 for the part numbers. Remove the left cover. See “Left cover removal” on page 4-10. Remove the waste toner left cover. See “Waste toner left cover removal”...
Page 318 5062 Remove the ratchet collar (C), and remove the bushing under it. From the front of the printer, rotate the front bushing so the tabs line up with the slots in the frame. 4-98 Service Manual...
Page 319 5062 Slide the rod toward the front of the printer to free the rear side. Installation note: Be sure to replace the thrust washer in the ratchet collar before installing the MPF drive pulley. 4-99 Repair information...
Page 320: Mpf Pick Rolls And Special Wear Strip Removal
5062 MPF pick rolls and special wear strip removal “Left and rear covers” on page 7-5 for the part number. Always replace both pick rolls and the special wear strip at the same time. Open the left access door. Remove the screw (A) in the top cover.Remove the rubber rolls (A) from the hubs. The hubs stay on the printer.
Page 321 5062 Installation notes: • Slide the edge of a pick tire between the rear hub extension and the printer frame, and then slide the roll down to the hub. • Be sure the flaps on the pick rolls slant away from the direction the rolls turn. 4-101 Repair information...
Page 322: Mpf Drive Assembly Removal
5062 • Verify the rolls turn freely. MPF drive assembly removal “Rear” on page 7-15 for the part number. Remove the LVPS exit duct. See “LVPS exit duct removal” on page 4-85. Slide the belt off the MPF redrive pulley. 4-102 Service Manual...
Page 323 5062 Remove four screws (A), and remove the assembly. (88A0323) Remove the E-clip (B) and the gear (C) to remove the belt from the assembly. (1126831) 4-103 Repair information...
Page 324: Mpf Sensor Plate Assembly Removal
5062 Installation note: When reinstalling the belt, be sure the belt sits on the teeth at the base of the gear. MPF sensor plate assembly removal “Left and rear covers” on page 7-5 for the part number. Open the left access door assembly. Use a flat-blade screwdriver to push in the tab, and lift to remove the assembly.
Page 325: Mpf Wear Strips Removal
5062 Disconnect the sensor cable (A), and remove the assembly. MPF wear strips removal “Left and rear covers” on page 7-5 for the part numbers. Open the left access door assembly. Insert a flat-blade screwdriver behind the top of the strip, and then twist the screwdriver to pop out the strip. Operator panel (OP) assembly removal Remove the top cap cover.
Page 326 5062 Remove four screws (A). A (88A0323) Rotate the panel up and pull it out. 4-106 Service Manual...
Page 327 5062 Disconnect the cables (B) going from the UICC card to the printer. Remove the operator panel assembly. 4-107 Repair information...
Page 328: Op Panel Button Removal
5062 OP panel button removal “Top, right, and front covers” on page 7-3 for the part number. Remove the OP panel UICC card. See “OP panel UICC card removal” on page 4-110. Remove the button you want by squeezing in the latches (A) and pushing the button through the front of the operator panel.
Page 329: Op Panel Display Removal
5062 OP panel display removal “Top, right, and front covers” on page 7-3 for the part number. Remove the OP panel UICC card. See “OP panel UICC card removal” on page 4-110. Remove the four screws (A) and lift off the holder. A (88A0323) 4-109 Repair information...
Page 330: Op Panel Uicc Card Removal
5062 Remove the ESD ground (B), and remove the display. Installation note: Be sure to secure the ESD ground on top of the UICC card. OP panel UICC card removal “Top, right, and front covers” on page 7-3 for the part number. Warning: The following components contain mirrored NVRAM.
Page 331 5062 Pull up the levers (A) to disconnect the display cable, and then disconnect all other cables from the UICC card. Remove the five screws (B), and remove the card. B (88A0323) Installation notes: Put the new UICC card in place, and attach the ribbon cable. Replace the five screws to secure the card.
Page 332: Pad Removal
5062 Pad removal “Left and rear covers” on page 7-5 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-142. Remove the waste toner container. See “Waste toner container removal” on page 4-147. Remove the print cartridges.
Page 333: Paper Auto-Size Sensor Removal
5062 Paper auto-size sensor removal “Front” on page 7-7 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-142. Push down on the sensor to remove it from the rear frame, and then disconnect the cable (A). Paper path redrive assembly with sensors removal “Left (continued)”...
Page 334 5062 Disconnect the sensor cables (A). Clip the cable tie, and route the cables through the frame. 4-114 Service Manual...
Page 335 5062 Remove six screws (B), three from the rear and three from the front. B B (88A0323) Insert a flat-blade screwdriver angled toward the top of the front side of the assembly, and deflect the front plate enough to drop down the front end of the assembly. Pull the sensor cables through the frame to remove the assembly.
Page 336: Paper Pick Mechanism Assembly Removal
5062 Installation note: Be sure the sensor cables are routed as shown before you reinstall the assembly. Paper pick mechanism assembly removal “Front (continued)” on page 7-9 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-142.
Page 337 5062 Lower the pick arm all the way. Rotate the release lever (B), pull it toward you, and then lower the assembly to remove it from the printer. 4-117 Repair information...
Page 338: Pick Rolls Removal
5062 Pick rolls removal “Front (continued)” on page 7-9 for the part number. Note: Replace both rolls at the same time. Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on page 4-116. Remove the screws (A) from both sides to release the pick roll hubs. A (88A0412) Remove the pick rolls.
Page 339: Printhead Removal, Installation, And Alignment
5062 Printhead removal, installation, and alignment “Top, right, and front covers” on page 7-3 for the part number. Remove the printhead access cover. See “Printhead access cover removal” on page 4-17. Remove the system board shield. See “System board shield removal” on page 4-26.
Page 340 5062 Remove the six screws (B) from the brackets, and remove the brackets. B (10J3568) Tilt the printhead forward, and lift to remove it. 4-120 Service Manual...
Page 341: Installing And Coarse Aligning The Printhead
5062 Installing and coarse aligning the printhead Place the printhead into the printer angled forward, sliding the adjustment screws into the slots in the printer frame. Lower the back of the printhead until the post on the back right corner drops into the hole in the printer frame.
Page 342 5062 Route the three printhead cables (A) through the frame, and then connect them to the system board. Warning: Be careful reconnecting the printhead ribbon cables. Flat ribbon cables can easily be damaged and should be connected gently by hand. Slide the left side of the printhead toward the back of the printer until the bottom of the coarse alignment screw (B) stops against the ridge in the printer frame.
Page 343 5062 Attach the three mounting brackets loosely to the printhead. Note: Do not tighten the six screws in the mounting brackets yet. The printhead needs to be able to move as you align it. Align the printhead to the printer frame until the gaps between the printhead and the four slots in the frame are as equal as possible.
Page 344: Aligning The Printhead
5062 Attach the front bracket, and tighten the screws (E). Reprint the alignment page and adjust the screw if necessary. Aligning the printhead There is one printhead that houses the four color planes. The black plane is aligned to the printer, and the color planes are aligned to black.
Page 345: Registration (Black)
5062 If the alignment is correct, the color bars on the page should look solid in the middle (between 1 and -1) with white lines starting to form near the top and bottom of each bar. If the solid color area of a bar is above 1 or below -1, then adjust the Dual Diode value for that color. Enter the number nearest the center of the solid color area to adjust it.
Page 346: Color Alignment (Cyan, Yellow, And Magenta)
5062 An alignment test page prints. Select Top Margin. Adjust the values to move the top alignment marks to the top edge of the page. • Increasing the value moves the alignment marks up the page. • Decreasing the value moves the alignment marks down the page. Reprint the test page and make adjustments as needed until you are satisfied with the alignment.
Page 347 5062 To use the skew tool, punch a screwdriver through the center of the wheel. Using a mark on the screwdriver handle as a point of reference, turn the paper until 0 lines up with your mark. From the Diagnostic menu, navigate to: ALIGNMENT MENU >...
Page 348 5062 Replace all the cartridges, and then reprint the test page and continue adjusting the screw until you are satisfied with the Skew alignment. Repeat steps 3 through 5 to adjust the Skew for cyan and magenta (selecting Cyan and Magenta from the Alignment menu).
Page 349: Redrive Gears Removal
5062 Example: The gray stripe on the following test page extends up to around 16 near the Center line. From the Yellow Linearity menu, enter 16 for the Center Adjustment value to move the gray stripe back toward 0. Repeat the color alignment process for Cyan and Magenta. Redrive gears removal “Left”...
Page 350: Redrive Motor Removal
5062 Redrive motor removal “Left” on page 7-11 for the part number. Remove the top cover. See “Top cover removal” on page 4-28. Slide off the cap (A). 4-130 Service Manual...
Page 351 5062 Disconnect the cable (B) from the motor. Remove the two screws (C) to remove the motor. C (88A0212) 4-131 Repair information...
Page 352: Sensor (D1, D2, And Fuser Bubble) Removal
5062 Sensor (D1, D2, and fuser bubble) removal Open the left access door. Remove two screws (A) from the duplex unit, and remove the rail cover. Pull out the sensor assembly, and rotate it up. Slide out the sensor you are replacing: fuser bubble (A), D1 (B), D2 (C). 4-132 Service Manual...
Page 353: Sensor (Input, S1, Narrow Media, Near Narrow Media) Removal
5062 Disconnect the cable to remove the sensor. Installation note: Place the plastic clip in the notch in the duplex unit before you reattach the rail cover. Sensor (input, S1, narrow media, near narrow media) removal “Left” on page 7-10 for the part number.
