Lexmark C752 Service Manual
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Lexmark C752 Service Manual

Lexmark C752 Service Manual

Service manual
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See also: User Reference , User Manual
Revised: July, 27 2005
™
Lexmark
C752
5060-2XX
• 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.

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Summary of Contents for Lexmark C752

  • Page 1 Revised: July, 27 2005 ™ Lexmark C752 5060-2XX • 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. ImageQuick, Optra Forms, and PrintCryption are trademarks of Lexmark International, Inc.

  • Page 3: Table Of Contents

    5060-2XX Table of contents Notices and safety information ......... . . xi Laser notice .
  • Page 4 5060-2XX 131 error code ..............2-51 132 error code .
  • Page 5 5060-2XX ..........2-127 Blank page (no image) .
  • Page 6 5060-2XX Misc Tests ..............3-17 .
  • Page 7 5060-2XX EP Setup ..............3-35 .
  • Page 8 5060-2XX Redrive assembly ..............4-63 Registration motor .
  • Page 9 5060-2XX Parts catalog ..............How to use this parts catalog .
  • Page 10 5060-2XX Appendix B—Print quality samples........B-1 Print Menus—Page one of two .

  • Page 11: Notices And Safety Information

    5060-2XX Notices and safety information The following laser notice labels may be affixed to this printer as shown: 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 12 5060-2XX 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 13 5060-2XX Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 14 5060-2XX Service Manual...

  • Page 15: Safety Information

    5060-2XX 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 16 5060-2XX 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 17 5060-2XX 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 18: Preface

    5060-2XX 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 are, as well as general environmental and safety instructions. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs).

  • Page 19: General Information

    5060-2XX 1. General information The Lexmark™ C752 is a network-capable color printer that uses electrophotographic technology to deliver high quality images, presentation graphics, line art, and text. It prints up to 20 pages per minute (ppm) for both four- color and monochrome print jobs.

  • Page 20: Options And Features

    5060-2XX Options and features Lexmark C752 printers support only Lexmark C750/C752 paper-handling options and the C752 envelope drawer. These options are not compatible with any other Lexmark printer. The C752 envelope drawer is not compatible with the C750. • 500-Sheet drawer - (includes 500-sheet tray and support unit) installs beneath the printer and holds approximately 500 sheets of 20 lb, 75 g/m paper.

  • Page 21: Toner Darkness

    The toner darkness default setting is 4. Color level 4 and level 5 are the same. The toner darkness setting is available through the operator panel under the Print Quality menu or through the Lexmark PostScript driver. Setting Delta toner from default (mono)

  • Page 22: Printer Specifications

    5060-2XX Printer specifications Description Width Depth Height Weight Printer Lexmark C752(n) 23.8 in. 18.5 in. 20.8 in. 105 lb (604.5 mm) (469.9 mm) (528.3 mm) (47.7 kg) Lexmark C752dn 23.8 in. 18.5 in. 24.3 in 118 lb (inc. duplex option) (604.5 mm)
  • Page 23 5-bin mailbox. Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296. 1-Meter average sound Model Status pressure Lexmark C752(n) 2400 image quality printing 52 dBA Idle (standby) 34 dBA Lexmark C752dn 2400 image quality printing...

  • Page 24: Print Speed And Performance Print Speed

    5060-2XX Environment Printer Temperature and Humidity • Operating – Temperature: 60 to 90° F (15.6 to 32.3° C) – Relative humidity: 8 to 80% – Maximum wet bulb temperature: 73° F (22.8° C) – Altitude: 10,000 ft. (0 to 3,048 meters) –...
  • Page 25 5060-2XX Media size—Tray 1 Smaller sizes, reduced throughput Nearly narrow (for example, More than 6.8 in., but less B5 or Exec) than 8.3 in. wide Narrow media (for Less than 6.8 in. wide example, A5). The first 25 narrow pages print at rated speed; subsequent pages print at the speed shown. Once the printer enters a reduced throughput mode as indicated, the printer remains at the given speed after the last sheet of smaller media, until the fuser return to standby temperature.

  • Page 26: Duty Cycle

    Standby times may be longer if the toner control senses that toner flow needs to be checked or adjusted. Processor Lexmark C752 Lexmark C752(n), dn Processor frequency (Mhz) Bus frequency (Mhz) Duty cycle •...

  • Page 27: Available Memory Options

    5060-2XX Available memory options Optional 64MB, 128MB 256MB and 512MB SDRAM DIMMs are available from Lexmark. The memory options are 168-pin synchronous DRAM DIMMs (dual in-line memory modules) meeting or exceeding the following specifications: • 100MHz or greater • 4KB refresh rate •...

  • Page 28: Media Specifications

    5060-2XX Media specifications Media type Media type Paper Card stock Transparencies Envelopes Vinyl labels Paper labels Polyester labels Dual web labels Integrated labels * Models 5060-22x only. Media size Media size supported 5, 6, 7 A4 8.27 in. x 11.7 in. (210 mm x 297 mm) A5 5.83 in.
  • Page 29 5060-2XX Media size supported 5, 6, 7 Letter 8.5 in. x 11 in. (216 mm x 279 mm) 5, 6, 7 Folio 8.5 in. x 13 in. (216 mm x 330 mm) 5, 6, 7 Legal 8.5 in. x 14 in. (216 mm x 356 mm) 6, 7 Executive 7.25 in.

  • Page 30: Index

    5060-2XX Media size supported Other envelope 3.87 x 6.38 in. to 6.93 x 9.84 in. (98.4 x 162 mm to 176 x 250 mm) When Universal is selected, the page is formatted for 8.5 x 14 in. (215.9 x 355.6 mm), unless the size is specified in the software application.
  • Page 31 Refer to the Converter Listing on Lexmark's Home Page and Automated FAX system (LEXFAX ) for information on whether your vinyl label converter has passed Lexmark's criteria. Refer to the Card Stock and Label Guide for more details. Lexmark transparency numbers 12A5940 and 12A5941 are supported from the standard tray, optional 500- sheet trays and the multipurpose feeder.

  • Page 32: Output Media Types And Weights

    5060-2XX Output media types and weights Media Weight Standard output bin and optional output expander b, f Paper Xerographic or 16 to 19.9 lb bond (60 to 74.9 g/m grain long) business paper 20 to 47 lb bond (75 to 176 g/m grain long) Specialty papers Gloss book...

  • Page 33: Web Oiler Upgrade Kit And Replacements

    Refer to the Converter Listing on Lexmark's Home Page and Automated FAX system (LEXFAX ) for information on whether your vinyl label converter has passed Lexmark's criteria. Refer to the Card Stock and Label Guide for more details. Lexmark transparency numbers 12A5940 and 12A5941 are supported from the standard tray, optional 500-sheet trays and the multipurpose feeder.

  • Page 34: Acronyms

    5060-2XX Acronyms BLDC Brushless DC Motor Black Only Retract Cyan 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 High-Capacity Input Tray HCOF High-Capacity Output Finisher HVPS...

  • Page 35: Diagnostic Information

    5060-2XX 2. Diagnostic information Start CAUTION: Unplug power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The printer weighs 47.7 kg (105 lb.) and requires at least two people to lift it safely.

  • Page 36: Por (Power-On Reset) Sequence

    5060-2XX POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed. Power the machine on. +5V LED (Power ON) on the system board comes on. Operator Panel LED comes on solid.

  • Page 37: Symptom Tables

    5060-2XX Symptom tables Symptom table - base printer Symptom Action Fuser fan fails to run or is noisy Go to “925 error code” on page 2-84. RIP fan fails to run or is noisy Go to “927 error code” on page 2-85.

  • Page 38: Symptom Table - 500-Sheet Drawer Option

    5060-2XX Symptom Action Print quality: Uneven printing Go to “Uneven printing” on page 2-135. Print quality: Poor color alignment Go to “Poor color alignment” on page 2-133. Print quality: Toner on the back of the page Go to “Toner is on the back of the printed page” on page 2-136.

  • Page 39: Symptom Table - 5-Bin Mailbox Option

    5060-2XX Symptom table - 5-bin mailbox option Symptom Action Printer fails to recognize the option is installed. Paper Go to “The printer does not recognize one or more feeds into the standard bin. output options as installed.” on page 2-98. Ready Bin x Full displays and won’t clear Go to “Ready bin x full message - may be able to...

  • Page 40: Error Code Table

    5060-2XX Error code table Error code Action 9xx service errors 900 RIP Software Error Go to “900 RIP Software Error” on page 2-82. 902 Service Engine Error 0 General Engine Software Errors 902 through 907 indicate an unrecoverable engine software error. The system board may cause this type of error.
  • Page 41 5060-2XX Error code Action 955 Code CRC <loc> System board - This error indicates that the Code ROM or NAND failed the CRC check. The location of the failure is indicated by <loc>. Replace the system board. See “System board” on page 4-67.

  • Page 42: 1Xx Service Errors

    5060-2XX Error code Action 983 <device> comm Invalid command received by the specified device. Note: This message is used for multiple bin output devices. Note: Check the autoconnects above and below the failing option to make sure they are seated and connected correctly. Go to service check for the device indicated.
  • Page 43 5060-2XX Error code Action 107 Printhead Error Magenta printhead lost Hsync Check for the correct installation of all the cables to the system board assembly and to the printhead assembly; J11 and J12 on the system board. Go to “System board” on page 5-8.
  • Page 44 5060-2XX Error code Action 113 Printhead Error No first Hysnc - black Check for the correct installation of all the cables to the system board and in the printhead assembly; J12 and J13 on the system board. Go to “System board” on page 5-8.
  • Page 45 5060-2XX Error code Action 117 Printhead Error A yellow printhead servo error has been detected. Verify all packing material have been removed from the printer. Check at the top of the printhead for the cardboard or plastic packaging. If error persists, see “Printhead diagnostics”...
  • Page 46 5060-2XX Error code Action 141 Motor DC pick motor excessive PWM - registration (staging) motor - replace the “Registration motor” on page 4-64. If this does not fix the problem, replace the “System board” on page 4-67. 142 Motor DC pick motor, over speed - registration (staging) motor - replace the “Registration motor”...
  • Page 47 5060-2XX Error code Action 164 Motor Cyan cartridge BLDC motor mfg. unknown - go to “164 error code” on page 2-64. 165 Motor Yellow cartridge BLDC motor mfg. unknown - go to “165 error code” on page 2-65. 167 Motor The incorrect configuration ID.

  • Page 48: Programming Errors - P101 Through P116

    5060-2XX Programming errors - P101 through P116 These error codes may be displayed whenever a new code upgrade has been attempted. It is possible that the wrong type of code, network versus non-network, or a corrupted file was probably sent to the printer. Verify that the correct type of code is being flashed to the printer.

  • Page 49: 2Xx Paper Jams

    5060-2XX 2xx Paper Jams User primary User secondary Explanation message message 200 Paper Jam Leave sheets in Primary: This message indicates that a paper jam has Clear Paper Path Finisher area 5 occurred at or near the printer Input Sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.
  • Page 50 5060-2XX User primary User secondary Explanation message message 230 Paper Jam Leave Job in Primary: Paper has most likely jammed in the duplex option. Clear Paper Path Finisher area 5 Remove the duplex tray to access the jam. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam...
  • Page 51 5060-2XX User primary User secondary Explanation message message 272 Paper Jam Leave Job in Primary: Media is jammed in the 5-Bin Mailbox Option. Clear Paper Path Finisher area 5 Open the rear door of option to access the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the...