Page 354: Speaker Removal
5062 Remove the sensor retainer (E), and then press the tabs to release the sensor. Disconnect the sensor cable to remove the sensor. Installation note: Reinstall a sensor retainer after you attach the new sensor. Speaker removal “Top, right, and front covers” on page 7-3 for the part number.
Page 355: Staging Deflector Assembly Removal
5062 Staging deflector assembly removal “Left” on page 7-11 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-72. Push the top of the deflector down and rotate it back to release the upper hooks. Disconnect the cables (A) from the four sensors.
Page 356: Staging Paper Path Reference Edge Assembly Removal
5062 Installation notes: • Be sure the cables are routed through the cable hooks (B) before you snap the assembly into place. Use the cable lengths as a guide to make sure you connect the correct cable to each sensor. •...
Page 357 5062 Push the top of the deflector assembly down and rotate it back to release the upper hooks. Set the deflector assembly out of the way as far as the sensor cables will allow. 4-137 Repair information...
Page 358 5062 Remove the screw (A) to remove the ground cable. (88A0212) Remove two screws (C) from the ITU DS roller plate, and then remove the plate. (10J1733) 4-138 Service Manual...
Page 359 5062 Remove two screws (D). (88A0329) Lift the bottom of the staging assembly and then rock it back to free it from the frame. Disconnect the two cables from the motors to remove the assembly. 4-139 Repair information...
Page 360: Aligning The Staging Paper Path Reference Edge
5062 Installation notes: • Be sure the duplex motor cable is not pinched or bound by the reference edge assembly. • Place the slot in the ITU DS roller plate over the ridge on the frame, and then swing the plate into place to reattach the two screws.
Page 361 5062 An alignment page prints. Note: If you cannot see both the right and left alignment marks on the top of the test page, go to “Aligning the top margin” on page 4-141, and adjust the top margin until the marks are visible. If the left and right top alignment marks are not parallel with the top edge of the page, then adjust the screw (A) accordingly.
Page 362: Standard Media Tray Removal
5062 Standard media tray removal “Top, right, and front covers” on page 7-3 for the part number. Pull the tray out and lift slightly. The tray will lift out of the slides (A), and the slides will retract. System board removal “Rear”...
Page 363 5062 Remove two screws (A) to remove the connector shield from the system board. A (88A0232) Disconnect all cables from the system board. Note: Some cables have special connectors that require you to press in tabs to disconnect the cables. Remove any options from the system board.
Page 364 5062 Remove the screws (B) from the ports. B (88A0232) Remove the nine screws (C), and then remove the system board by sliding it to the left so the Ethernet port (D) clears the shield. C (88A0232) 4-144 Service Manual...
Page 365: System Board Cage With Board Removal
5062 Installation notes: Install the new system board, and be sure all cables are securely connected. Be sure to reinstall any toroids you had to remove. Note: Some connectors have the same number of pins, so be sure each cable is connected to the correct connector.
Page 366 5062 Disconnect all cables from the system board and feed them through the slots in the system board cage. Note: Some cables have special connectors that require you to press in tabs to disconnect the cables. Remove the screw (B). B (88A0212) Tilt the cage forward and slide it up to remove it.
Page 367: Waste Toner Container Removal
5062 Waste toner container removal Open the front access door. Open the standard media tray. Flip the green handles forward and pull out the waste toner container. Waste toner gears removal “Rear” on page 7-15 for the part number. Remove the EP drive. See “EP drive assembly removal”...
Page 368: Waste Toner Sensor Removal
5062 Waste toner sensor removal “Front” on page 7-7 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-147. Remove the screw (A), and remove the waste toner sensor cover. A (88A0323) From the left side of the printer, push in the clips, and then pull the sensor out from the front. Disconnect the cable to remove the sensor.
Page 369: Waste Toner Cable Removal
5062 Waste toner cable removal “Waste toner cable” on page 7-37 for the part number. Remove the waste toner sensor cover. See “Waste toner sensor cover removal” on page 4-34. Remove the waste toner left cover. See “Waste toner left cover removal” on page 4-32.
Page 370: Waste Toner Full Cable Removal
5062 Remove the screw (A) to disconnect the cable from the beacon, and then disconnect the cable from the two sensors (B). A (88A0313) Clip any cable ties holding the cable, and then pull the cable through the frame to remove it. Waste toner full cable removal “Waste toner full cable”...
Page 371: Waste Toner Full Sensor Removal
5062 Disconnect the cable from the sensor, and pull the cable through the frame. Waste toner full sensor removal “Front” on page 7-7 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-147. Pry out the sensor from the front, and disconnect the cable to remove the sensor.
Page 372: Waste Toner Tray Bracket Removal
5062 Waste toner tray bracket removal “Front” on page 7-7 for the part number. Remove the lower frame cable cover. See “Lower frame cable cover removal” on page 4-15. Disconnect the cable. Using a short screwdriver, remove five screws (D), four from the bottom of the tray and one from the front. (88A0323) 4-152 Service Manual...
Page 373 5062 Pull the right frame back to free the side of the tray, and then pull the tray forward to remove it. 4-153 Repair information...
Page 374: Input Option Removals
5062 Input option removals 550-sheet tray Note: Carefully remove the 550-sheet tray option from the base printer before proceeding. 4-154 Service Manual...
Page 375: 550-Sheet Drawer Assembly Removal
5062 550-sheet drawer assembly removal “Optional 550-sheet tray” on page 7-17 for the part number. Remove the 550-sheet media tray assembly from the 550-sheet drawer assembly. The 550-sheet drawer assembly remains. 550-sheet media tray assembly removal See“Optional 550-sheet tray” on page 7-17 for the part number.
Page 376: 550-Sheet Tray Controller Card Assembly Removal
5062 Slide the 550-sheet media tray assembly out of the drawer. 550-sheet tray controller card assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-155.
Page 377 5062 Remove the 550-sheet tray controller card assembly from the shield. 4-157 Repair information...
Page 378: 550-Sheet Tray Deflector Removal
5062 550-sheet tray deflector removal Remove the top metal cover. See “550-sheet tray top metal cover removal” on page 4-172. Disconnect the pass thru sensor connector (A) from the pass thru sensor. Remove the pass thru sensor cable. Remove the screw (B) securing the deflector to the drawer. Remove the 550-sheet tray deflector.
Page 379: 550-Sheet Tray Drive Assembly Removal
5062 Installation note: Be sure that the tabs are inserted in their corresponding hole. 550-sheet tray drive assembly removal Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-155. Remove the top metal cover. See “550-sheet tray top metal cover removal” on page 4-172.
Page 380 5062 Release the cord with a prying tool. Remove the six screws (A) and one screw (B) securing the drive assembly to the drawer. B (88A0001) A (88A0323) Open the jam clearance cover. Lift the left side of the drive assembly to access the controller card assembly. 4-160 Service Manual...
Page 381 5062 Disconnect the three drive connectors (C) from the controller card assembly. Pull up the left side of the drive assembly until the left tip (D) clears the drawer. 4-161 Repair information...
Page 382: 550-Sheet Tray Left Anti-Tip Latch Removal
5062 Remove the 550-sheet tray drive assembly. 550-sheet tray left anti-tip latch removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-155. Place the drawer on a vertical position to have access to the bottom cover screws. Remove the nine screws (A) and the two screws (B) securing the bottom cover to the drawer.
Page 383 5062 Warning: Do not forcefully separate the bottom cover from the drawer; the ground cable (C) is still attached to it. Remove the two screws (D) securing the left anti-tip latch assembly to the drawer. D (88A0232) 4-163 Repair information...
Page 384: 550-Sheet Tray Pass Thru Sensor Removal
5062 Remove the left anti-tip latch assembly. 550-sheet tray pass thru sensor removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the top metal cover. See “550-sheet tray top metal cover removal” on page 4-172. Remove the deflector. See “550-sheet tray deflector removal”...
Page 385: 550-Sheet Tray Pick Assembly Removal
5062 Remove the pass thru sensor. 550-sheet tray pick assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-155. Disconnect the pick assembly connector (A) from the drive assembly. 4-165 Repair information...
Page 386 5062 Turn the shaft clockwise until the tab (B) aligns with the opening. Pull down the pick arm to release the pick assembly. 4-166 Service Manual...
Page 387 5062 Pull out the pick assembly. Remove the 550-sheet tray pick assembly. Warning: Do not change the location of the spring. 4-167 Repair information...
Page 388 5062 Installation notes: Align the shaft to the left hole of the drive assembly. Insert the shaft into the hole. 4-168 Service Manual...
Page 389: 550-Sheet Tray Pick Roll Assembly Removal
5062 Be sure that the tab is aligned in the opening and then turn the shaft counterclockwise. 550-sheet tray pick roll assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal”...
Page 390 5062 This is the photo of the pick roll assembly. Installation note: Before installing the pick tire, be sure that the pick tire is fully aligned against one end of the hub. 4-170 Service Manual...
Page 391: 550-Sheet Tray Right Anti-Tip Latch Assembly Removal
5062 550-sheet tray right anti-tip latch assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-155. Remove the top metal cover. See “550-sheet tray top metal cover removal” on page 4-172.
Page 392: 550-Sheet Tray Top Metal Cover Removal
5062 550-sheet tray top metal cover removal Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-155. Remove the 10 screws (A) and one screw (B) securing the top metal cover to the drawer. B (88A0001) A (88A0323) Remove the 550-sheet tray top metal cover.
Page 393: 2000-Sheet High-Capacity Feeder
5062 2000-sheet high-capacity feeder Note: Carefully remove the 2000-sheet high-capacity feeder option from the base printer before proceeding. 2000-sheet high-capacity feeder bellcrank assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal”...
Page 394: 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal
5062 This is the photo of the 2000-sheet high-capacity feeder bellcrank assembly. 2000-sheet high-capacity feeder controller card assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-218.
Page 395: 2000-Sheet High-Capacity Feeder Drive Assembly Removal
5062 Remove the controller card assembly from the shield. 2000-sheet high-capacity feeder drive assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204.
Page 396 5062 Remove the screw (A) to disconnect the ground cable from the rear. A (88A0231) Remove the three drive assembly connectors (B) from the controller card assembly. 4-176 Service Manual...
Page 397 5062 Release the three drive assembly cables from the cable guides (C). 4-177 Repair information...
Page 398 5062 Remove the three screws (D) securing the drive assembly to the drawer. D (88A0442) Remove the drive assembly. 4-178 Service Manual...
Page 399: 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal
5062 This is the photo of the 2000-sheet high-capacity feeder drive assembly. 2000-sheet high-capacity feeder elevator home sensor removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-218.
Page 400 5062 Remove the three screws (B) securing the controller card housing. B (88A0231) 4-180 Service Manual...
Page 401 5062 Detach the controller card housing. Note: The controller card housing does not need to be completely removed from the machine. It may be allowed to hang on the side. Remove the screw (C) securing the elevator home sensor. C (88A0312) 4-181 Repair information...
Page 402 5062 Press the latch (D) to remove the elevator home sensor. Remove the elevator home sensor cable. 4-182 Service Manual...
Page 403: 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal
5062 2000-sheet high-capacity feeder jam clearance cover removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204. Remove the jam clearance top cover. See “2000-sheet high-capacity feeder jam clearance top cover removal”...
Page 404 5062 Release the jam clearance cover cable from the cable guides (B). Open the jam clearance cover. Remove the 4 screws (C) securing the jam clearance cover to the drawer. C (88A0231) Close the jam clearance cover. 4-184 Service Manual...
Page 405 5062 Pull out the jam clearance cover to clear the slots from the frame. Press the metal tab to release the jam clearance cover, and pull up to remove the jam clearance cover. 4-185 Repair information...
Page 406 5062 Warning: Be careful not to damage the jam clearance cover sensor. This is the photo of the 2000-sheet high-capacity feeder jam clearance cover. 4-186 Service Manual...
Page 407: 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal
5062 2000-sheet high-capacity feeder jam clearance top cover removal Open the jam clearance cover. Remove the two screws (A) and one screw (B) securing the jam clearance top cover to the drawer. A (88A0414) B (88A0231) Lift the right side of the jam clearance top cover to clear it from the LED bracket. 4-187 Repair information...
Page 408: 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal
5062 Remove the jam clearance top cover. 2000-sheet high-capacity feeder jam door clearance sensor removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204.
Page 409 5062 Release the jam clearance cover cable from the cable guides (B). Remove the screw (C) and press the latch (D) to release the jam clearance cover sensor. C (88A0312) 4-189 Repair information...
Page 410: 2000-Sheet High-Capacity Feeder Led Bracket Removal
5062 Remove the jam clearance cover sensor. 2000-sheet high-capacity feeder LED bracket removal Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-218. Remove the left side cover. See “2000-sheet high-capacity feeder left side cover removal” on page 4-193.
Page 411: 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal
5062 Remove the two screws (A) securing the LED bracket to the drawer. A (88A0231) Detach the LED bracket. Note: The LED bracket does not need to be completely removed from the machine. It may be allowed to hang on the side. 2000-sheet high-capacity feeder left anti-tip latch assembly removal See“Optional 2000-sheet high-capacity feeder”...
Page 412 5062 Remove the two screws (A) securing the left anti-tip latch assembly to the drawer. Note: Hold the left anti-tip latch assembly to prevent it from falling off after removing the screws. A (88A0231) This is the photo of the left anti-tip latch assembly. 4-192 Service Manual...
Page 413: 2000-Sheet High-Capacity Feeder Left Side Cover Removal
5062 Installation note: The right anti-tip latch assembly (A) is thinner compared to the left-anti-tip latch assembly (B). 2000-sheet high-capacity feeder left side cover removal Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-218. Open the media tray assembly. Remove the seven screws (A) securing the left side cover to the drawer.
Page 414 5062 Remove the left side cover by slightly lifting it. This is the photo of the 2000-sheet high-capacity feeder left side cover. 4-194 Service Manual...
Page 415: 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal
5062 Installation note: Be sure that the latch is inside the slot. 2000-sheet high-capacity feeder lift drive gear assembly removal Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal”...
Page 416 5062 Disconnect the lift drive motor connector from the controller card assembly. Release the lift drive motor cable from the cable guide (A). Remove the four screws (B) to remove the bracket. 4-196 Service Manual...
Page 417 5062 Remove the E-clip securing the elevator gear (C) to the frame. Note: The spring from gear (C) will pop out when removing the E-clip. Remove the elevator gear (C). Remove the E-clip securing the elevator gear (D) to the frame. Remove the elevator gear (D).
Page 418 5062 Remove the E-clip securing the elevator gear (E) to the frame. Remove the elevator gear (E). Remove the E-clip securing the elevator gear (F) to the bracket. Remove the elevator gear (F). 4-198 Service Manual...
Page 419 5062 Remove the bearing (G). This is the photo of the 2000-sheet high-capacity feeder lift motor drive assembly. 4-199 Repair information...
Page 420 5062 Installation notes: Make sure that the bearing is reinstalled as shown in the picture. Make sure that the gear is reassembled as shown in the picture. 4-200 Service Manual...
Page 421: 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal
5062 2000-sheet high-capacity feeder lift drive motor assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal”...
Page 422 5062 Remove the four screws (B) to remove the bracket. Remove the two screws (H) securing the motor to the bracket. 4-202 Service Manual...
Page 423 5062 Remove the motor from the bracket. 4-203 Repair information...
Page 424: 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal
5062 2000-sheet high-capacity feeder media tray assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Open the media tray assembly until it stops. Slightly pull the media tray to the right, push the latch on the media tray slide, and push the slide until it clears the tray.
Page 425: 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal
5062 Slightly lift the tray to clear it from the stopper and pull to remove the media tray assembly out of the drawer. 2000-sheet high-capacity feeder pass thru sensor removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Open the media tray assembly.
Page 426 5062 Release the latch (B) securing the pass thru sensor. Remove the pass thru sensor. 4-206 Service Manual...
Page 427: Sheet High-Capacity Feeder Pick Assembly Removal
5062 2000-sheet high-capacity feeder pick assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204. Remove the jam clearance top cover. See “2000-sheet high-capacity feeder jam clearance top cover removal”...
Page 428 5062 Disconnect the four pick assembly connectors (C) from the controller card assembly. 4-208 Service Manual...
Page 429 5062 Release the pick assembly cables from the cable guide (D). 4-209 Repair information...
Page 430 5062 Remove the two screws (E) securing the cave light to the drawer. E (88A0231) Lift the lower right side of the pick assembly and pull to remove it. 4-210 Service Manual...
Page 431 5062 This is the photo of the 2000-sheet high-capacity feeder pick assembly. 4-211 Repair information...
Page 432 5062 Installation note: Align the upper left part of the pick assembly. Align the frame tabs to their corresponding pick arm slots. 4-212 Service Manual...
Page 433 5062 Installation note: Make sure that the pick arm lever (A) is on top of the actuator lever (B). If the pick arm is hanging, press the actuator lever as shown in the picture. Make sure that the pick arm is positioned as shown in the picture. 4-213 Repair information...
Page 434: 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal
5062 2000-sheet high-capacity feeder pick roll assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-204. Open the jam clearance cover. Push down the pick arm until it clicks.
Page 435 5062 Press down the black latch (A) to release the pick tire. Remove the pick roll tire. Repeat steps 4-5 to remove the pick tire on the other side. 4-215 Repair information...
Page 436 5062 This is the photo of the 2000-sheet high-capacity feeder pick roll assembly. 4-216 Service Manual...
Page 437 5062 Installation note: Be sure that the pick arm lever (A) is on top of the actuator lever (B). If the pick arm is hanging, press the actuator lever as shown in the picture. Be sure that the pick arm is positioned as shown in the picture. 4-217 Repair information...
Page 438: 2000-Sheet High-Capacity Feeder Rear Cover Removal