  • Page 52: Sub Error Code Table

    5060-2XX Sub error code table Use this table to troubleshoot the printer when 9xx and 2xx Error Codes are displayed. When a 9xx or 2xx error code is displayed, press and hold Return and press Select to view the Sub error code. Sub error code Explanation 2D 00...
  • Page 53 5060-2XX Sub error code Explanation 2D 1D Fuser exit sensor obstructed. 2D 1E Duplex sensor(s) obstructed. 2D 1F Tray 2 sensor obstructed. 2D 20 Tray 3 sensor obstructed. 2D 21 Tray 4 sensor obstructed. 2D 22 Pass thru sensor in Stacker 1 obstructed. 2D 23 Pass thru sensor in Stacker 2 obstructed.
  • Page 54 5060-2XX Sub error code Explanation 2D 3E Tray 4 pick motor stall error detected. 2D 3F Tray 4 pick motor PWM error detected. 2D 40 Tray 4 pick motor Encoder error detected. 2D 41 Tray 4 feed motor stall error detected. 2D 42 Tray 4 feed motor PWM error detected.

  • Page 55: Understanding The Printer Operator Panel

    5060-2XX Understanding the printer operator panel The operator panel has five buttons, a display, and a light that flashes when the printer is processing a job indicated by the Busy message. Operator panel buttons Button Function Press Go to: • Return to the Ready state if the printer is offline (the Ready message does not appear on the display).
  • Page 56 5060-2XX Select a menu or menu item for more details. Supplies Menu Job Menu Serial Menu PCL Emul Menu Color Menu <color> Toner Cancel Job PCL SmartSwitch Font Source Color Adjust Oiler Reset Printer PS SmartSwitch Font Name Color Balance Waste Bottle Print Buffer NPA Mode...

  • Page 57: Color Menu

    5060-2XX Color Menu Use the Color Menu to adjust print quality and customize color printing. Note: Values marked by an asterisk (*) are the factory default settings. Menu Item Purpose Values Color Adjust To manually recalibrate the color No selections exist for this operation. conversion tables, adjusting for variations Pressing Select initiates this operation.
  • Page 58 5060-2XX Menu Item Purpose Values Color Saver To conserve toner. If selected, this setting Off* Prints using Toner Darkness setting. overrides Toner Darkness settings. Applies a lower Toner Darkness level. Toner Darkness setting is ignored. Manual Color To let users customize the RGB or CMYK RGB Image •...

  • Page 59: Utilities Menu

    5060-2XX Menu Item Purpose Values Toner To lighten or darken printed output, or If Print Mode is Black & White, a Darkness conserve toner. setting of 5 increases toner density and darkness to all print jobs (PCL or Note: Setting Toner Darkness to values of PostScript).
  • Page 60 5060-2XX Menu Item Purpose Values Format Disk To format the printer hard disk. Deletes any data stored on the hard disk and prepares the device to Warning: Do not turn off the printer while receive new resources. the hard disk is formatting. Cancels the request to format the hard disk and leaves current resources stored on the disk.

  • Page 61: User Attendance Messages

    5060-2XX User attendance messages Note: A secondary message only displays if the finisher option is installed. Use the “Sub error code table” on page 2-18 to help diagnose paper jam problems. User primary User secondary Explanation message message Setup Required This message is displayed when the printer has detected at POST, that packing material is still installed and must be removed.
  • Page 62 5060-2XX User primary User secondary Explanation message message Close Door This message is displayed when the printer upper front cover (door) is open. Close the upper front cover (door). Close <tray> Door This message is displayed when the HCIT (2000-sheet) option tray door is open.
  • Page 63 5060-2XX User primary User secondary Explanation message message Load Staples This message is displayed when the Staples Empty Alarm is activated and there are no staples in the staple unit or the staple unit is not installed. This message appears: •...
  • Page 64 5060-2XX User primary User secondary Explanation message message Install Tray x or This message is displayed when the printer requests the Cancel Job user to insert tray x before it can continue printing the job. The printer needs to pick media from the missing tray or the Install Bin x or trays below it.
  • Page 65 5060-2XX User primary User secondary Explanation message message 30 Yellow Toner This message is displayed when the printer is missing the Cart Missing yellow, magenta, cyan, or black toner cartridge. Open the front cover, insert the toner cartridge, and close the cover. 30 Magenta Toner Cart Missing Note: Verify that cartridge packing material is removed.
  • Page 66 5060-2XX User primary User secondary Explanation message message 34 Short Paper This message is displayed when the printer determines that the paper length is too short to print the data as formatted. The following actions can be taken: • Press Go to clear the error and continue printing pages •...
  • Page 67 5060-2XX User primary User secondary Explanation message message 37 Insufficient Defrag This message is displayed when insufficient printer memory Memory is available to perform Flash Memory Defragment operation. This message appears prior to the actual start of the defragment operation. Press Go to clear the message.
  • Page 68 5060-2XX User primary User secondary Explanation message message 38 Memory Full This message is displayed when the printer is processing an incoming job and there is not enough memory available to continue processing the job. The following actions can be taken: You may want to determine how to make more memory available to your print job by: •...
  • Page 69 5060-2XX User primary User secondary Explanation message message 50 PPDS This error displays when the PPDS interpreter has detected Font Error a font error. When a specific font, which is not installed is requested, based on a PPDS mode Set Font Global command, a Select Code Page command, or a comprehensive Font Selection command and the printer BEST FIT setting is OFF.
  • Page 70 5060-2XX User primary User secondary Explanation message message 54 Std Network This message is displayed when the RIP software detects Software Error that a network port is installed but cannot establish communications with it. 54 Network x Press Go to clear this message. Software Error The printer disables all communications to the associated network interface.
  • Page 71 5060-2XX User primary User secondary Explanation message message 56 Standard USB These messages may appear when data is sent to the Port Disabled printer across the USB port, but the port is disabled. 56 USB Port x Note: Once the error is displayed the first time, reporting of Disabled further errors is suppressed until the printer is reset or menus are entered.
  • Page 72 Output Bin x incompatible option. 59 Incompatible The following options may be incompatible for use on one or Tray x more C752 models: 59 Incompatible • Output Bin x (x=1, 2 or 3) Duplex • Tray x (x=2,3,4 or 5) •...
  • Page 73 5060-2XX User primary User secondary Explanation message message 80 Fuser This messages displays when the printer requires Maintenance replacement of a worn assembly. The message is independently posted when a fuser needs to be replaced. Press Go to clear this message. See “Scheduled maintenance”...
  • Page 74 5060-2XX User primary User secondary Explanation message message 88 Yellow Toner These messages are displayed when either the Yellow, Magenta, Cyan, or Black toner cartridge is low on toner. 88 Magenta Toner The following actions can be taken: • Open the front door, remove the old toner cartridge, 88 Cyan Toner insert a new toner cartridge, and close the door •...

  • Page 75: Service Checks

    5060-2XX Service checks 100 ITU Error A 100 ITU error indicates that the printer did not detect the ITU belt home sensor. Before proceeding with this service check make sure that the Second Transfer Roll is correctly installed. After you reinstall the Second Transfer Roll, check to see if a 100 ITU error is still displayed.
  • Page 76 5060-2XX Step Action and questions Check the ITU Release Lever for correct operation. Go to step 3 Repair as The ITU Release Lever is the blue lever located on the necessary left upper side frame above the ITU opening and can be seen by opening and lowering the MPF Assembly.
  • Page 77 5060-2XX Step Action and questions Check to see if the ITU Drive Roll Gear (A) is turning Go to step 10 Go to step 9 during POR. Observe the gear by opening the MFP door to its horizontal position. Observe the gear on the left end of the ITU Drive Roll.

  • Page 78: 104 Itu Error

    5060-2XX 104 ITU Error The ITU has an optical sensor that watches for a piece of reflective tape on the inside of the image belt. This tape is read every revolution of the belt. If a signal is not received from the belt sensor within a certain time period, the printer posts an error due to the loss of signal.

  • Page 79: 120 Error Code

    5060-2XX Step Action and questions Check the printer is setting on a solid, flat surface. Go to step 5 Inform the customer that the Is the printer setting on a solid flat surface? printer must be setting on a solid flat surface.
  • Page 80 5060-2XX 121 error code This error code displays whenever an incorrect fuser backup roll lamp is installed. Step Action and questions Check to make sure that the line voltage to the printer Go to step 2 Set the line matches the setting of the line voltage selection switch voltage selection on the LVPS.
  • Page 81 5060-2XX 124 error code Hot fuser Error code 124 displays whenever the printer detects a problem with the fuser running over temperature or the fuser lamps have been on too long. A problem could exist in the fuser assembly with the hot roll bearings, hot roll thermistor, or other hot roll parts.
  • Page 82 5060-2XX 126 error code Hot roll thermistor or thermistor circuits are open If error code 126 displays, the printer detects a problem in the fuser hot roll, back up roll lamp circuits, fuser hot roll thermistor, back up roll thermistor, system board, or LVPS fuser control circuits. Step Action and questions Turn the printer on and allow it to reach the Ready...

  • Page 83: 128 Error Code

    5060-2XX 128 error code Fuser hot roll is under temperature during standby Step Action and questions Turn the printer on and allow it to reach a Ready Go to step 2 Replace the prompt. “System board” on page 4-67. Note: The printer may not complete POR and continue to display the 128 Error message.

  • Page 84: 130 Error Code

    5060-2XX 130 error code Hot roll did not reach the correct standby temperature This error displays when the fuser hot roll does not reach the correct standby temperature. Step Action and questions Measure the voltage on connector J33-11 on the Replace the Go to step 2 system board.

  • Page 85: 131 Error Code

    5060-2XX 131 error code Backup roll did not reach the correct standby temperature. Step Action and questions Measure the voltage on connector J33-12 on the Go to step 2 Replace the system board. “Fuser assembly” on The voltage measures approximately 0.14 V dc to page 4-32 0.64 V dc as the back up roll lamp turns off and on.

  • Page 86: 132 Error Code

    5060-2XX 132 error code Cold hot roll. Step Action and questions Measure the voltage on connector J33-11 on the Go to step 2 Replace the system board. The voltage should measure “System board” approximately +0.13 V dc to +0.64 V dc as the hot roll on page 4-67 lamp turns off and on.

  • Page 87: 133 Error Code

    5060-2XX 133 error code Cold backup roll Step Action and questions Measure the voltage on connector J33-12 on the Go to step 2 Replace the system board. The voltage should measure “System board” approximately +0.13 V dc to +0.64 V dc as the backup on page 4-67.
  • Page 88 5060-2XX 134 error code Hot fuser Error code 134 indicates that the fuser is running over temperature or the hot roll fuser lamp has been on too long. Error code 134 may also indicate a problem in the fuser assembly with the hot roll bearings, hot roll thermistor, LVPS, or the system board.

  • Page 89: 136 Error Code

    5060-2XX 136 error code Fuser assembly cam position is not found. Step Action and questions Observe the fuser drive assembly gears rotate during Go to step 2 Go to step 5 POR. Do the gears rotate? Do the gears stop and the fuser drive assembly gears Replace the Go to step 3 make a loud buzzing sound?
  • Page 90 5060-2XX 148 error code Step Action and questions Connector J30 on the system board - Check for correct Go to step 2 Install the cable installation of the ITU drive motor cable from the ITU correctly drive motor to the system board connector J30. Is the cable connected correctly? ITU drive motor - Check for continuity between pin 4 of Replace the drive...

  • Page 91: 150 Error Code

    5060-2XX 150 error code Black cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Indicates the black cartridge drive motor has either Go to step 2 Install the cable...

  • Page 92: Error Code

    5060-2XX Step Actions and questions Replace the system board. Problem solved Call your next level support Does this fix the problem? 152 error code Cyan cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect”...

  • Page 93: Error Code

    5060-2XX 153 error code Yellow cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Indicates that the yellow cartridge drive motor has Go to step 2 Install the cable...
  • Page 94 5060-2XX 154 error code ITU belt motor Step Action and questions Connector J30 on the system board - Check for correct Go to step 2 Install the cable installation of the ITU drive motor cable from the ITU correctly drive motor to the system board connector J30. Is the cable connected correctly? ITU drive motor - Check for continuity between pin 4 of Replace the drive...

  • Page 95: 156 Error Code

    5060-2XX 156 error code Black cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Error code 156 - The black cartridge drive motor has Go to step 2 Install the cable...

  • Page 96: 158 Error Code

    5060-2XX Step Actions and questions Replace the magenta cartridge drive assembly. Problem solved Go to step 5 Perform “Motor Detect” on page 3-17. Does this fix the problem? Replace the system board. Problem solved Call your next level support Does this fix the problem? 158 error code Cyan cartridge drive assembly Step...

  • Page 97: 160 Error Code

    5060-2XX 159 error code Yellow cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions The yellow cartridge drive motor has either failed to Go to step 2 Install the cable...

  • Page 98: 162 Error Code

    5060-2XX 162 error code Black cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Black cartridge drive assembly - Error code 162 Go to step 2 Problem solved...

  • Page 99: Paper Jam—Tray 1

    5060-2XX 165 error code Yellow cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Yellow cartridge drive assembly - Error code 165 Go to step 2 Problem solved...
  • Page 100 5060-2XX Step Action and questions Are the sensors connectors fully seated? Go to step 5 Reseat the sensor connector. Are connectors at J21 fully seated on the system Go to step 6 Reseat the board? connector on the system board. Check sensor cables.
  • Page 101 5060-2XX S2 or narrow media sensor made early • 2D 0F—S2 sensor early • 2D 02—S2 sensor early • 2D 05—Narrow media sensor early Note: See “Printer sensors” on page 5-3. Step Action and questions Check tray for the edge guide setting and media Go to step 2 Properly load loading.

  • Page 102: Paper Jam—Options And Multipurpose Feeder

    5060-2XX 200 Paper Jam—Options and multipurpose feeder 500-sheet option or envelope option Step Action and questions Does media feed correctly from Tray 1? Go to step 2 Go to “200 Paper Jam— Tray 1” on page 2-65 Check the tray 2 for proper media loading. Media Go to step 3 Load media should be fanned before loading and must lay flat in...
  • Page 103 5060-2XX High-capacity input tray (HCIT) Step Action and questions Make sure the media installed in the tray meets Go to step 2 Inform customer specifications. that media does not meet Note: The HCIT only supports paper. specifications. Does the media meet specifications? Does the media feed correctly from tray 1? Go to step 3 Go to...

  • Page 104: Paper Jam

    5060-2XX Step Action and questions Check the vacuum transport belts (VTB) for motion. Go to step 6 Go to “Vacuum Observe the belt through the front door. transport belt (VTB)” on Are the belts on the VTB assembly turning? page 4-71 verify correct installation.
  • Page 105 5060-2XX Step Action and questions Reinstall the fuser and perform the “Base Sensor Got to step 5 Perform the Test” on page 3-30 for the fuser exit sensor. following in order: Note: Use a spring hook to actuate the flag. 1.

  • Page 106: Paper Jam

    5060-2XX 230 Paper Jam Step Action and questions Thoroughly examine the duplex paper path for torn Go to step 2 Clear the paper paper that may be blocking the sensors or paper path. path. Is the duplex paper path clear? Check the lower right door paper path.

  • Page 107: 24X Paper Jam

    5060-2XX 24x Paper jam 500-sheet drawer option Media does not reach the pass thru sensor Step Action and questions Is Tray x a HCIT 2000-sheet option? Go to “HCIT” on Go to step 2 page 2-74 Make sure the media installed in the tray meets Go to step 3 Inform the specifications.
  • Page 108 5060-2XX Step Action and questions Check the autocompensator cable for correct Replace the Install the cable installation to Tray x system board. option or replace correctly the following Is the cable connected correctly? parts in the order until the error is cleared: •...
  • Page 109 5060-2XX Step Action and questions Check the pick motor cable to HCIT system board Replace the Install the cable cable connected to CN4 for correct installation. following FRUs in correctly the order shown: Is the cable connected correctly? 1. HCIT system board 2.
  • Page 110 5060-2XX Envelope feeder Before proceeding with this service check, make sure the envelope option is installed correctly. Step Action and questions Make sure the envelopes installed in the tray meet Inform the Go to step 2 specifications. customer of the problems with the Some guidelines that can be used in selection of envelopes that...

  • Page 111: Paper Jam

    5060-2XX 250 Paper Jam Unable to clear the message—Multipurpose feeder loaded Note: A 250 Paper Jam displays when using a multipurpose feeder. Step Action and questions Make sure the media in the MPF meets specifications. Go to step 2 Inform user that the media in the Does media meet specifications? MPF does not...
  • Page 112 5060-2XX Displayed with no media in MPF A 250 Paper Jam indicates that the MPF tried to feed a sheet of media from the MPF tray. A 250 Paper Jam may occur when there is no paper in the MPF, MPF is selected as the paper source, or the MPF sensor is malfunctioning.

  • Page 113: Paper Jam - Check Bin 1

    5060-2XX 271 Paper Jam - check bin 1 Output bin POST complete, first sheet of paper feeds into output bin x. Note: Before proceeding with this service check run the Output Bin x Sensor Test and check for the failing sensor.

  • Page 114: Paper Jam - Check Bin X

    5060-2XX 272 Paper Jam - check bin x 5-bin mailbox Step Action and questions Bottom pass thru sensor flag - Make sure the flag is Fix or replace the Go to step 2 operating correctly and is not binding, broken, and flag there is no interference from the sensor cable.

  • Page 115: 280 Paper Jam

    5060-2XX 280 Paper Jam Use the table below to determine where to check for jams in the printer and to diagnose a 280 Paper Jam. Check the area indicated to find the jam and the problem. If this does not fix the problem, contact the next level ow support.

  • Page 116: 900 Rip Software Error

    5060-2XX Explanation Paper detected at punch timing sensor too long. Dirty or failed punch timing sensor. Paper not detected at punch timing sensor within timeout. Jam near input, misdirected sheet (diverter stuck or misaligned), sensor failure. Finisher internal software error. Intermittent sensor might cause this error. Unexpected sheet detected at punch timing sensor.
  • Page 117 5060-2XX Step Action and questions Restore factory defaults from the Configuration Menu. Record the Problem solved. secondary error Warning: When factory defaults or restored, all menu codes. With the items are returned to the factory default values except: 900 Service RIP Error displayed, •...

  • Page 118: 925 Error Code

    5060-2XX 925 error code Fuser fan (main fan) Step Actions and questions Turn the power off and manually spin the fan and Go to step 2 Replace the check that it rotates freely. “Fuser fan” on page 4-34 Does the fan rotate freely? Check the fuser fan cable connection to the system Go to step 3 Install the cable...

  • Page 119: 927 Error Code

    5060-2XX 927 error code RIP Fan service check Step Actions and questions Turn the power off and manually spin the fan and Go to step 2 Replace the “RIP check that it rotates freely. fan” on page 4-64 Does the fan rotate freely? Check the RIP fan cable connection to the system Go to step 3 Install the cable...

  • Page 120: Error Code

    5060-2XX 940 error code Cyan toner metering cycle (TMC) The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed. Replacement of the cartridge may fix the problem temporarily if the problem is with the printer.
  • Page 121 5060-2XX Step Actions and questions Go to “Base Sensor Test” on page 3-30 and check Replace the Go to step 4 the cyan TMC sensor. When you press the TMC pin in cartridge. the cyan cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.

  • Page 122: Error Code

    5060-2XX 941 error code Magenta toner metering cycle (TMC) The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed. Replacement of the cartridge may fix the problem temporarily if the problem is with the printer.
  • Page 123 5060-2XX Step Actions and questions Go to “Base Sensor Test” on page 3-30 and check Replace the Go to step 4 the magenta TMC sensor. When you press the TMC cartridge. pin in the magenta cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.
  • Page 124 5060-2XX 942 error code Yellow toner metering cycle (TMC) The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed. Replacement of the cartridge may fix the problem temporarily if the problem is with the printer.
  • Page 125 5060-2XX Step Actions and questions Go to “Base Sensor Test” on page 3-30 and check Replace the Go to step 4 the yellow TMC sensor. When you press the TMC pin cartridge. in the yellow cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.

  • Page 126: Error Code

    5060-2XX 943 error code Black toner metering cycle (TMC) Toner metering cycle (TMC) is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed.
  • Page 127 5060-2XX Step Actions and questions Go to “Base Sensor Test” on page 3-30 and check Replace the Go to step 4 the black TMC sensor. When you press the TMC pin in cartridge. the black cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.

  • Page 128: 990 Service Error

    5060-2XX 990 service error This error indicates which option is causing the error. 5-Bin mailbox Step Action and questions Mechanical linkage/DC motor assembly - Check the Go to step 2 Reseat the cable DC motor cable connector to make sure it is installed at and recheck for J4 on the control board.

  • Page 129: Output Expander

    5060-2XX Step Action and questions Check for worn or broken parts in the autocompensator Replace the Replace the and drive assemblies. assembly that FRUs in the has the defective following order: Are any parts worn, broken, or damaged? parts 1. Electronic/ size sensing assembly 2.

  • Page 130: 5-Bin Mailbox Option Service Check

    5060-2XX Finisher Step Actions and questions Make sure the top options cable is correctly plugged Go to step 2 Install correctly into the system board. Is the cable correctly installed? Make sure the finisher cable is correctly installed on Go to step 3 Install correctly top of the printer.
  • Page 131 5060-2XX Step Symptoms 271 Paper Jam - Check Bin 1 message Go to “271 Go to step 4 Paper Jam - check bin 1” on page 2-79 274 Paper Jam - Check Bin 4 displays. Go to “Ready Go to step 5 bin x full message - may be able to clear...
  • Page 132 5060-2XX The printer does not recognize one or more output options as installed. Note: If more than a single output option is installed, check each one to see if the printer recognizes any single option as being installed. If the printer recognizes any of the output options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized option.
  • Page 133 5060-2XX Ready bin x full message - may be able to clear message and will feed paper into bin selected. Note: This sensor is normally in a open position with the flag out of the sensor slot. Step Action and questions Bin x sensor (bin x=Sensor 1 through 5) - Make sure Go to step 2 Install the sensor...

  • Page 134: 500-Sheet Drawer Option Service Check

    5060-2XX Paper does not feed into the bin selected. 271 Paper Jam - check bin 1 message Step Action and questions Bin parts - Check all the bin parts, deflector, deflector Replace parts or Go to step 2 spring, deflector cover, deflector cover spring, and repairs shaft assemblies for signs of missing or loose springs.
  • Page 135 5060-2XX Step Action and questions Tray x autoconnect cable - check the tray x Go to step 6 Install the cables autoconnect cable(s) for correct installation at the correctly and tray x system board. recheck Are the tray x autoconnect cable(s) connected correctly? Tray x autoconnect cable continuity - Check the Go to step 7...
  • Page 136 5060-2XX The printer detects paper low in tray x when adequate paper is installed in the tray. Step Action and questions Run Tray x sensor test from the Diagnostics Menu. Go to step 3 Go to step 2 Does the test pass for sensor L2? Check the cable connection for the paper low/out Go to step 3 Install the cable...
  • Page 137 5060-2XX Step Action and questions Make sure the paper level sensing assembly arm goes Recheck the arm. See why the arm all the way through the bottom of tray x. If the problem is not extending continues, all the way to the Does the arm extend all the way down through the replace the paper bottom of the...

  • Page 138: Ac And Dc Power Service Check

    5060-2XX AC and DC power service check Before proceeding with this service check remove or disconnect any options that may be installed. Turn the machine on. If it operates correctly, reattach one option at a time until the failing option is located. Note: Set the voltage range switch to the proper power setting for the geographic area you are in.

  • Page 139: Dc Power Service Check

    5060-2XX Step Actions and questions Low voltage power supply - Turn the power off and Replace the Replace the disconnect the LVPS at J35 on the system board. “System board” “LVPS Measure the voltages on J35-3 and J35-4. The voltage on page 4-67 assembly”...