5062 2000-sheet high-capacity feeder rear cover removal Remove the two screws (A) securing the rear cover to the drawer. A (88A0442) Position the printer so that the rear cover is over the edge of the table. 4-218 Service Manual...
Page 439 5062 Release the two latches, and remove the rear cover. This is the photo of the 2000-sheet high-capacity feeder rear cover. 4-219 Repair information...
Page 440: 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal
5062 2000-sheet high-capacity feeder right anti-tip latch assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-21 for the part number. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-218. Remove the right side cover. See “2000-sheet high-capacity feeder right side cover removal”...
Page 441: 2000-Sheet High-Capacity Feeder Right Side Cover Removal
5062 Installation note: The right anti-tip latch assembly (A) is thinner compared to the left-anti-tip latch assembly (B). 2000-sheet high-capacity feeder right side cover removal Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-218. Open the media tray assembly. Remove the seven screws (A) securing the right side cover to the drawer.
Page 442 5062 Pull the upper back portion of the right side cover. Lift the right side cover to remove it. 4-222 Service Manual...
Page 443 5062 This is the photo of the 2000-sheet high-capacity feeder right side cover. 4-223 Repair information...
Page 444: Output Option Removals
5062 Output option removals 5-bin mailbox 5-bin mailbox access door removal Remove the mailbox from the printer. Remove the front cover. See “Finisher or stacker front cover removal” on page 4-248. Open the access door, and press in to release the support pins from each side of the door. Flex a side plate enough to free one hinge of the door, and then remove the door.
Page 445: 5-Bin Mailbox Assembly Media Bin Full Actuator Removal
5062 Remove five screws (B) to remove the beacon LED and cover. 5-bin mailbox assembly media bin full actuator removal 1. Remove the front cover. See “5-bin mailbox front cover removal” on page 4-233. 2. Pry the front hinge of the media bin full actuator towards the rear until the front boss is released from its socket.
Page 446: 5-Bin Mailbox Assembly Sensor (Pass Thru) Removal
5062 5-bin mailbox assembly sensor (pass thru) removal Remove the 5-bin mailbox option from the printer. Remove the 4th mailbox output bin deflector. See “5-bin mailbox output bin deflector removal” on page 4-236. Disconnect the pass thru cable from the controller card. Release the tabs (A) holding the sensor, and then remove the sensor with its cable.
Page 447: 5-Bin Mailbox Assembly Spring Removal
5062 5-bin mailbox assembly spring removal 1. Remove the mailbox option from the printer. Open the left access door. 3. Using a spring hook or needlenose pliers, remove the spring off the hooks. 4-227 Repair information...
Page 448: 5-Bin Mailbox Backup Roll Plate Assembly Removal
5062 5-bin mailbox backup roll plate assembly removal Remove the mailbox from the printer. Remove the mailbox rear cover. See “5-bin mailbox rear cover removal” on page 4-239. Open the left access door, and press in to release the support pins from each side of the door. Flex the sides to remove the roller frame.
Page 449: 5-Bin Mailbox Bin-Full Beacon Card And Covers Removal
5062 5-bin mailbox bin-full beacon card and covers removal Remove the mailbox from the printer. Remove the mailbox front cover. See “5-bin mailbox front cover removal” on page 4-233. Remove the five screws (A), and then remove the beacon card and covers. 5-bin mailbox cave beacon removal Remove the mailbox from the printer.
Page 450: 5-Bin Mailbox Controller Card Removal
5062 Remove the screw (C), and then disconnect the cable (B) from the card to remove the beacon. Note: Observe the cable routing for reinstallation. To replace the cable, remove the rear cover and disconnect the cable from the printer circuit board. See “5-bin mailbox rear cover removal”...
Page 451: 5-Bin Mailbox Diverter Solenoid Removal
5062 5-bin mailbox diverter solenoid removal Remove the mailbox from the printer. Remove the 5-bin mailbox feed motor with plate. See “5-bin mailbox feed motor with plate removal” on page 4-232. Remove the four screws (A) securing the diverter plate. Remove the screw (B) of the deflector gate solenoid you need to remove.
Page 452: 5-Bin Mailbox Feed Motor With Plate Removal
5062 5-bin mailbox feed motor with plate removal Remove the mailbox from the printer. Remove the mailbox front cover. See “5-bin mailbox front cover removal” on page 4-233. Remove the printer circuit board. See “5-bin mailbox controller card removal” on page 4-230.
Page 453: 5-Bin Mailbox Front Cover Removal
5062 5-bin mailbox front cover removal Remove the mailbox from the printer. Remove two screws (A) from the bottom. From the left side, use a flat-blade screwdriver to pry up and disengage the tabs. 4-233 Repair information...
Page 454 5062 Pull out on the right side to disengage the tabs, and then remove the cover. Disconnect the cable from the beacon card. Note: If you are replacing the cover FRU, then remove the bin-full beacon card. See “5-bin mailbox bin-full beacon card and covers removal”...
Page 455: 5-Bin Mailbox Option Cable Removal
5062 5-bin mailbox option cable removal Remove the mailbox from the printer. Remove the rear cover. See “5-bin mailbox rear cover removal” on page 4-239. Press the tabs to release the cable, and push the cable through the frame. Disconnect the cable (A) from the controller card, and press the latch to disconnect cable (B) from the controller card.
Page 456: 5-Bin Mailbox Output Bin Deflector Removal
5062 5-bin mailbox output bin deflector removal Remove the mailbox option from the printer. Remove the mailbox access door roller assembly. Remove the rear cover. See “5-bin mailbox rear cover removal” on page 4-239. Remove the mailbox feed motor with plate assembly. See “5-bin mailbox feed motor with plate removal”...
Page 457: Bin Mailbox Output Bin Paper Bail Removal
5062 Pull the left side out. 5-bin mailbox output bin paper bail removal Top bail: Remove the mailbox from the printer. Remove the top cover. See “5-bin mailbox top cover removal” on page 4-240. From the top cover, lift the bail to line up the bail arm with the slot (A), and squeeze the bail to release the rear side.
Page 458: 5-Bin Mailbox Output Bin Sensors Removal
5062 Lower four bails: Squeeze both sides of the bail to release the arms from the slots. Remove the bail. 5-bin mailbox output bin sensors removal Remove the mailbox from the printer. Remove the rear cover. See “5-bin mailbox rear cover removal” on page 4-239.
Page 459 5062 5-bin mailbox paper jam beacon removal Remove the mailbox from the printer. Remove the mailbox front cover. See “5-bin mailbox front cover removal” on page 4-233. Remove the mailbox access door. See “5-bin mailbox access door removal” on page 4-224.
Page 460: 5-Bin Mailbox Top Cover Removal
5062 Use a flat-blade screwdriver to pry out the right side to disengage the latches. Use the screwdriver to disengage the two latches on the left side, and then remove the cover. 5-bin mailbox top cover removal Remove the mailbox from the printer. Remove the front cover.
Page 461 5062 Remove the two screws (A), and remove the top cover. Remove the rear cover. See “5-bin mailbox rear cover removal” on page 4-239. Remove the two screws (B), and then lift off the top cover. 4-241 Repair information...
Page 462: 5-Bin Mailbox Tray Extension Removal
5062 5-bin mailbox tray extension removal Pull out the extension until it stops. Push to release the two tabs (A) on the bottom of the extension, and then pull the extension out to remove 4-242 Service Manual...
Page 463: Staplesmart Finisher And High-Capacity Output Stacker
5062 StapleSmart finisher and High-capacity output stacker Finisher or stacker access door beacon LED and beacon housing removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Remove the left access door assembly. See “Finisher or stacker left access door assembly removal”...
Page 464 5062 Using a spring hook, remove the spring. 4-244 Service Manual...
Page 465: Finisher Or Stacker Bottom Cover Removal
5062 Finisher or stacker bottom cover removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Remove the standard output bin LED and LED lens. See “Finisher or stacker standard output bin LED and LED lens removal” on page A-264.
Page 466 5062 Remove the three screws (A) securing the stapler/stacker controller card assembly. Remove the stapler/stacker controller card assembly. Installation note: Be sure to place the black plastic under the controller card before you put the card in place. 4-246 Service Manual...
Page 467: Finisher Or Stacker Feed Roller Removal
5062 Finisher or stacker feed roller removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Open the option left access door. Using a screwdriver, force the rear hinge (A) out of the slot by pushing the door to the front. Remove the screw (B) to remove the roller you are replacing.
Page 468: Finisher Or Stacker Front Cover Removal
5062 Finisher or stacker front cover removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Remove the two screws (A) on the inside of the exit bin compartment. 4-248 Service Manual...
Page 469: Finisher Or Stacker Led Sensor Cover Removal
5062 Using a flat-blade screwdriver, pry up to disengage the tabs on the right, left, and top sides of the cover. Remove the left cover. Finisher or stacker LED sensor cover removal Remove the option from the printer. Remove the standard output bin LED lens. See “Finisher or stacker standard output bin LED and LED lens removal”...
Page 470: Finisher Or Stacker Left Access Door Assembly Removal
5062 Finisher or stacker left access door assembly removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Open the left access door. Using a screwdriver, force the rear hinge (A) out of the slot to lower the door all the way, and then pry the rear hinge out by pushing the door to the front.
Page 471: Finisher Or Stacker Media Stack Flap And Media Stack Flap Actuator Removal
5062 Disconnect the cable (D) from the beacon card. Remove the beacon lens (E), and remove the door assembly Finisher or stacker media stack flap and media stack flap actuator removal “Finisher assembly (continued)” on page 7-25 for the part number. Remove the option from the printer.
Page 472: Finisher Or Stacker Option Cable Removal
5062 Use plyers to straighten the locking tab (A) of the actuator you are replacing, and then slide the actuator to the right to remove it. Installation note: Use a flat-blade screwdriver to bend the locking tab back into place after you position the actuator.
Page 473 5062 Disconnect the cable (A), and press the latch to disconnect the cable (B) from the controller card. Route the cables through option. Press the tabs to disconnect the option connector, and route the cables through to remove it. 4-253 Repair information...
Page 474: Finisher Or Stacker Output Bin Extension Removal
5062 Finisher or stacker output bin extension removal “Finisher assembly” on page 7-23 for the part number. While pulling out the extension, push in the left and right tabs, and pry up the center tab. Finisher or stacker output bin LED and LED lens removal “Finisher assembly”...
Page 475: Finisher Or Offset Stacker Paddle Drive Gear Removal
5062 Finisher or offset stacker paddle drive gear removal Remove the option from the printer. Remove the paddle drive motor. See “Finisher or stacker paddle drive motor assembly removal” on page 4-255. Remove the E-clip (A), and remove the gear. Finisher or stacker paddle drive motor assembly removal “Finisher assembly (continued)”...
Page 476 5062 Remove the three screws (A) securing the two paddle drive motor assemblies. Remove the paddle drive motor assembly. Installation note: Be sure to line up the locator (B) when you install the motor. 4-256 Service Manual...
Page 477: Finisher Or Stacker Rear Cover Removal
5062 Finisher or stacker rear cover removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Remove the four screws (A) from the bottom of the option. Using a flat-blade screwdriver, pry out the bottom plate, and then remove it. 4-257 Repair information...
Page 478: Finisher Or Stacker Sensor (Bin-Full Receive) Removal
5062 Remove the two screws (B) on the inside of the exit bin compartment. Pull out on the right side of the cover to disengage the tabs, and remove the cover. Finisher or stacker sensor (bin-full receive) removal “Finisher assembly” on page 7-23 for the part number.
Page 479: Finisher Or Stacker Sensor (Bin-Full Send) Removal
5062 Remove the two screws (A) securing the sensor. Disconnect the cable, and remove the sensor. Finisher or stacker sensor (bin-full send) removal See XXXX for the part number. Remove the option from the printer. Remove the finisher or stacker controller card assembly. See “Finisher or stacker controller card assembly removal”...
Page 480: Finisher Or Stacker Sensor (Finisher Bin Media Present) Removal
5062 Finisher or stacker sensor (finisher bin media present) removal See XXXX for the part number. Remove the option from the printer. Remove two screws (A), and pull out the sensor cover. Press the tabs to remove the sensor from the cover. Disconnect the cable from the sensor to remove the sensor.
Page 481: Finisher Or Stacker Sensor (Paddle Hp) Removal
5062 Finisher or stacker sensor (paddle HP) removal “Finisher assembly (continued)” on page 7-25 for the part number. Remove the option from the printer. Remove the paddle drive motor. See “Finisher or stacker paddle drive motor assembly removal” on page 4-255.
Page 482: Finisher Sensor (Stapler Pass Thru) Removal
5062 Finisher sensor (stapler pass thru) removal “Finisher assembly” on page 7-23 for the part number. Remove the finisher from the printer. Remove the finisher rear cover. See “Finisher or stacker rear cover removal” on page 4-257. Remove the finisher front cover. See “Finisher or stacker front cover removal”...
Page 483: Finisher Or Stacker Sensor (Tamper Hp Left And Right) Removal
5062 Press the tabs to remove the sensor. Finisher or stacker sensor (tamper HP left and right) removal Remove the option from the printer. Remove the option top cover. See “Finisher or stacker top cover removal” on page 4-267. Disconnect the cable from the sensor. Pinch the tabs (A) to remove the sensors.
Page 484: Finisher Or Stacker Standard Output Bin Led And Led Lens Removal
5062 Finisher or stacker standard output bin LED and LED lens removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Remove two screws (A), and pull out the sensor cover. To remove the LED, remove the screw (B), and then disconnect the cable from the LED card. To remove the lens, remove the screw (B) and the screw (C), and then remove the lens.
Page 485: Finisher Or Stacker Tamper Drive Belt Removal
5062 Finisher or stacker tamper drive belt removal “Finisher assembly (continued)” on page 7-25 for the part number. Remove the option from the printer. Remove the tamper drive motor from the belt you need to replace. See “Finisher or stacker tamper drive motor assembly removal”...
Page 486: Finisher Or Stacker Tamper Recoil Spring Removal
5062 Clip the cable tie (D). Use a spring hook to remove the tamper recoil spring (E) for the motor you are removing. Remove the two screws (F) from the motor you are removing, and remove the motor assembly. Finisher or stacker tamper recoil spring removal “Finisher assembly (continued)”...
Page 487: Finisher Or Stacker Top Cover Removal
5062 Finisher or stacker top cover removal “Finisher assembly” on page 7-23 for the part number. Remove the option from the printer. Remove the front cover. See “Finisher or stacker front cover removal” on page 4-248. Remove the rear cover. See “Finisher or stacker rear cover removal”...
Page 488: Finisher Stapler Unit Assembly Removal
5062 Remove two screws (B). Pull up to remove the top cover. Finisher stapler unit assembly removal Remove the finisher from the printer. Remove the finisher rear cover. See “Finisher or stacker rear cover removal” on page 4-257. Remove two screws (A) to remove rear cable from the stapler unit assembly, and then remove the other three cables (B) attached to the assembly.
Page 489: Horizontal Transport Unit (Htu)
5062 Horizontal transport unit (HTU) HTU access door removal Remove all output options from the printer. Open the access door, and press the tabs to disconnect the beacon cable. Insert a flat-blade screwdriver below the bottom hinge, and flex the door enough to pull out the hinge. Remove the door.
Page 490: Htu Access Door Paper Jam Beacon (With Cover And Cable) Removal
5062 HTU access door paper jam beacon (with cover and cable) removal Remove all output options from the printer. Remove the HTU access door. See “HTU access door removal” on page 4-269. Remove six screws (A), and turn over the beacon cover. Remove the screw (B) to remove the beacon card, and disconnect the cable.
Page 491: Htu Access Door Rollers Removal
5062 HTU access door rollers removal Remove all output options from the printer. Remove the HTU access door. See “HTU access door removal” on page 4-269. Remove the screw (A) from the roller you are replacing, and remove the roller. HTU bin diverter gate spring removal Remove all output options from the printer.
Page 492 5062 Use a spring hook to remove the spring (A). 4-272 Service Manual...
Page 493: Htu Bin Media Exit Spring Removal
5062 HTU bin media exit spring removal Remove all output options from the printer. Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-280. Use a spring hook to remove the spring (A). HTU card (bin-full receive card and lens) removal Remove all output options from the printer.
Page 494 5062 Remove the two screws (A), and then remove the sensor card. Disconnect the cable to remove the sensor. If you are replacing the lens, then remove two screws (B) to remove it. 4-274 Service Manual...
Page 495: Htu Card (Bin-Full Send Card And Lens) Removal
5062 HTU card (bin-full send card and lens) removal Remove all output options from the printer. Remove the HTU controller card. See “HTU controller card removal” on page 4-276. Remove the two screws (A), and then remove the sensor card. Disconnect the cable from the sensor to remove the sensor.
Page 496: Htu Controller Card Removal
5062 HTU controller card removal Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Disconnect all cables connected to the controller card. Remove four screws (A). 4-276 Service Manual...
Page 497: Htu Drive Belt Removal
5062 HTU drive belt removal Remove all output options from the printer. Remove the HTU controller card. See “HTU controller card removal” on page 4-276. Remove four screws (A). HTU drive gear spring removal Remove all output options from the printer. Remove the controller card.
Page 498: Htu Engagement Roller Removal
5062 Slide the belt off the lowest gear. HTU engagement roller removal Remove all output options from the printer. Lay the HTU on its back. Remove the screw (A) to remove the roller you are replacing. 4-278 Service Manual...
Page 499: Htu Exit Roller Removal
5062 HTU exit roller removal Remove the upper exit shaft. See “HTU upper exit shaft removal” on page 4-314. Unsnap the left side of the roller from the cover and remove the roller. HTU front redrive cover removal Remove all output options from the printer. Lay the HTU on its back, and open the access door.
Page 500: Htu Front Standard Bin Cover Removal
5062 HTU front standard bin cover removal Remove all output options from the printer. Remove two screws (A) from the bottom. Remove the screw (B) from the top. 4-280 Service Manual...
Page 501: Htu Locking Lever Removal
5062 Remove the screw (C) inside the output bin, and remove the cover. HTU locking lever removal Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-280. Remove the three E-Clips (A) holding the locking lever. 4-281 Repair information...
Page 502: Htu Locking Lever Card Removal
5062 Use a flat-blade screwdriver to slide the lever out. Remove the screw (B). HTU locking lever card removal Remove the locking lever. See “HTU locking lever removal” on page 4-281. Disconnect the cable to remove the locking level card. 4-282 Service Manual...
Page 503: Htu Lower Redrive Guide Removal
5062 HTU lower redrive guide removal Remove all output options from the printer. Remove the upper guide. See “HTU upper guide removal” on page 4-315. Remove 13 screws (A) from the bottom of the transport unit.. Press the tabs to remove the connector from the rear frame. 4-283 Repair information...