  • Page 140: Autocompensator Service Check

    5060-2XX Step Actions and questions Turn off the printer and plug in the cable for the Check the cable If printer comes component that is related to the error presented. For and component to Ready, example, for the 114 Service Printhead error, plug in that was last connect the the black printhead J11 and J12.
  • Page 141 5060-2XX Step B Step Action and questions Check Tray 1 for damage to the pick arm lift bellcrank Replace tray 1 Go to step 2 activation tabs on the rear of the tray. Is there any damage to the tray? Check the following parts for damaged, loose, or Repair or replace Go to step 3...

  • Page 142: Black Only Retract (Bor) Service Check

    5060-2XX Step D Step Action and questions Enter the Diagnostics Mode and select the Tray 1 Call your next Go to step 2 Sensor Test from the Input Tray Tests menu. You can level support activate the paper level sensor inside the printer. The paper level sensor is a dual sensor and checks the following levels for Tray 1.

  • Page 143: Close Door/Hvps/Printhead Interlock Switch Service Check

    5060-2XX Close door/HVPS/printhead interlock switch service check Note: There are two separate cables that contain microswitches and a cable. These cable/switches provide separate interlocks for the printhead and HVPS. One switch in the Printhead/cover open cable is mounted in the front access door support and the other switch in the printhead/open cover cable is mounted on the ITU light shield assembly.
  • Page 144 5060-2XX POR complete, printer feeds blank page This symptom is usually associated with the upper switch mounted on the front access door support. Step Action and Questions Make sure that the ITU light shield is not broken. Replace the ITU Go to step 2 light shield Is the ITU light shield broken?

  • Page 145: Duplex Option Service Check

    5060-2XX Duplex option service check Before proceeding with this service check: Check for any pieces of media or obstructions in the duplex paper path that might cause a paper jam. Check for correct installation of the front duplex jam tray and right side clearance tray. Check the duplex option for any signs of loose, damaged, contaminated, or warped parts that might cause a jam.

  • Page 146: Envelope Feeder Option Service Check

    5060-2XX Step Action and questions Check the voltages on the bottom options cable Go to step 8 Replace the connector. The voltages are with the printer in standby bottom options mode. cable in the printer Note: All voltages are approximate values. Connector pin Voltage J37-1 +5 V dc...
  • Page 147 5060-2XX Step Action and questions Check for the correct installation of the lower options Go to step 5 Install the cable autoconnect cable for the system board connector J37. correctly and recheck Is the cable installed correctly? performance Autoconnect cable - Check the autoconnect from the Go to the service Replace the printer or option installed above the envelope feeder.

  • Page 148: Finisher Service Check

    5060-2XX Finisher service check If a failure is detected by the system board, an error may be displayed. The LEDs on the HCOF system board can help in diagnosing the errors. HCOF error code table LEDs lit by number Description Error detected by Punch Timing Sensor Error detected by Inverter Jam Sensor Error detected by Drop Timing Sensor...
  • Page 149 5060-2XX Step Action and questions Check the joint switch cable connection to CN19 on the Go to step 4 Install the cable finisher system board. correctly Is the cable installed correctly? Check the joint switch activating spring for any signs of Replace the joint Go to step 5 damage.
  • Page 150 5060-2XX Step Action and questions Check the voltage on the output options autoconnect Go to step 7 Go to step 10 connector Pin 2 located on the top right rear of the printer. The voltage measures approximately +5 V dc. Is the voltage correct? Check the AC line voltage between CN2-1 and CN2-3 Replace the...
  • Page 151 5060-2XX Fan in finisher inoperative Step Action and questions Make sure the fan cable, H6, is correctly connected to Go to step 2 Install the cable CN21 on the finisher system board. correctly Is the cable connected correctly? Check the cable H6 connection to the fan assembly. Go to step 3 Install the cable correctly...

  • Page 152: Hcit 2000-Sheet Option Service Check

    5060-2XX Chad Box Full message when chad box is not full Step Action and questions Make sure the chad box is correctly installed in the Go to step 2 Install the chad finisher. box correctly Is the chad box correctly installed? Check the chad box sensor with a voltmeter.
  • Page 153 5060-2XX Printer does not recognize that the HCIT 2000-sheet option is installed. Step Action and questions Is the HCIT 2000-sheet option the only paper input Go to step 5 Go to step 2 option that is not recognized? Make sure that the printer and any option above the Go to step 3 Install the options HCIT 2000-sheet option are installed correctly.
  • Page 154 5060-2XX HCIT inoperative Before proceeding with this service check make sure the 2000-sheet tray option is properly connected to AC power. • If a finisher is installed: The AC jumper should go from the HCIT to the finisher. The finisher AC power cord should attach to the AC voltage source.

  • Page 155: Fuser Drive Assembly Noise Check

    5060-2XX HCIT 2000-sheet option does not recognize the size paper selected. Step Action and questions Make sure the media loaded in the tray meets Go to step 2 Load the media specifications. properly or inform the customer that Is the media loaded properly and meet specifications? the media does not meet specifications...

  • Page 156: Operator Panel Lcd/Status Led/Buttons Service Check

    5060-2XX Operator panel LCD/status LED/buttons service check Use this service check to check both the operation of the panel buttons and to test the LCD display for correct operation. • Replace the operator panel assembly if the LCD display functions normally, but the LED does not come on. •...
  • Page 157 5060-2XX Step Action and questions Operator panel cable (operator panel connection) - Go to step 9 Seat the cable Make sure that the operator panel cable is seated correctly correctly in the connector on the operator panel board. Is the cable seated correctly? Operator panel cable - Check continuity of the operator Replace the Go to...

  • Page 158: Output Expander Option Service Check

    5060-2XX Output expander option service check Note: The majority of the mechanical components can be observed during operation by removing the covers. The output expander functions without the covers installed. Make sure the option is correctly installed before attempting to service the unit. Step Symptoms The printer does not recognize one or more output...
  • Page 159 5060-2XX Printer does not recognize that one or more output options as being installed. Step Actions and questions Excessive static electricity buildup - Check the output Go to step 2 1. Attach the expander control board cover to make sure the ESD ground cable if brush ground lead is firmly attached to the output not installed...
  • Page 160 5060-2XX No indication that bin x is full or no indication that bin x is near full. Step Actions and questions Sensor cable installation - Check for correct installation Go to step 2 Install the cable of the sensor cable at J5 on the control board. correctly Is the cable installed correctly? Dual output bin x sensor assembly...

  • Page 161: Print Quality Service Check

    5060-2XX Print quality service check Note: This symptom 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 an ITU, fuser assembly, second transfer roll, or print cartridge. Check the following before proceeding with any of the print quality service checks.

  • Page 162: Entire Page Is Mostly One Color-Full Bleed Planes In One Color

    5060-2XX Entire page is mostly one color—Full bleed planes in one color Some printing may appear in other colors. This applies to black, cyan, magenta and yellow. Step Action and questions Using a piece of paper, block the laser path between Go to step 2 Go to step 4 the printhead and cartridge for the color that is...

  • Page 163: Missing Colors—Complete Or Partially Missing Color Planes

    5060-2XX Missing colors—Complete or partially missing color planes • If a color or colors are missing, or a color is partially missing, go to “If cyan, magenta, and yellow is missing, go to “Black and white only—cyan, magenta, and yellow are missing” on page 2-130.” on page 2-129.

  • Page 164: Black And White Only-Cyan, Magenta, And Yellow Are Missing

    5060-2XX Step Action and questions Perform a continuity check on the developer HVPS Replace in order: Replace the cable. developer HVPS 1. Developer cable. Does the cable check out? HVPS board. “Developer HVPS board” on page 4-30. 2. System board. See “System board”...

  • Page 165: Vertical Lines Or Streaks

    5060-2XX One color has light print over the entire page Step Action and questions Print cartridge - Make sure the cartridge is seated Go to step 2 Remove the properly and all packaging material is removed from packaging the cartridge. material and seat the cartridge.

  • Page 166: Horizontal Lines Or Streaks

    5060-2XX Horizontal lines or streaks If the horizontal marks or lines repeat at evenly-spaced intervals, use the “Print quality defect locator chart” on page 3-4 to determine the part to be replaced. For lines or marks appearing at random intervals, go to step 1. Step Action and questions Are the horizontal marks or lines in a single color?

  • Page 167: Poor Color Alignment

    5060-2XX Step B Step Action and questions Make sure that color calibration has not been disabled Set Color Go to step 2 in the Diagnostics menus, especially if the printer has Calibration on been previously serviced. Was color calibration disabled? Toner density calibration - Run toner density calibration Problem solved Replace the...

  • Page 168: Transparency Print Quality Is Poor

    5060-2XX Transparency print quality is poor Step Action and questions Transparencies - Check the media type and Go to step 2 Inform the transparency in use. customer Are the recommended transparencies and media type used? Is the quality of the transparency poor or do brown Go to step 3 Go to step 4 colors appear when projected?

  • Page 169: Residual Image

    5060-2XX Residual image • If only one color has a residual image repeated every 95mm, replace the print cartridge. • If all colors have a residual image 147 mm from the top of the page, replace the fuser assembly. Note: Do the following steps before you replace the fuser assembly: Check Media Type setting on the operator panel.

  • Page 170: Smudged Or Distorted Images On Fused Page

    5060-2XX Smudged or distorted images on fused page Step Action and questions Remove the ITU assembly and check for any signs of Remove the Go to step 2 debris near the paper feed reference edge mechanism debris underneath the ITU assembly. Are there any signs of any debris in this location? Check for any signs of debris on the surface of the ITU Remove the...

  • Page 171: Light Lines Or Streaks Appear On The Page

    5060-2XX Light lines or streaks appear on the page Single color streaks outside the printed page are most likely caused by a problem in the print cartridge. Replace the print cartridge. All the colors streaking at a different spot on each page is probably caused by a damaged ITU assembly. Replace the “ITU assembly”...

  • Page 172: Paper Wrapped Around The Second Transfer Roll

    5060-2XX Paper wrapped around the second transfer roll Step Action and questions Some media can get wrapped around the second Remove the Problem solved transfer roll and can affect print quality. piece of media and go to step 2. Is there a piece of media wrapped around the second transfer roll? Run several pages to see if the media wraps around Replace the...
  • Page 173 5060-2XX Step Actions and questions Check the continuity of the second transfer cable. Replace the Replace the FRUs in order: 1) second transfer Is there continuity? “Second cable transfer roll” on page 4-66 2)“Transfer HVPS board” on page 4-68. If this does not correct the problem, go to step 5.

  • Page 174: Tray 1 Service Check

    5060-2XX Tray 1 service check Tray 1 does not stay seated or fit correctly in the printer, the media fails to feed correctly from tray 1 or tray 1 is difficult to install The Tray 1 Feed Test in the Diagnostics Menu can be used to help isolate problems with paper feeding from Tray 1.

  • Page 175: Tray 1 Paper Size Sensing Service Check

    5060-2XX Tray 1 paper size sensing service check The printer does not sense the size of the media installed in Tray 1. Note: If there is a problem when installing Tray 1, Tray 1 is difficult to remove or does not stay locked in position, go to “Tray 1 service check”...
  • Page 176 5060-2XX 2-142 Service Manual...

  • Page 177: Diagnostic Aids

    5060-2XX 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. There are different test menus that can be accessed to identify problems with the printer. Diagnostic aids Printhead diagnostics “Printheads”...
  • Page 178 5060-2XX Install the printhead diagnostic tool and determine the problem. The following procedure shows the yellow and cyan switch as an example. Turn off the printer. Unplug the printhead cables from the system board in the printer and connect them to the printhead diagnostic tool.
  • Page 179 5060-2XX Turn on the printer and note the new error codes. • If an automatic calibration begins, 36 Printer Service Required may appear. The printhead and system board are working correctly and the printhead cable connections should be checked. Press Go to clear the error. •...