Page 504: Htu Option Hook Removal
5062 Lift the back edge of the plate, and then slide the plate to the rear to remove it. HTU option hook removal Remove all output options from the printer. Front hook Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-280.
Page 505 5062 Remove one screw (A), and then remove the hook. Installation note: From the back of the hook, turn the spring arm 1/2 turn counterclockwise, and then hold the arm in place while you install the hook. 4-285 Repair information...
Page 506 5062 Rear hook Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Remove the screw (A), and then remove the hook. Installation note: From the back of the hook, turn the spring arm 1/2 turn counterclockwise, and then hold the arm in place while you install the hook.
Page 507: Htu Option Roller Removal
5062 HTU option roller removal Remove all output options from the printer. Front roller Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-280. Remove the screw (A) to remove the roller. 4-287 Repair information...
Page 508 5062 Rear roller Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Remove the screw (A) to remove the roller. 4-288 Service Manual...
Page 509: Htu Output Bin Removal
5062 HTU output bin removal Remove the output option from the HTU. Rotate the bin up, and then pull back to remove it. Installation note: If you are replacing the output bin FRU, then remove the wire stop. See “HTU output bin wire stop removal”...
Page 510: Htu Output Bin Solenoid Removal
5062 Press the tabs (A) to release the latches, and then pull to remove the extension. HTU output bin solenoid removal Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Disconnect the output bin solenoid cable (A). Note: Tie a string onto the cable so you can route the new cable through the HTU.
Page 511: Htu Output Bin Wire Stop Removal
5062 Remove the two screws (D) and remove the solenoid. HTU output bin wire stop removal Remove the output option from the HTU. Rotate the extension cover down. Pull out the sides of the stop to remove it. 4-291 Repair information...
Page 512: Htu Output Option Guide Removal
5062 HTU output option guide removal Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Slide the cables through the rear standard bin cover. HTU output option solenoid removal Remove the rear standard bin cover. See “HTU rear standard bin cover removal”...
Page 513: Htu Output Sensor Removal
5062 Remove the two screws (D). and then remove the solenoid. HTU output sensor removal Remove the right inner cover. See “HTU right inner cover removal” on page 4-300. Release the tabs that hold the sensor in place, and then disconnect the cable. 4-293 Repair information...
Page 514: Htu Outer Front Cover Removal (Aio Only)
5062 HTU outer front cover removal (AIO only) Remove all output options from the printer. Push up the tabs to release the latches, and rotate the cover up to remove it. HTU rear redrive cover removal Remove all output options from the printer. Remove the access door.
Page 515 5062 Remove the screw (B) from the rear. Pull out the side to release the tabs. Installation note: Use a screwdriver to push the tabs back into the slots 4-295 Repair information...
Page 516: Htu Rear Standard Bin Cover Removal
5062 HTU rear standard bin cover removal Remove all output options from the printer. Remove two screws (A) from the bottom. Remove the screw (B) inside the output bin. 4-296 Service Manual...
Page 517 5062 Remove the screw (C) from the left side. 4-297 Repair information...
Page 518 5062 Remove three screws (D) from the top. LIft off the output option connector bracket (E), and then lift off the rear standard bin cover. Disconnect the cable (F), and press the tab to disconnect the cable (G) from the controller card. Note: If you are replacing the rear standard bin cover FRU, then feed the cables through the slot in the cover.
Page 519: Htu Right Bottom Cover Removal
5062 HTU right bottom cover removal Remove all output options from the printer. Remove three screws (A) from the inside. Remove two screws (B) from the bottom, and remove the cover. 4-299 Repair information...
Page 520: Htu Right Inner Cover Removal
5062 HTU right inner cover removal Remove all output option from the printer. Remove the output bin. See “HTU output bin removal” on page 4-289. Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-280.
Page 521 5062 Remove the two screws (D), one screw (E) and disconnect the cable (F). 4-301 Repair information...
Page 522 5062 Remove the right lower cover. Note: Observe the routing of cable through the side frame. 4-302 Service Manual...
Page 523 5062 Remove the two screws (H). Remove the two screws (I), and two screws (J). 4-303 Repair information...
Page 524: Htu Sensor (Access Door Interlock) Removal
5062 Lift up the frame and slide the right inner cover out. HTU sensor (access door interlock) removal Remove all output options from the printer. Remove the front redrive cover. See “HTU front redrive cover removal” on page 4-279. Press the outer tabs (A) to remove the sensor cover. Press the inner tabs (B) to pull out the sensor.
Page 525: Htu Sensor (Empty Bin) Removal
5062 HTU sensor (empty bin) removal Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Disconnect the sensor cable (A) from the controller card. Remove the output bin. See “HTU output bin removal”...
Page 526: Htu Sensor (Input) Removal
5062 HTU sensor (input) removal Remove all output options from the printer. Remove the HTU lower redrive guide. See “HTU lower redrive guide removal” on page 4-283. Press the tabs to release the sensor, and then disconnect the cable to remove the sensor. 4-306 Service Manual...
Page 527: Htu Sensor (Output Option Position) Removal
5062 HTU sensor (output option position) removal Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Press the tabs to pull out the sensor. Disconnect the cable to remove sensor. 4-307 Repair information...
Page 528: Htu Sensor (Second) Removal
5062 HTU sensor (second) removal Remove all output options from the printer. Remove the HTU lower redrive guide. See “HTU lower redrive guide removal” on page 4-283. Press the tabs to release the sensor, and then disconnect the cable to remove the sensor. HTU sensor cable (bin-full send and receive) removal Remove all output options from the printer.
Page 529: Htu Stopper Diverter Removal
5062 HTU stopper diverter removal Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-280. Remove the solenoid plunger and spring from the stopper diverter, and then slide the stopper diverter off the option. 4-309 Repair information...
Page 530: Htu Timing Belts (Rear) Removal
5062 HTU timing belts (rear) removal Remove all output options from the printer. Remove the rear redrive cover. See “HTU rear redrive cover removal” on page 4-294. Remove one of the gears (A) to remove the belt you are replacing. Note: Remove the center belt to access the other two belts.
Page 531: Htu Top Redrive Cover Removal
5062 Press on the tabs to release the connector. HTU top redrive cover removal Remove all output options from the printer. Remove the front redrive cover. See “HTU front redrive cover removal” on page 4-279. Remove two screws (A). Remove the rear redrive cover. See “HTU rear redrive cover removal”...
Page 532: Htu Top Right Cover Removal
5062 Remove two screws (B), and then remove the cover. HTU top right cover removal Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-296. Remove two screws (A) from the top. 4-312 Service Manual...
Page 533: Htu Transport Gear Removal
5062 Remove two screws (B) from the rear, and then remove the top cover. HTU transport gear removal Remove the HTU drive belt. See “HTU drive belt removal” on page 4-277. Use a flat screwdriver to remove the gear (A). Remove the E-clips, and then slide the gears off their posts.
Page 534: Htu Transport Motor Removal
5062 HTU transport motor removal Remove the right inner cover. See “HTU right inner cover removal” on page 4-300. Remove the two screws (A), and then remove the transport motor. HTU upper exit shaft removal Remove the right inner cover. See “HTU right inner cover removal”...
Page 535: Htu Upper Guide Removal
5062 Unsnap the upper exit shaft out of the cover. HTU upper guide removal Remove all output options from the printer. Remove the top redrive cover. See “HTU top redrive cover removal” on page 4-311. Remove the screw (A) from the front. Remove the screw (B) from the rear.
Page 536 5062 Flex the back of the frame to release the rear edge, and then remove the guide. 4-316 Service Manual...
Page 537 5062 4-317 Repair information...
Page 538 5062 4-318 Service Manual...
Page 539: Connector Locations
5062 5. Connector locations Locations System board cabling reference For more information, see the connector diagram for the “System board” on page 5-2. Connector locations...
Page 540: Connectors
5062 Connectors System board Service Manual...
Page 541 5062 System board System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal UI REset NR OP panel UICC card TX1- TX1+ Cable: 10J0972 User TX2- TX2+ Interface Card CLKTX- CLKTX+ V15_UI w/RES I2C_CLK_LL I2C_DATA_LL TXO- TXO+ V15_UI...
Page 542 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JBOOT1 (Not used) JBUSB1 (Out) JCCT1 (Not used) JCCT2 REMOTE_WS Thermistor on LVPS Cable: 10J0974 Weather Station JCFT1 (Not used) JCM1 C_BLDC_HOME C & M Block C_BLDC_HALL_U V45_M_WIND_W Cable: 10J0932 BLDC C...
Page 543 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JDDIV1 V10_D_D_MTR- Duplexer Diverter Mtr V10_D_D_MTR+ Cable: In FRU JDDLED1 SDLED1 +5V or GND Duplex Door LED SDLED3 +5V or GND Cable: 10J0948 Duplex SDLED5 +5V or GND Door...
Page 544 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JHVPS1 +24V_SW CHR_AC_ENA HVPS M_DEV_PWM_OUT M_AC_PWM_OUT Cable: 10J0939 HVPS C_AC_PWM_OUT K_DEV_PWM_OUT C_DEV_PWM_OUT K_AC_PWM_OUT C_CHG_PWM_OUT M_CHG_PWM_OUT Y_CHG_PWM_OUT K_CHG_PWM_OUT Y_AC_PWM_OUT Y_DEV_PWM_OUT ITM_TX_PWM_CUR_O KCMY_TX_ENA_OUT ITM_TX_ENA_OUT K_TX_PWM_OUT ITM_TX_PWM_OUT K_SERVO_INTO CHG_AC_FREQ M_SERVO_INTO...
Page 545 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JKI1 K_BLDC_HOME V45_I_WIND_W K* ITU Blck K_BLDC_HALL_U V45_I_WIND_V Cable: 10J0930 BLDC K_BLDC_HALL_V V45_I_WIND_U K & ITU K_BLDC_HALL_W +5V_SW K_BLDC_FG I2C_DATA_F I2C_CLK_F V10_FRU_3.3V I_BLDC_FG +5V_SW I_BLDC_HALL_W V45_K_WIND_U I_BLDC_HALL_V...
Page 546 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JMPF1 VS10_MPF_OUT Multipurpose feeder sensor S_MPF_OUT_SNS Cable: 10J0929 MPF sensor cable VS10_MPF_SM_OUT S_MPF_SM_OUT_SNS +24V_DUP MPF_PIO_GEN MPF_PIO_ENC JOOPT1 TXD1_OPT_OUT Output Option RXD1_OPT_IN Cable: 10J0941 Output +24V_TOPT Options +5V_OPTS...
Page 547 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JPY1 V_CART_3V Yellow Memory XP_DAT_C Cable: Part of unit XP_CLK_C JRDR1 VS10_SWS Paper path Redrive S_SWS_FB Cable: 10J0951 (In FRU) S_ACC_JAM2_SNS VS10_ACC_JAM2 JSTAG1 VS10_STAGING_LED Staging Motor S_STAGING_ENC Cable: 10J0936 Staging...
Page 548 5062 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal JWTB1 VS10_WB_LED RT SIDE WT Waste Toner Sensor VS_10_WB_PRES Cable: 10J0943 Waste S_WB_PRES_IN Toner S_WLED7 PAPER TRAY S_WLED9 NARROW MEDIA S_WLED11 FR DOOR BEACON S_WLED13 LT SIDE WT S_FD_OPEN_SNS...
Page 549: 550-Sheet Tray Option System Card
5062 550-sheet tray option system card JPTS1 5-11 Connector locations...
Page 550 5062 550-sheet tray option system card 550-sheet tray option system card connectors “550-sheet tray option system card” on page 5-11. Connector Pin # Signal Pin # Signal Jam door sensor Input +5V_Switch +5V_Switch Pick motor ENCODER Motor + Motor - +5V_Switch Paper level sensor P_LEV_SENSOR_1...
Page 551 5062 550-sheet tray option system card connectors “550-sheet tray option system card” on page 5-11. Connector Pin # Signal Pin # Signal TRAY_LIGHTPIPE LED tray +24V Power IN Ground JPTS1 +24V Pass thru sensor +5V_Switch 5-13 Connector locations...
Page 552: 2000-Sheet High-Capacity Feeder Option System Card
5062 2000-sheet high-capacity feeder option system card JPTS1 5-14 Service Manual...
Page 553 5062 2000-sheet high-capacity feeder option system card 2000-sheet high-capacity feeder option system card connectors “2000-sheet high-capacity feeder option system card” on page 5-14. Connector Pin # Signal Pin # Signal Jam door sensor Input +5V_Switch +5V_Switch Pick motor ENCODER Motor + Motor - +5V_Switch Paper level sensor...
Page 554: Uicc Card
5062 2000-sheet high-capacity feeder option system card connectors “2000-sheet high-capacity feeder option system card” on page 5-14. Connector Pin # Signal Pin # Signal Paper port to printer PP_RXD PP_TXD TRAY_LIGHTPIPE LED tray +24V Power IN Ground JPTS1 +24V Pass thru sensor +5V_Switch UICC card 5-16...
Page 555: 5-Bin Mailbox- Printer Circuit Board
5062 5-bin mailbox- printer circuit board 5-17 Connector locations...
Page 556 5062 5-18 Service Manual...
Page 557: Preventive Maintenance
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
Page 558: Redrive Parts Packet
5062 Redrive parts packet Using the 739A grease that came with the redrive assembly, lubricate the four posts (A). Install the gears. Using the 744 grease, lubricate the teeth (B) of the gears as shown. Service Manual...
Page 559: Fuser Drive Assembly
5062 Fuser drive assembly Using the 739A grease that came with the fuser drive assembly, lubricate the post (A). Install the gear. Using the 744 grease, lubricate the teeth (B) of the gear as shown. Preventive maintenance...
Page 560 5062 Service Manual...
Page 561: Parts Catalog
5062 7. Parts catalog How to use this parts catalog Asm- Part Units/ Units/ Description Removal procedure index number mach • 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. •...
Page 562: Assembly 1: Top, Right, And Front Covers
5062 Assembly 1: Top, right, and front covers Service Manual...
Page 563 5062 Assembly 1: Top, right, and front covers Units/ Units/ Index Description Removal procedure mach 1—1 40X7109 Printhead access cover “Printhead access cover removal” on page 4-17 40X7127 Printhead assembly “Printhead removal, installation, and alignment” on page 4-119 40X7117 Speaker “Speaker removal”...
Page 564: Assembly 2: Left And Rear Covers
5062 Assembly 2: Left and rear covers Service Manual...
Page 565 5062 Assembly 2: Left and rear covers Units/ Units/ Index Description Removal procedure mach 2—1 40X7151 MPF sensor plate assembly “MPF sensor plate assembly removal” on page 4-104 40X7122 Left cover assembly with LVPS power “Left cover removal” on page 4-10 switch cable 40X7149 MPF pick tire roll assembly, including...
Page 566: Assembly 3: Front
5062 Assembly 3: Front Service Manual...
Page 567 5062 Assembly 3: Front Units/ Units/ Index Description Removal procedure mach 3—1 40X7145 ITU contact block assembly “ITU block assembly removal” on page 4-76 40X7130 Cartridge blower assembly “Cartridge blower assembly removal” on page 4-37 40X7141 Cartridge rail assembly, including “Cartridge rail removal”...
Page 568 5062 Assembly 3.1: Front (continued) Service Manual...
Page 569 5062 Assembly 3.1: Front (continued) Units/ Units/ Index Description Removal procedure mach 3.1—1 40X7142 Cartridge memory block with sensor “Cartridge memory block removal” on page 4-42 40X7160 Paper pick mechanism assembly “Paper pick mechanism assembly removal” on page 4-116 40X6104 Pick tire roll assembly “Pick rolls removal”...
Page 570: Assembly 4: Left
5062 Assembly 4: Left 7-10 Service Manual...
Page 571 5062 Assembly 4: Left Units/ Units/ Index Description Removal procedure mach 4—1 40X7133 Redrive parts packet, including “Redrive gears removal” on page 4-129 • Gear thrust washer (2) • Gear—Idler 50T (2) • Gear—64T 22T Compound • Gear—36T 18T Compound 40X7166 ITU autoconnect cable “ITU autoconnect removal”...
Page 572 5062 Assembly 4.1: Left (continued) 7-12 Service Manual...
Page 573 5062 Assembly 4.1: Left (continued) Units/ Units/ Index Description Removal procedure mach 4.1—1 40X7134 Paper path redrive assembly “Paper path redrive assembly with sensors removal” on page 4-113 40X7153 Left access door pistons parts packet, “” on page 4-77 including •...
Page 574: Assembly 5: Rear
5062 Assembly 5: Rear 7-14 Service Manual...
Page 575 5062 Assembly 5: Rear Units/ Units/ Index Description Removal procedure mach 5—1 40X0269 Bolivia, Peru (8’ ST) 40X0270 Japan (8’ ST) 40X0271 UK, Ireland (8' ST) 40X0273 Chile, Uruguay (8’ ST) 40X0275 Israel (8’ ST) 40X0288 Argentina (8’ ST) 40X0301 Australia (8’...
Page 576: Assembly 6: Optional 550-Sheet Tray
5062 Assembly 6: Optional 550-sheet tray 7-16 Service Manual...
Page 577 5062 Assembly 6: Optional 550-sheet tray Units/ Units/ Index Description Removal procedure 6—1 40X6102 550-sheet drawer assembly “550-sheet drawer assembly removal” on page 4-155 40x6099 550-sheet media tray assembly “550-sheet media tray assembly removal” on page 4-155 7-17 Parts catalog...
Page 578: Assembly 7: Optional 550-Sheet Drawer Assembly
5062 Assembly 7: Optional 550-sheet drawer assembly 7-18 Service Manual...
Page 579 5062 Assembly 7: Optional 550-sheet drawer assembly Units/ Units/ Index Description Removal procedure 7—1 40X6100 550-sheet tray controller card “550-sheet tray controller card assembly assembly removal” on page 4-156 40X6101 Anti-tip latch assembly “550-sheet tray right anti-tip latch assembly removal” on page 4-171 “550-sheet tray left anti-tip latch removal”...
Page 580: Assembly 8: Optional 2000-Sheet High-Capacity Feeder
5062 Assembly 8: Optional 2000-sheet high-capacity feeder 7-20 Service Manual...
Page 581 5062 Assembly 8: Optional 2000-sheet high-capacity feeder Units/ Units/ Index Description Removal procedure 8—1 40X6275 2000-sheet high-capacity feeder pick “2000-sheet high-capacity feeder roll assembly pick roll assembly removal” on page 4-214 40X6119 2000-sheet high-capacity feeder pick “2000-sheet high-capacity feeder assembly pick assembly removal”...
Page 582: Assembly 9: Finisher Assembly
5062 Assembly 9: Finisher assembly 7-22 Service Manual...
Page 583 5062 Assembly 9: Finisher assembly Asm- Part Units/ Units/ Description Removal procedure Index number mach 9—1 40X7234 Left access door assembly “Finisher or stacker left access door assembly removal” on page 4-250 40X7238 Backup redrive roller “Finisher or stacker feed roller removal”...
Page 584 5062 Assembly 9.1: Finisher assembly (continued) 7-24 Service Manual...
Page 585 5062 Assembly 9.1: Finisher assembly (continued) Asm- Part Units/ Units/ Description Removal procedure Index number mach 9.1—1 40X7244 Rear media stack flap “Finisher or stacker media stack flap and media stack flap actuator removal” on page 4-251 40X7245 Front media stack flap “Finisher or stacker media stack flap and media stack flap actuator removal”...
Page 586: Assembly 10: Finisher Stapler Assembly
5062 Assembly 10: Finisher stapler assembly 7-26 Service Manual...
Page 587 5062 Assembly 10: Finisher stapler assembly Asm- Part Units/ Units/ Description Removal procedure Index number mach 10—1 40X7230 Stapler assembly “Finisher stapler unit assembly removal” on page 4-268 40X5909 Sensor (media in stapler) “Finisher sensor (stapler pass thru) removal” on page 4-262 7-27 Parts catalog...
Page 588: Assembly 11: High-Capacity Output Stacker
5062 Assembly 11: High-capacity output stacker 7-28 Service Manual...
Page 589 5062 Assembly 11: High-capacity output stacker Asm- Part Units/ Units/ Description Removal procedure Index number mach 11—1 40X7234 Left access door assembly “Finisher or stacker left access door assembly removal” on page 4-250 40X7238 Backup redrive roller “Finisher or stacker feed roller removal”...
Page 590 5062 Assembly 11.1: High-capacity output stacker (continued) 7-30 Service Manual...
Page 591 5062 Assembly 11.1: High-capacity output stacker (continued) Asm- Part Units/ Units/ Description Removal procedure Index number mach 11.1—1 40X7244 Rear media stack flap “Finisher or stacker media stack flap and media stack flap actuator removal” on page 4-251 40X7245 Front media stack flap “Finisher or stacker media stack flap and media stack flap actuator removal”...
Page 592: Assembly 12: Internal Options
5062 Assembly 12: Internal options Units/ Units/ Index Description mach IPDS SCS card Forms & bar code card PRESCRIBE card 40X4819 Serial interface adapter 40X4823 Parallel 1284-B SERI adapter 40X4826 MarkNet N8120 10/1000 card 40X4827 MarkNet N8130 10/1000 F adapter 40X5301 256MB DDR DRAM DIMM 40X5302...