  • Page 180: Print Quality Defect Locator Chart

    5060-2XX Print quality defect locator chart The print quality locator chart is copied below, but the tool is a transparent sheet available with this printed book. Use the tables and rulers to determine the source of repeating defects. Using the chart Measure repeating horizontal lines from the reference lines at the top to determine what may have caused the lines to form in that pattern.
  • Page 181 5060-2XX Printing the chart The printer has an internal copy of the defect locator chart under the Help Menu. Verify the proper image size by measuring any of the marks on the chart and comparing them to the corresponding measurement in the chart. Use Step 2 if adjustments are needed.

  • Page 182: Partial Print Test

    5060-2XX Partial Print Test Diagnostic procedure for missing or faded planes Turn the printer off. Remove all cartridges and the ITU. Inspect the bellcranks. Enter the Configuration Menu. See “Configuration Menu” on page 3-8. Select Prt Quality Pgs and press Select. Open the vacuum transport belt (VTB) jam access door and watch the test pages pass from left to right over the VTB.
  • Page 183 5060-2XX Interpreting the results If the developed images are not visible on one of the PC drums, the following components should be checked: • Toner cartridge - Switch cartridges to determine if the problem stays with the slot or cartridge. •...

  • Page 184: Configuration Menu

    5060-2XX 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. To access to the Configuration Menu: Turn the printer off, press and hold Select and Return while you turn the printer on and wait until Performing Self Test is displayed.

  • Page 185: Reset Fuser Cnt

    5060-2XX Reset Fuser Cnt This only displays if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID. The fuser maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. The counter can be used to track printer usage. When the counter reaches 200,000, the printer posts a fuser maintenance message on the operator panel.

  • Page 186: Panel Menus

    5060-2XX Panel Menus Disabling Panel Menus prohibits users from modifying any setting or executing any operation available in the Ready Menu group. Select Panel Menus from the Configuration Menu. =Disable =Enable* PPDS Emulation This only displays if the PPDS interpreter is available. Select PPDS Emulation from the Configuration Menu.

  • Page 187: Auto Color Adjust

    5060-2XX Auto Color Adjust Automatic color adjustments periodically occur during printing, based on internal algorithms The following situations prompt the adjustment: • If the printer detects a new or different color cartridge is installed, usually at power on or when the cover is closed.

  • Page 188: Paper Prompts

    5060-2XX Paper Prompts Setting Paper Prompts controls which tray a change prompt is directed to when paper is sensed to be the wrong size. =Auto =MP Feeder =Manual Paper Env Prompts Env Prompts controls which tray a change prompt is directed to when the envelopes are sensed to be the wrong size.

  • Page 189: Diagnostics Mode

    5060-2XX Diagnostics Mode To run the printer diagnostic tests described in this chapter, put the printer in Diagnostics Mode. The tests display on the operator panel in the order shown: • Registration • Alignment Menu • Top Fine Margin Adjustment •...

  • Page 190: Registration

    5060-2XX Registration The print registration range is: Bottom Margin: -25 to +25 Top Margin: -25 to +25 Left Margin: -15 to +15 Right Margin: -15 to +15 To set Print Registration: Select Registration from the Diagnostics Mode. T=sxx* B=sxx* L=sxx* R=sxx* B=Bottom margin T=Top margin...

  • Page 191: Alignment Menu

    5060-2XX Alignment Menu Cyan, Yellow, Magenta Select Alignment Menu. Select Cyan, Yellow, or Magenta. The following screen is displayed: T=sxx* R=sxx* L=sxx* Z=sxx* Value: Description: Range: Top Margin Offset -127 to +127 Left Margin Offset -300 to +300 Right Margin Offset -350 to +350 Theta Offset (Skew -16 to +16...

  • Page 192: Drift Sensor Check

    5060-2XX Alignment Test Page. Buttons are not active when the Alignment Test Page is printing. Also the thermal drift sensors will be calibrated at this time Note: The Alignment Test Pages should be printed on A4 or Letter paper. The printer tries to print the test page from the default paper source, however if the default source only supports envelopes, then the page prints from Tray 1.

  • Page 193: Misc Tests

    5060-2XX Misc Tests Motor Detect This test initiates an Automated Motor Detection. It must be performed if the NVRAM contents are lost during the replacement of a paper size sensing board. This test must also be performed anytime the ITU motor, fuser motor, or cartridge drive motors are replaced.

  • Page 194: Belt Tracking (Itu 4Th Point Adjustment)

    5060-2XX Belt Tracking (ITU 4th point adjustment) This test is used to determine the need for the ITU Shim to correct 4th point alignment following the ITU replacement. Note: Remove all cartridges before initiating this test and note the belt position. Select Belt Tracking from the menu.

  • Page 195: Print Tests

    5060-2XX Print Tests The Print Tests consist of the following tests: Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) MP Feeder For examples of the Print Quality Pages, see “Print tests” on appendix page B-3.

  • Page 196: Hardware Tests

    5060-2XX Hardware Tests The following hardware tests can be selected from this menu: LCD Test Button Test DRAM Test Cache Test ROM Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 2 Wrap (if available) Serial 3 Wrap (if available) LCD Test This test verifies the operator panel LCD function.

  • Page 197: Dram Test

    5060-2XX DRAM Test This test checks the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: Select DRAM Test from the menu.

  • Page 198: Rom Test

    5060-2XX ROM Test The ROM memory test is used to check the validity of the controller board code and fonts. To run the ROM Test: Select ROM Test from the menu. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in progress.

  • Page 199: Serial Wrap Test

    5060-2XX 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. Select the appropriate Serial Wrap Test from the menu: Serial Wrap, Serial 1 Wrap, Serial 2 Wrap or Serial 3 Wrap.

  • Page 200: Duplex Tests

    5060-2XX Duplex Tests Duplex Quick Test This test verifies if the Duplex Option Top Margin is set correctly. This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the back of the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages (Continuous) until Return or Stop is pressed.

  • Page 201: Input Tray Tests

    5060-2XX Input Tray Tests Feed Test This test lets you observe the paper path as media is feeding through the printer. The upper front door, used to access the print cartridge, cannot be opened during the feed test. To observe the paper path, you must open the lower front door, used to access the paper jams on the vacuum transport belt.

  • Page 202: Output Bin Tests

    5060-2XX For 2000-sheet trays This test can also be used to determine if the 2000-sheet tray sensors are working correctly. Select Sensor Test from the menu for the tray you want to test. The following is displayed: <input tray> EM=OP NE=OP LE=OP SC=OP The selected tray is displayed on line 1 <input tray>...
  • Page 203 5060-2XX Sensor Test This test verifies if the output bin sensors are working correctly. The following Output options, if installed, are supported by this test. Standard Bin Output Expander 5-Bin Mailbox To run the Output Bin Sensor Test: Select Sensor Test from the menu. Select the bin you want to test.

  • Page 204: Finisher Tests

    5060-2XX Finisher Tests Staple Test This test verifies the operation of the staple mechanism in the finisher. To run the Staple Test, select Staple Test from the test menu. The printer feeds eight pieces of media to the finisher and accumulates all eight pieces in the accumulator. After the last sheet is accumulated, the pack is stapled.

  • Page 205: Hole Punch Test

    5060-2XX • If you select Media 2 from the menu the following is displayed and the sensors polled: Media Path 2 Testing.... Once the sensors are polled the following is displayed and the sensors are ready to test. Media Path 2 S3=OP S4=OP =Inverter Jam Sensor =Drop Timing Sensor...

  • Page 206: Base Sensor Test

    5060-2XX Base Sensor Test Use the Base Sensor Test to determine that the sensors located inside the printer are operating correctly. The following sensors can be checked using this test: • Input Sensor S1 • Input Sensor S2 • Inline Media Sensor •...

  • Page 207: Flash Test

    5060-2XX The power indicator blinks during the test. The test can be canceled anytime during the test by pressing Return or Stop. • Once the test is complete, the power indicator turns on solid and a message displays. • xxxx Bad Blocks/yyyyyy Usable is displayed if fewer than 2000 bad blocks are detected. xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks.

  • Page 208: Printing The Error Log

    5060-2XX Printing the error log The history of printer errors can be printed. The first page of the error log contains a Printer Information section similar to what is printed on a Menu Setting Page. Printed at the top of each page is the model name and serial number to assist in tracking each page of a report to a specific printer.

  • Page 209: Printer Setup

    5060-2XX 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: Default values Printer setting US value Non-US value Paper size (paper feeding sources which do not have Letter hardware size sensing capabilities)

  • Page 210: Serial Number

    5060-2XX Serial Number You can view the serial number. Engine Setting x Warning: Should not be changed without specific instructions from the next level support. Model Name You can view the model name. Configuration ID Warning: Should not be changed without specific instructions from the next level support. The configuration ID is used to communicate characteristics of certain areas of the printer that cannot be determined by hardware sensors.

  • Page 211: Edge To Edge

    5060-2XX Edge to Edge Turn Edge to Edge printing on or off. Cal Ref Adj Warning: Should not be changed without specific instructions from the next level support. EP Setup EP Defaults Fuser Temp DC Charge Adjustment Dev Bias Adj Transfer Adjust EP Defaults The EP Defaults is used to restore each of the printer settings contained in the EP Setup menu to their factory...

  • Page 212: Hcit Standalone Test Mode

    5060-2XX HCIT standalone test mode This test lets you check out and test the HCIT (2000-Sheet High Capacity Input Tray) without removing any option or the base printer mounted above the optional HCIT. Note: During normal operation, the red LED on the HCIT system board blinks or flashes on for one second and off for one second.

  • Page 213: Repair Information

    5060-2XX 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 214: Screw Identification Table

    5060-2XX Screw identification table The following table contains screw types, 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. Reference Screw type Location...
  • Page 215 5060-2XX Reference Screw type Location Purpose number M3x6 mm Taptite Ground cable to right front cover support Attach Metal Thread and upper frame. Forming Blank INA covers to system card shield Mounting Rear V-block plate to upper frame Mounting Transfer HVPS to card shield Attach Media size card to support plate Attach...
  • Page 216 5060-2XX Reference Screw type Location Purpose number M3.5x1.35 mm x Left lower cover to lower frame Attach 1.35 Plastite 8 long Left upper cover asm to lower frame Attach (continued) Left upper cover asm to upper frame Attach Left lower pivot to lower frame Attach Left upper pivot lower frame Attach...
  • Page 217 5060-2XX Reference Screw type Location Purpose number M3.5x10 mm Transfer HVPS/RIP fan asm to RIP shield Attach Plastite Thread Front left light shield to left upper cover asm Attach Forming and top cover Front right light shield to right front cover Attach support and top cover Cartridge drive assemblies to upper frame...

  • Page 218: Removal Procedures

    5060-2XX Removal procedures CAUTION: Remove the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The C752n weighs 68 kg (105.8 lb) and requires at least two people to lift it safely.
  • Page 219 5060-2XX Remove the right light shield. Unsnap the bottom of the operator panel bezel and remove. Remove the top cover screws (D) type “323” on page 4-4 from the rear of the printer. Open the MPF and remove the top cover screw (E) type “323”...
  • Page 220 5060-2XX Remove the top cover mounting screws (F) from the front of the printer. Remove four screws (G) holding the outer system board shield. Disconnect the cable from J2 (H) on the system board. Remove the top cover. Service Manual...

  • Page 221: Rear Cover

    5060-2XX Rear cover Go to “Rear cover” on page 7-5 for part number. Remove the “Outer system board shield” on page 4-50. Remove 13 rear cover screws (A). Open MPF door. Repair information...
  • Page 222 5060-2XX Remove two screws (B). Remove tabs (C) from slots (D). Remove the rear cover. 4-10 Service Manual...

  • Page 223: Front Right Handle Cover Assembly

    5060-2XX Front right handle cover assembly Go to “Front right handle cover assembly” on page 7-3 for part number. Open the front cover. Remove the light shield screw (A) type “324” on page 4-5 and (B) “323” on page 4-3. Remove the light shield.

  • Page 224: Front Left Handle Cover Assembly

    5060-2XX Front left handle cover assembly Go to “Front left handle cover assembly” on page 7-3 for part number. Open the front cover. Remove the four front left handle cover assembly screws (A) type “323” on page 4-3 and remove the assembly.
  • Page 225 5060-2XX Unsnap the bottom of the operator panel bezel and remove. Hold the front cover and remove the two screws (C) from the upper front pivot cover. Remove the front cover assembly. 4-13 Repair information...

  • Page 226: Front Lower Right Cover

    5060-2XX Front lower right cover Remove tray. Remove“Front right handle cover assembly” on page 4-11 Remove the left lower cover screw (A) type “323” on page 4-3. Close the paper path access door and tape front jam access door (B) if tape is available, to help hold the door in place.

  • Page 227: Lower Right Door Assembly

    5060-2XX Lower right door assembly Go to “Lower right door assembly” on page 7-3 for part number. Open the lower right door assembly. Remove the“Front lower right cover” on page 4-14. Loosen the two screws (A). Remove the lower right door assembly. Left lower cover Remove the “Lower jam access door assembly”...

  • Page 228: Lower Jam Access Door Assembly

    5060-2XX Lower jam access door assembly Go to “Cover, left lower” on page 7-5 for part number. Remove the “Paper path access door cover” on page 4-17. Remove the “Front left handle cover assembly” on page 4-12. Remove the lower jam access door assembly screws (A) type “323”...

  • Page 229: Paper Path Access Door Cover

    5060-2XX Paper path access door cover Go to “Paper path access door” on page 7-3 for part numbers. Remove the paper tray. Remove the “Front left handle cover assembly” on page 4-12. Open the paper path access door, carefully remove screw (A) type “323”...

  • Page 230: Front Lower Left Cover

    5060-2XX Front lower left cover Go to “Front lower left cover” on page 7-3 for part numbers. Remove the paper tray. Remove the “Front left handle cover assembly” on page 4-12. Open the paper path access door, carefully remove screw (A) type “323”...

  • Page 231: Autocompensator Pick Assembly

    5060-2XX Autocompensator pick assembly Remove the “ITU assembly” on page 4-40. Remove tray 1. Remove the transfer plate. Lifting and rotating the right edge of the plate up to a 45° angle releases the transfer plate. Remove the grounding strap (A) attached to the bottom of the transfer plate. 4-19 Repair information...
  • Page 232 5060-2XX Remove the black mylar piece by removing the two screws (B) or cutting the cable tie. Remove the five screws (C) and remove the lower left cover and the jam access door. C(323) 4-20 Service Manual...
  • Page 233 5060-2XX Remove the pin (D) that holds in the MPF swing arm assembly. Remove the MPF swing arm assembly (E). 4-21 Repair information...

  • Page 234: Left Side View

    5060-2XX Remove the paper level sensor. There are two screws located under the back VTB belt. Remove both of them along with a third that is located at the rear pivot point for the transfer plate (F). This allows the paper level assembly to drop into the cavity that the tray is inserted into.
  • Page 235 5060-2XX Disconnect the pick motor connector (G). Remove four screws (H) holding the pick assembly in place. 4-23 Repair information...
  • Page 236 5060-2XX Push the bellcrank (I) in to allow the pick arm to fall to the bottom of the tray. Disconnect the spring clip (J) from the pick arm. Be sure not to let the spring come off of the lower frame. Also identify which pegs the spring clip is sitting on.
  • Page 237 5060-2XX Leaving the pick arm down, lift the pick assembly and slide it toward the back of the machine and drop it through the holes located next to the brackets. Put the new pick assembly into the printer. Make sure the pick motor connector is placed through the holes before you insert the brackets.
  • Page 238 5060-2XX Lift the pick assembly to insert the brackets up through the appropriate openings. Once the pick assembly brackets are through their openings, slide the assembly toward the front of the machine until the half moon on the bracket is against the locator pin (L). Reattach the spring clip to the pick arm.

  • Page 239: Bor Drive Assembly

    5060-2XX Position the mylar piece using two screws or one cable tie. When you place the mylar piece, make sure you place it back under the metal bar (M) under the inner deflector. if a cable tie is used to secure the mylar piece, make sure that the blue cable running under the mylar piece is retained by the cable tie.

  • Page 240: Cartridge Contact Assembly

    5060-2XX Cartridge contact assembly Go to “Cartridge contact assembly” on page 7-28 for part numbers. Warning: Do not remove printheads. Open the front cover. Remove the toner cartridges. Remove the “ITU assembly” on page 4-40. Remove the “Top cover assembly” on page 4-6.

  • Page 241: Cartridge Drive Assembly

    5060-2XX Cartridge drive assembly Note: Drive assemblies must be removed in the following order until the desired assembly can be removed: • Black • Magenta • Cyan • Yellow Go to “Cartridge drive assembly, cyan/magenta/black (one drive assembly per package)” on page 7-29 part number.

  • Page 242: Developer Hvps Board

    5060-2XX Developer HVPS board Remove “Inner system board shield” on page 4-39. Remove four top machine screws (A) and four bottom screws (B) from the developer HVPS board. Remove all connectors (C) from the left board. 4-30 Service Manual...

  • Page 243: Friction Buckler

    5060-2XX Remove connectors (D) from the right board. Remove developer HVPS boards. Reinstall HVPS boards. Installation note: Disconnect the cable between boards. Install the large board by attaching the bottom screws loosely, attach the top screws, then tighten the bottom screws. Connect the boards Install the small board in the same manner as the large board.

  • Page 244: Fuser Assembly

    5060-2XX Replace the friction buckler (B). Fuser assembly CAUTION: Be sure the fuser assembly has cooled before you remove it. “Fuser assembly” on page 7-7 for part numbers. Open the lower right door assembly and redrive door. Unlatch the two fuser latches (A). Remove the fuser assembly.

  • Page 245: Fuser Bottom Duct

    5060-2XX Fuser bottom duct Go to “Fuser bottom duct” on page 7-5 for part number. Remove “Fuser assembly” on page 4-32. Remove “Fuser top duct” on page 4-35. Remove the redrive belt cover duct (A). Remove fuser left duct (B). Remove fuser bottom duct.

  • Page 246: Fuser Drive Card Assembly

    5060-2XX Fuser drive card assembly Go to “Card assembly - fuser drive” on page 7-10 for part number. Remove the rear cover. See “Rear cover” on page 4-9. Remove the fuser fan. See “Fuser fan” below. Disconnect the cable (A). Remove the three screws (B).

  • Page 247: Fuser Top Duct

    5060-2XX Fuser top duct Go to “Fuser top duct” on page 7-5 for part number. Remove “Rear cover” on page 4-9. Remove the fuser top duct screw (B) and disconnect tab (A). Remove the top duct. B(323) 4-35 Repair information...

  • Page 248: Fuser Web Oiler Motor Assembly And Card

    5060-2XX Fuser web oiler motor assembly and card “Fuser assembly” on page 7-7. Open the front cover. Remove the yellow print cartridge. Remove the “Front lower right cover” on page 4-14. Remove screw (A) from the top front support bracket. Swing bracket to the right. 4-36 Service Manual...
  • Page 249 5060-2XX Remove screws (B) for motor and screws (C) for the web oiler card. Remove the fuser web oiler motor assembly and card. 4-37 Repair information...

  • Page 250: Installation Notes

    5060-2XX Installation notes Note: When you reinstall the web oiler motor assembly, route the cable along the right side frame and through the cable clip (A). Note: Make sure the cables from the drive assembly are routed along the lower frame and are not in contact with the drive assembly gears.

  • Page 251: Inner System Board Shield

    5060-2XX Inner system board shield Remove the “Transfer HVPS board” on page 4-68. Remove the “System board” on page 4-67. Remove the six screws (A). Remove ground wire screw (B). Remove the inner system board shield. 4-39 Repair information...

  • Page 252: Itu Assembly

    5060-2XX ITU assembly Go to “ITU assembly” on page 7-22 for part number. Open the front cover. Remove the toner cartridges. Open the MPF to the lowest position. Raise the ITU release lever (A) and slide the ITU from the printer. ITU drive assembly Remove the black cartridge drive assembly.

  • Page 253: Itu Drive Motor

    5060-2XX Remove the three ITU drive assembly mounting screws (C) and disconnect the ITU drive motor cable (D). Move the bottom of the ITU drive assembly toward you as you rotate the top of the assembly out of the printer. Be careful not to damage the large drive gear as you remove the ITU drive assembly. ITU drive motor Remove the system board shield.

  • Page 254: Lvps Assembly

    5060-2XX LVPS assembly Go to “LVPS, 115V/230V switchable” on page 7-31 for part number. Note: Set the voltage range switch to the proper power setting for the geographic area you are in. Remove the “Fuser drive assembly” on page 4-33. Remove the “Rear cover”...
  • Page 255 5060-2XX Remove the screw type “121” on page 4-2 (C) from the top of the LVPS and remove the LVPS from the printer. Installation notes • When installing the new power supply, set the voltage range switch to the proper power setting for the geographic area you are in.

  • Page 256: Multipurpose Feeder (Mpf)

    5060-2XX Multipurpose feeder (MPF) Go to “Multipurpose feeder (MPF)” on page 7-19 for part numbers. Open the MPF to the lowest position. Remove the MPF cable cover screw (A). Place flatblade screwdriver in the slot (B) on the MPF cable cover and gently pry open the cover. 4-44 Service Manual...
  • Page 257 5060-2XX Disconnect the MPF switch cable from the MPF sensor (C). Pull the MPF cable free of the enclosure and out from under the cable retainer (D). Remove the MPF strap screw (E) type “412” on page 4-5. 4-45 Repair information...

  • Page 258: Nip Relief Handle

    5060-2XX Release the MPF latch (F) and remove the MPF. Nip relief handle Remove “Left lower cover” on page 4-15 to access the nip relief handle. Remove waste toner container. Reinsert paper tray into printer. Remove the broken pieces of old handle. Pull up the upper piece of handle to raise the nip relief link (A) and rotate upper piece of handle 90°...
  • Page 259 5060-2XX Pull down the lower portion of the broken handle as far as it goes. Rotate the handle to slide off the post. Installation notes Rotate the new nip relief handle into place to connect it to the nip relief link (A). Using a screwdriver, gently pry the nip relief lever (B) toward the rear of the machine and insert lower portion of the handle so that it is between the nip relief lever and the reference edge plate (C).
  • Page 260 5060-2XX Holding the handle in place, use a flathead screwdriver to gently pry up on the top portion of the nip relief lever allowing the handle to snap into place onto the post using moderate force. Once the handle snaps onto the post, press the upper portion of the handle to the right and rotate the handle into its home position.

  • Page 261: Operator Panel

    5060-2XX Operator panel page 7-3 for the part number. Open the front cover assembly. Remove the operator panel bezel. Unlatch the operator panel latches (A). 4-49 Repair information...

  • Page 262: Outer System Board Shield

    5060-2XX Disconnect the operator panel cable from the operator panel and remove the panel. Outer system board shield Remove four screws (A). Remove outer system board shield. 4-50 Service Manual...

  • Page 263: Paper Size Sensing Assembly

    5060-2XX Paper size sensing assembly Remove the“Inner system board shield” on page 4-39. Open the waste toner container door and slide the container out. Remove the four screws (A) on the lower shield and remove the ground wire screw (B). Remove screw (C) from the paper size sensing assembly.
  • Page 264 5060-2XX Gently twist and remove the paper size sensing assembly. As shown, the assembly touches at the spring (D), the fingers (E), the bottom (F), and the right side (G). This also occurs when replacing the assembly. Replacing the paper size sensing assembly: Press on the back of the paper size sensing assembly fingers (A).