Page 593: Assembly 13: Miscellaneous
5062 Assembly 13: Miscellaneous Units/ Description Removal procedure 40X7163 Sensors parts packet, including “Waste toner sensor removal” on page 4-148 • Waste toner sensors (2) • Paper auto size sensor “Waste toner full sensor removal” on • Paper path sensor (not shown) page 4-151 •...
Page 594: Cable And Thermistor Location Table
5062 Cable and thermistor location table Using the following table, locate the part you need to replace, and then go to the listed removal to find instructions for accessing the cable or thermistor. Cable location table item number Description Location To access 40X7165 10J0938...
Page 595 5062 Cable location table item number Description Location To access 40X7168 10J0927 Paper path Deflector assembly 1. Remove the lower frame cable cables cover. See “Lower frame cable • System board connector: cover removal” on page 4-15. JPP2 2. Remove the staging deflector assembly.
Page 596 5062 Cable location table item number Description Location To access 40X7168 10J0937 Thermistor & Behind fuser “Fuser thermistor removal” redrive cable on page 4-66. (Cont.) System board connector: JFSRD1 10J0939 HVPS cable Under HVPS board “High-voltage power supply (HVPS) board removal” on •...
Page 597 5062 Cable location table item number Description Location To access 40X7170 10J0943 Waste toner Under lower frame cable cover “Waste toner cable removal” cable on page 4-149. • System board connector: JWTB1 10J0950 Bin-full sensor Top cover “Top cover removal” on cable page 4-28.
Page 598: Screw And Retainer Identification Table
5062 Screw and retainer identification table The following table contains screw and fastener descriptions, locations, and quantities necessary to service the printer. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly. Sizes are as close to actual as possible, as long as the printout is not scaled or resized.
Page 599 5062 Screw identification table (continued) Screw type Location 27S2839 Taptite M3 x 6 mm System board shield to system board cage slotted hex black 88A0001 MACH M3X0.5-6G 550-sheet drive assembly to 550-sheet drawer 88A0121 M3.5 x 6 Machine Standoff to HVPS board Panhead 88A0212 Taptite Metal...
Page 600 5062 Screw identification table (continued) Screw type Location 88A0232 Taptite M3 x 6 mm 550-sheet left anti-tip latch assembly to 550-sheet drawer MTF PAN 550-sheet right anti-tip latch assembly to 550-sheet drawer Cable cover to system board cage System board to cage Fax ports on system board to cage 88A0233 M3 x 8 Taptite...
Page 601 5062 Screw identification table (continued) Screw type Location 88A0323 Plastite 550-sheet top metal cover to 550-sheet drawer M3.5 x 8 mm PAN 550-sheet bottom cover to 550-sheet drawer 550-sheet option deflector to 550-sheet drawer 550-sheet drive assembly to 550-sheet drawer ACM bias spring to lower frame Auto-connect harness to frame Bottom plate to frame...
Page 602 5062 Screw identification table (continued) Screw type Location 88A0329 M3.5 x 30 mm Paper path staging assembly to frame 88A0412 PL ROLN 550-sheet pick tire to 550-sheet pick arm assembly 2.9 x 5.2 mm Pick tires to Tray 1 paper pick mechanism 88A0414 SEMS PL ROLN 2000-sheet jam clearance top cover to 2000-sheet drawer...
Page 603 5062 Screw identification table (continued) Screw type Location 1126830 E-clip M5 Bellcrank daturn, front and rear MPF pivot shaft MPF pulley Spur 17T Helicai gear 1126831 E-clip M6 MPF redrive gear 7-43 Parts catalog...
Page 604 5062 7-44 Service Manual...
Page 605: Appendix A-Print Samples
5062 Appendix A—Print samples The following pages represent some of the pages available in various menus. While they are as close as possible to what you will see, variations in printing may result from individual user printer settings, media, and printer alignment.
Page 606: Print Quality Pages-Page 1 (Total Of Five)
5062 Print Quality Pages—Page 1 (total of five) Service Manual...
Page 607: Print Quality Pages-Page 2 (Total Of Five)
5062 Print Quality Pages—Page 2 (total of five) Appendix A—Print samples...
Page 608: Print Quality Pages-Page 3 (Total Of Five)
5062 Print Quality Pages—Page 3 (total of five) Service Manual...
Page 609: Print Quality Pages-Page 4 (Total Of Five)
5062 Print Quality Pages—Page 4 (total of five) Appendix A—Print samples...
Page 610: Registration And Alignment
5062 Registration and alignment Quick Test Page From the Diagnostics menu, select: REGISTRATION > Quick Test. Service Manual...
Page 611: Printhead Mechanical Alignment Test Page
5062 Printhead mechanical alignment test page From the Diagnostics menu, select MISC TESTS > Printhead Inst. Appendix A—Print samples...
Page 612: Printhead Electronic Alignment Test Page-Magenta (One Of Two)
5062 Printhead electronic alignment test page—Magenta (one of two) From the Diagnostics menu, select Alignment Menu > [select a color] > Quick Test. Service Manual...
Page 613: Printhead Electronic Alignment Test Page-Magenta (Two Of Two)
5062 Printhead electronic alignment test page—Magenta (two of two) Appendix A—Print samples...
Page 614: Printhead Linearity Test Page
5062 Printhead linearity test page From the Diagnostics menu, select Alignment Menu > [select a color] > Linearity > Quick Test] A-10 Service Manual...
Page 615: Index
5062 Index Numerics 550-sheet tray left anti-tip latch 4-162 removal 2-20 2xx paper jam codes – 550-sheet tray pass thru sensor 2-43 2-49 3x–8x attendance messages – 4-164 removal 2000-sheet high capacity feeder input option 550-sheet tray pick assembly 2-56 diagnostics 4-165 removal...
Page 616 5062 3-28 Color Alignment 3-26 Color Trapping ACM bias spring 3-28 Disk Encryption 4-35 removal 3-27 Download Emuls acoustics 3-27 Energy Conserve 1-13 acronyms 3-25 entering 3-10 ALIGNMENT MENU 3-28 Envelope Prompts alignments 3-26 3-29 Exit Config Menu black printhead electronic alignment 3-27 Factory Defaults 3-11...
Page 617 Lexmark confidential until announced 5062 3-13 HARDWARE TESTS EP drive assembly 3-14 4-54 Button Test removal 3-14 DRAM Test error codes and messages 3-13 2-20 Panel Test 2xx paper jams – 3-15 2-43 2-49 Serial Wrap Test 3x–8x attendance messages –...
Page 618 5062 finisher or stacker option cable finisher stapler unit 4-252 4-268 removal removal finisher or stacker output bin extension finisher stapler unit assembly 4-254 4-268 removal removal finisher or stacker output bin LED and LED lens finisher tamper drive belt 4-254 4-265 removal...
Page 619 Lexmark confidential until announced 5062 HTU card (bin-full send card and lens) HTU sensor cable (bin-full send and receive) 4-275 4-308 removal removal HTU controller card HTU stopper diverter 4-276 4-309 removal removal HTU drive belt HTU timing belts (rear)
Page 620 5062 low-voltage power supply MPF sensor cover 4-82 removal parts catalog lubrication MPF sensor plate assembly 4-104 fuser drive assembly removal redrive parts packet MPF wear strips 4-105 lubrication specifications removal LVPS multipurpose feeder assembly 7-14 parts catalog parts catalog LVPS exit duct multipurpose feeder cover 7-14...
Page 621 Lexmark confidential until announced 5062 power cable rear upper cover 7-14 parts catalog parts catalog 4-21 power-on self test (POST) sequence removal 3-27 PPDS Emulation redrive motor 7-10 preventive maintenance parts catalog 4-130 print quality removal 2-22 background redrive parts packet...
Page 622 5062 4-229 4-267 5-bin mailbox cave beacon finisher or stacker top cover 4-230 4-254 5-bin mailbox controller card finisher output bin extension 4-231 4-255 5-bin mailbox diverter solenoid finisher paddle drive gear 4-232 4-255 5-bin mailbox feed motor with plate finisher paddle drive motor 4-233 4-257...
Page 623 Lexmark confidential until announced 5062 4-304 4-245 HTU sensor (access door interlock) stacker controller card 4-305 4-247 HTU sensor (empty bin) stacker feed roller 4-306 4-248 HTU sensor (input) stacker front cover 4-307 4-249 HTU sensor (output option position) stacker LED sensor cover...
Page 624 5062 2-102 2-111 900.xx-990.05 – stacker paddle drive gear 2-108 4-255 950.00–950.29-EPROM mismatch removal 2-109 956.xx-system board failure stacker paddle drive motor 2-131 4-255 bin-full sensor removal 2-112 bubble sensor stacker rear cover 2-114 4-257 D1 and D2 sensor removal 2-117 dead printer stacker rear door...
Page 625 Lexmark confidential until announced 5062 1-12 tools required top cap cover parts catalog top cover parts catalog 4-28 removal 3-23 Transfer Adjust 3-26 Tray Insert Msg troubleshooting map 3-16 USB HS Test Mode waste toner container 4-147 removal waste toner cover...
Page 626 5062 I-12 Service Manual...
Page 627: Part Number Index
5062 Part number index Description Page 40X0269 Power cord—Bolivia, Peru - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 40X0270 Power cord—Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 628 5062 40X6118 2000-sheet high-capacity feeder jam clearance cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 40X6119 2000-sheet high-capacity feeder pick assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 629 5062 40X7150 MPF pick parts packet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X7151 MPF sensor plate assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X7152...
Page 630 5062 I-16 Service Manual...

This manual is also suitable for:

C792dte 5062-230 C792de 5062-230 C792dhe 5062-235

Lexmark C792e 5062-210 Service Manual

Notices and Safety Information

Laser Notice

Safety Information

Preface

Navigation Buttons

Conventions

General Information

Models

Maintenance Approach

Printer Configurations

Options and Features

Printer Specifications

Tools Required for Service

Acronyms

Diagnostic Information

Troubleshooting Map

Paper Jams

Print Quality

User Messages

Service Errors

Symptoms

Service Checks

Diagnostic Aids

Understanding the Operator Panel and Menus

Accessing Service Menus

Diagnostics Menu

Configuration Menu

Theory of Operation

Printhead Verification

Repair Information

Handling ESD-Sensitive Parts

Removal Procedures

Base Printer Cover Removals

Base Printer Removals

Input Option Removals

550-Sheet Tray

2000-Sheet High-Capacity Feeder

Quick Links

Related Manuals for Lexmark C792e 5062-210

Summary of Contents for Lexmark C792e 5062-210