  • Page 265: Paper Size Sensing Board

    5060-2XX Gently wiggle the entire assembly and press in and around the corner to the right. Grasp the rectangular piece (B) of the paper size sensing assembly and move up and to the left until the screw hole (C) lines up. Paper size sensing board Warning: Whenever the paper size sensing board is removed, customer settings in the NVRAM may be lost.

  • Page 266: Pick Rolls

    5060-2XX Pick rolls Front roll Wipe any toner or debris from the bottom pan to avoid contaminating the pick rolls. Pull the pick assembly down into the bottom pan and remove the screw. Note: Do not attempt to remove either the shaft or the clutch races. Rear roll Reach around and depress the latch on the side of the shaft and remove the roll.

  • Page 267: Printhead Removal And Adjustments

    5060-2XX Printhead removal and adjustments Identifying the printheads A color version of this sheet is available in the appendix. See“Identifying the printheads” on page A-4. Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost.

  • Page 268: Printhead Mechanical Alignment

    5060-2XX Printhead mechanical alignment Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost. Install two printhead alignment assemblies, one in the front and another in the rear (see Figure 2 and Figure 3), by aligning the locating pin on the printhead alignment bracket (see Figure 1) with the hole in the printer frame.
  • Page 269 5060-2XX Turn the thumbwheel (see Figure 1) until the end of the thumbwheel just touches the printhead mounting beam for both the front and rear alignment assemblies. Remove the old printhead and install a new printhead assembly. Do not tighten the printhead screws yet. Note: Make sure the right rear screw goes through the printhead spacer located at the right rear of the printer frame.
  • Page 270 5060-2XX Print the Printhead Mechanical Alignment Test page to determine the printhead alignment. See Figure 6 for example. Note: To see a printhead mechanical alignment test in color page, see “Printhead mechanical alignment test page” on page B-9. Loosen the printhead screws before making any adjustments to the thumbwheel. Turn each thumbwheel the appropriate number of clicks as indicated by the test page.

  • Page 271: Printhead Electronic Alignment

    5060-2XX Printhead electronic alignment After completing all mechanical adjustments return to Alignment Menu. See “Alignment Menu” on page 3-15 to electronically align the cyan, magenta, or yellow printheads to black. Rear bellcrank (cyan, magenta, yellow) Power off the printer. Remove the four toner cartridges and leave the front door open. Remove “ITU assembly”...
  • Page 272 5060-2XX Rotate the contact end of the bellcrank down (B) and remove. Be careful not to lose the contact spring (C). Installation note Replace the bellcranks by reversing the order of removal. Note: Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu. 4-60 Service Manual...

  • Page 273: Rear Bellcrank (Black)

    5060-2XX Rear bellcrank (black) Power off the printer. Remove the four toner cartridges and leave the front door open. Remove “ITU assembly” on page 4-40. Check each of the rear bellcranks for cracks or breakage. Remove the spring. Remove the stop screw (A) and two washers (B). Be careful not to lose the washers. Recommend using a magnetic tipped screwdriver to remove the screw.
  • Page 274 5060-2XX Rotate the contact end of the bellcrank down (C) and remove. Be careful not to lose the spring (D). Installation note Replace the bellcranks by using reverse order of removal. Note: Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu. 4-62 Service Manual...

  • Page 275: Redrive Assembly

    5060-2XX Redrive assembly Go to “Redrive assembly” on page 7-14 for part number. Remove the “Redrive door” on page 4-16. Remove the “Fuser bottom duct” on page 4-33. Remove the redrive assembly screw (A) type “323” on page 4-3. A(323) Remove the drive belt (B) from the lower redrive pulley.

  • Page 276: Registration Motor

    5060-2XX Registration motor Remove the system board shield. Remove the registration motor mounting screws (B), cut the cable tie (A), and remove the assembly. RIP fan Go to “RIP fan, 80 mm” on page 7-35 for part number. Remove the “Rear cover”...

  • Page 277: S2/Narrow Media/Transparency/Multipurpose Feeder Cable

    5060-2XX S2/narrow media/transparency/multipurpose feeder cable Remove the J21 connector cable to allow space. Note the route it shares with the sensor cable assembly through the frame. Route the new cable connector through the rectangular opening in the upper frame and out through the opening in the lower frame.

  • Page 278: S2/Narrow Media/Transparency/Multipurpose Feeder Sensors

    5060-2XX S2/narrow media/transparency/multipurpose feeder sensors Replace only the necessary sensors. Second transfer roll Go to “Second transfer roll” on page 7-12 for part number. Remove the “ITU assembly” on page 4-40. Lift the transfer roll from the front bearing and remove the transfer roll. 4-66 Service Manual...

  • Page 279: System Board

    5060-2XX System board Remove the “Outer system board shield” on page 4-50. Disconnect all the cables from the system board. Remove the eight screws (A) from the system board. Remove the system board. 4-67 Repair information...

  • Page 280: Transfer Hvps Board

    5060-2XX Transfer HVPS board Remove the “Rear cover” on page 4-9. Remove three transfer HVPS board screws (A). A(232) A(323) 4-68 Service Manual...
  • Page 281 5060-2XX Remove all connectors (B). Remove the transfer HVPS board. 4-69 Repair information...

  • Page 282: Transfer Plate Assembly

    5060-2XX Transfer plate assembly Go to “Transfer plate assembly” on page 7-12 for part number. Remove the “S2/narrow media/transparency/multipurpose feeder cable” on page 4-65. Remove the transfer plate. Lifting and rotating the right edge of the plate up to a 45° angle releases the transfer plate.

  • Page 283: Vacuum Transport Belt (Vtb)

    5060-2XX Vacuum transport belt (VTB) Go to “Vacuum transport belt assembly” on page 7-11 for part number. Remove the “Transfer plate assembly” on page 4-70. Remove the “Fuser bottom duct” on page 4-33. Remove the two front screws (A). Loosen belt (B) on redrive assembly and remove from redrive gear. Remove belt from gear on vacuum belt transfer unit.
  • Page 284 5060-2XX Rotate release lever on gear until the gear can be removed. Remove screw from ground wire. Remove vacuum belt transfer belt unit far enough to release ground wire from restraint clips and remove completly. 4-72 Service Manual...

  • Page 285: Vacuum Transport Belt (Vtb) Fan

    5060-2XX Vacuum transport belt (VTB) fan Go to “VTB fan, 60 mm” on page 7-35 for part number. Disconnect VTB fan from the system board. Remove VTB fan with a flatblade screwdriver. Waste container door Go to “Waste container door” on page 7-5 for part number.

  • Page 286: Waste Container Latch

    5060-2XX Waste container latch Go to “Waste container latch” on page 7-26 for part number. Remove the “Paper size sensing assembly” on page 4-51. Use a flatblade screwdriver to release the waste container latch from the paper size sensing assembly. Web oiler fuser kit installation Enter CE Diagnostic mode.
  • Page 287 5060-2XX Unlatch the two fuser latches (A). Remove the fuser assembly. Open the front cover. Remove the yellow print cartridge. Remove the front right light shield screws (B) and (C) and remove the light shield. B(323) C(324) 4-75 Repair information...
  • Page 288 5060-2XX Carefully remove the paper path access door cover right mounting screw (D). Tape front jam access door (E) if tape is available, to help hold the door in place. 4-76 Service Manual...
  • Page 289 5060-2XX Remove the front right handle cover assembly screws (F) and remove the assembly. F(323) Open paper tray (G). 4-77 Repair information...
  • Page 290 5060-2XX Remove screw (H) from the top front support bracket. Swing bracket to the right. Use the alignment pins (I) on the web oiler fuser motor assembly to position the assembly in holes (J) and install the assembly. 4-78 Service Manual...
  • Page 291 5060-2XX Secure the web oiler motor assembly with screws (K). Install the web oiler card using screws (L). 4-79 Repair information...
  • Page 292 5060-2XX Plug web oiler cable into web oiler card connector (M). Plug web oiler drive assembly cable into cable connector (N). Note: Make sure the cables from the drive assembly are routed along the lower frame and are not in contact with the drive assembly gears.
  • Page 293 5060-2XX Align tabs on the front right light shield with the slots (O) on the frame. Move the front right light shield up until alignment stud (P) and the screw hole (Q) are aligned. 4-81 Repair information...
  • Page 294 5060-2XX Attach the new fuser web oiler fuser housing (R) to the new web oiler fuser. Insert the web oiler fuser assembly into the fuser assembly and install the fuser assembly into the printer. 4-82 Service Manual...

  • Page 295: Connector Locations

    5060-2XX 5. Connector locations Locations Printer boards Connector locations...

  • Page 296: Printer Motors

    5060-2XX Printer motors Web oiler drive motor (optional) Printheads BOR drive motor RIP fan Yellow carriage drive motor Fuser drive motor and card Pick asm motor Fuser fan VTB fan Registration drive motor Magenta carriage ITU drive motor drive motor Cyan carriage Black carriage drive motor...

  • Page 297: Printer Sensors

    5060-2XX Printer sensors Connector locations...

  • Page 298: Cartridge Contact Assembly Pin Locations (Cyan, Magenta And Yellow)

    5060-2XX Cartridge contact assembly pin locations (cyan, magenta and yellow) Service Manual...

  • Page 299: Cartridge Contact Assembly Pin Locations (Black)

    5060-2XX Cartridge contact assembly pin locations (black) Connector locations...

  • Page 300: Connectors

    5060-2XX Connectors System board - non-network Service Manual...

  • Page 301: System Board - Network

    5060-2XX System board - network Connector locations...
  • Page 302 5060-2XX System board “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J1 USB Port Ground USB +5 V dc USB D- USB D+ Ground Ground J2 Top Options Connector Bin Full Printer TXD Ground Ground...
  • Page 303 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J7 Yellow Printhead Mirror Motor FUSE24V Ground Ground +5 V dc (through fuse F12) Y MMSTART Y HSYN-SOS Y MMLOCK Ground Y MMREF J8 Yellow and Cyan Video to C_DATA+...
  • Page 304 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J9 Printhead - Cyan Mirror Motor FUSE24V Ground Ground +5 V dc (through fuse F12) C_MMSTART C_HSYN_SOS C_MMLOCK Ground C_MMREF J10 Cover Open Switch +5 V dc (direct from low voltage power supply) Ground VDO_ERR (+5 V dc to J8 and J12)
  • Page 305 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J12 Printhead - Black/Magenta Video K_DATA+ Ground K_DATA- M_THERMISTOR Ground M_LENA +5 V dc (through fuse F12 and safety switches at J10) Ground K_LPWM...
  • Page 306 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J14 Developer HVPS -CART_METER_K_IN K_AC_BIAS_ENABLE (active low) SC_K_CHIP K_DEV_PWM_OUT -CART_METER_M_IN K_CHARGE_PWM_OUT CMY_CHARGE_PWM_OUT SC_M_CHIP -CART_METER_C_IN CMY_AC_BIAS_ENABLE (active low) SC_C_CHIP M_DEV_PWM_OUT -CART_METER_Y_IN C_DEV_PWM_OUT Y_DEV_PWM_OUT SC_Y_CHIP Ground...
  • Page 307 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J15 Transfer HVPS ITU_TX_ENA_OUT (active low) ITU_TX_CUR_PWM_OUT ITU_SERVO_IN ITU_TX_PWM_OUT CMY_TX_ENA_OUT (active low) K_SERVO_IN K_TX_PWM_OUT C_SERVO_IN C_TX_PWM_OUT M_SERVO_IN Y_TX_PWM_OUT Y_SERVO_IN M_TX_PWM_OUT Ground +24V_SWITCHED J16 Option DRAM Socket J17 Not Used...
  • Page 308 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J21 S2/Narrow Media/Prism/ Ground MPF Sensor +5V dc S2 (switched) NARROW_MEDIA_IN PAPERPATH_S2_IN +5 V dc NM (switched) Ground Ground +5 V dc PRISM (switched) PRISM_SENSOR_IN PRISM_LED_VOLT Ground...
  • Page 309 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J29 Fuser Stepper Motor/ Y_ON_OUT Yellow BLDC Motor FUSER_ON_OUT (Fuser current I0) +5V dc (Through fuse F8) +5V dc (Through fuse F8) Y_DIR_OUT FUSER_DIR_OUT (Fuser phase B) +24V _Y_AND_FUSER (Through fuse F3)
  • Page 310 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J32 VTB Fan FAN2_STALL_IN Ground VTB_FAN_OUT (Fan 2 control) +24V_LEFTSIDE J33 Fuser Interface EXIT_SENSOR_IN FUSER_CAM_1_IN Ground OILER_ENC_A_IN OILER_ENC_B_IN HR_THERM_IN (hot roll thermistor) BR_THERM_IN (backup roll thermistor) Ground +5V_SWITCHED...
  • Page 311 5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J35 Low Voltage Power Supply +3.3 V dc +3.3 V dc +5 V dc +5 V dc +24V dc +24V dc +24V dc +3.3 V dc Sense Ground...

  • Page 312: Autoconnect-Top

    5060-2XX “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal JT25 - Diagnostic port Ground Printer RXD Printer TXD +5V dc (Through fuse F8) Autoconnect—top Connector Pin no Color Signal CN1 Autoconnect—top White +24 V dc Black...

  • Page 313: Autoconnect-Bottom

    5060-2XX Autoconnect—bottom Connector Pin no Signal Signal CN1 Autoconnect—bottom White +24 V dc Black Ground Yellow Printer RXD Black Ground Brown STAGING_ENCODER +5 V dc Black Ground Blue Printer TXD 5-19 Connector locations...

  • Page 314: Transfer High Voltage Power Supply (Hvps)

    5060-2XX Transfer high voltage power supply (HVPS) 5-20 Service Manual...
  • Page 315 5060-2XX Connector Pin no Signal CN1 HVPS Input Connector +24 V dc Switched +24 V dc Return M-Txpwm M-Srvo out Y-Txpwm Y-Srvo out C-Txpwm C-Srvo out K-Txpwm K-Srvo out KCYM-Txenable ITU-Txpwm ITU-Srvo out ITU-Txcurpwm TUI-Txenable T102 Transformer HV Terminal I HV Transformer output to 2nd Transfer Roll Cable (ITU) T201 Transformer HV Terminal K...

  • Page 316: Developer High Voltage Power Supply (Hvps) Board

    5060-2XX Developer high voltage power supply (HVPS) board Connector Pin no Signal CN1 Developer HVPS Input +24 V dc Return +24 V dc Y-Ctsense Y-Devpwm Y-TnrSense C-Devpwm C-CtSense M-Devpwm C-TnrSense CYM-Acenable M-CtSense CYM-Chgpwm M-TnrSense K-Chgpwm K-CtSense K-Devpwm K-TnrSense K-Acenable CN2 Cartridge Signature Button - K-CtSense (red wire) Black K-TnrSense (Gnd Return) (black wire)

  • Page 317: Low Voltage Power Supply (Lvps)

    5060-2XX Connector Pin no Signal CN5 Cartridge Signature Button - Y-CtSense (red wire) Yellow Y-TnrSense (Gnd Return) (black wire) CB Terminal Cleaner Bias Terminal (not used) Low voltage power supply (LVPS) LVPS cable connectors to system board Connector Signal Main power to +3.3 V dc system board +3.3 V dc...

  • Page 318: Lvps Fuser Connectors

    5060-2XX LVPS fuser connectors Connector Pin no. Signal LVPS AC Fuser Connector AC Load #1 AC Common Ground AC Load #2x LVPS DC Fuser Control Connector FusExitSen BURCam1 WebEncoderA WebEncoderB HRThermistor BURThermistor Return - Analog Ground +5 V dc switched 5-24 Service Manual...

  • Page 319: Paper Size Sensing Board

    5060-2XX Paper size sensing board Connector Signal +3.3V dc EPROM Data Ground EPROM Clock J3-1 (Waste BTL Full) Ground Waste BTL PRESENT (SW4) Tray Size 1 (SW3) Ground Tray Size 2 (SW2) Tray Size 3 (SW1) J2-1 (Waste BTL Full) Ground 5-25 Connector locations...

  • Page 320: High-Capacity Input Tray (Hcit)

    5060-2XX High-capacity input tray (HCIT) HCIT 2000-sheet board Connector Signal CN1 I/F Send PRI RXD PGND PERON SGND PRI TXD CN2 LVPS Poweron +5 V dc SGND PGND PGND PGND +24 V dc +24 V dc +24 V dc CN3 REG Motor +24 V dc +24 V dc REG A...
  • Page 321 5060-2XX Connector Signal CN6 Sensors +5 V dc Side Door/Level/ Empty/ Registration SIDE Home/Pick Home +5 V dc LEVEL +5 V dc EMPTY +5 V dc RHOME +5 V dc PHOME CN7 Size +5 V dc Sensors/Near Empty SIZE 0 +5 V dc SIZE 1 +5 V dc...

  • Page 322: High-Capacity Output Finisher (Hcof)

    5060-2XX High-capacity output finisher (HCOF) HCOF system board For a more detailed diagram, see “Finisher cables” on page 7-68. 5-28 Service Manual...
  • Page 323 5060-2XX “HCOF system board” on page 5-28. Connector Pin no Signal CN1 Drop Solenoid SOL+ SOL- CN2 Stapler Assembly MTR- MTR- MTR+ MTR+ No Cartridge Low Staple Home Position Unit Check Ground +5 V dc CN3 Jogger Motor/ Jog A Accumulator Drive Motor Jog *A Jog B...
  • Page 324 5060-2XX “HCOF system board” on page 5-28. Connector Pin no Signal CN6 Tray Sensors Tray Limit/ Tray Limit SW Near Full/Output Tray Offset Sensor Ground +5 V dc Tray Near Full Sensor Ground +5 V dc Tray Offset Posit Sensor Ground CN7 Output Tray Offset Motor MTR +...
  • Page 325 5060-2XX “HCOF system board” on page 5-28. Connector Pin no Signal CN14 Low Voltage Power Supply +24 V dc +24 V dc P-Ground P-Ground CN15 Enter Motor CN16 Punch Motor Homing Sensor/ +5 V dc Drop Timing Sensor/ Drop Timing Sensor Inverter Timing Sensor/ Punch timing Sensor Ground...

  • Page 326: Hcof Lvps Board

    5060-2XX HCOF LVPS board Connector Pin No Signal CN2 LVPS Out +24 V dc +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground AC In from Relay Not used Not used Not used AC In from Relay HCOF sub LVPS relay board Connector Signal...

  • Page 327: 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 328: Lubrication For Replacement Motors

    5060-2XX Lubrication for replacement motors The motor drive FRUs contain the proper lubricant in the FRU. Only use the lubricant included. Fuser drive assembly Before installing the new fuser drive assembly: Apply a thin coating of Nyogel type 774 grease to the points identified (A) from the supplied packet. Rotate the motor housing (B) to distribute evenly.

  • Page 329: Cartridge Drive Assembly

    5060-2XX Cartridge drive assembly Apply a thin coating of Nyogel type 744 grease to the points identified (A) from the supplied packet. Rotate the motor housing (B) to distribute evenly. ITU drive assembly Apply a thin coating of Nyogel type 744 grease to the points identified (A) from the supplied packet. Note: Do not lubricate Gear 58 (C).

  • Page 330: Scheduled Maintenance

    5060-2XX Scheduled maintenance The operator panel displays 80 Fuser Maintenance and 83 ITU Maintenance for scheduled maintenance. 80 Fuser Maintenance is displayed at each 200,000 copies when the fuser assembly needs to be replaced to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers: Standard fusers •...

  • Page 331: Parts Catalog

    NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. • PP: (Parts Packet) in the Description column indicates the part is contained in a parts packet. The Lexmark C752 (5060-2XX) laser printer is available in four models: Lexmark C752 5060-221 Non-network...

  • Page 332: Assembly 1: Covers

    5060-2XX Assembly 1: Covers Service Manual...
  • Page 333 5060-2XX Assembly 1: Covers Asm- Part Units Description index number 1–1 56P2189 Top cover assembly 12G6507 250 output flag and retainer 56P1539 Cable, options - stacker, including output bin sensor 12G6409 Redrive cap cover assembly 12G6380 Machine pad 12G6389 Top front support bracket 12G6396 Right rear cover Screw, PP 12G6530...
  • Page 334 5060-2XX Assembly 1.1: Covers Service Manual...
  • Page 335 5060-2XX Assembly 1.1: Covers Asm- Part Units Description index number 1.1–1 12G6408 Left upper cover assembly Screw, PP 12G6309 12G6392 Left upper pivot cover 12G6491 Jam access spring 12G6485 Lower access jam door assembly 12G6398 Left lower pivot cover 12G6395 Cover, left lower 12G6400 Waste container door...

  • Page 336: Assembly 2: Cartridge Mounting

    5060-2XX Assembly 2: Cartridge mounting Asm- Part Units Description index number 2–1 12G6535 Guide assembly, left side 12G6536 Guide assembly, right side Screw, PP 12G6532 Service Manual...

  • Page 337: Assembly 3: Fuser Assembly

    5060-2XX Assembly 3: Fuser assembly Asm- Part Units Description index number 3–1 12G6302 Fuser assembly, 220V 500W 12G6301 Fuser assembly, 115V 500W 12G6495 Fuser assembly, 100V 500W (Japan) Parts catalog...
  • Page 338 5060-2XX Assembly 3.1: Fuser (web oiler) Service Manual...
  • Page 339 5060-2XX Assembly 3.1: Fuser (web oiler) Asm- Part Units Description index number 3.1–1 12G6545 Web oiler assembly 12G6515 Fuser assembly, web oiler 220V 500W 12G6514 Fuser assembly, web oiler 115V 500W 12G6502 Fuser assembly, web oiler 100V 500W (Japan) 56P1558 Web oiler driver board assembly 12G6543 Web oiler index drive assembly...

  • Page 340: Assembly 4: Fuser Drive

    5060-2XX Assembly 4: Fuser drive Asm- Part Units Description index number 4–1 Screws PP 12G6309 56P1553 Fuser drive assembly 56P1563 Card assembly - fuser drive Screws, card assembly mounting - PP 12G6531 7-10 Service Manual...

  • Page 341: Assembly 5: Vacuum Transport Belt (Vtb) Assembly

    5060-2XX Assembly 5: Vacuum transport belt (VTB) assembly Asm- Part Units Description index number 5–1 12G6491 Jam access spring 12G6489 Vacuum transport belt assembly 7-11 Parts catalog...

  • Page 342: Assembly 6: Transfer

    5060-2XX Assembly 6: Transfer Asm- Part Units Description index number 6–1 12G6303 Second transfer roll 12G6488 Transfer plate assembly 7-12 Service Manual...

  • Page 343: Assembly 7: Printheads

    5060-2XX Assembly 7: Printheads Asm- Part Units Description index number 7–1 56P1505 Printhead assembly (do not replace more than one printhead at a time) Screw, PP 12G6534 56P2292 Printhead spacer 56P1198 Thermistor card Screw, PP 12G6533 56P2296 Card assembly, printhead diagnostic aid 7-13 Parts catalog...

  • Page 344: Assembly 8: Paper Feed Output (Redrive)

    5060-2XX Assembly 8: Paper feed output (redrive) Asm- Part Units Description index number 8–1 56P0167 Anchor, bracket mounting 12G6493 Upper door hinge Screw, PP 12G6533 56P2204 Redrive belt 300 T 12G6492 Redrive assembly 12G6355 Redrive door assembly 56P1532 Lower right door latch 56P1533 Lower left door latch Screw, PP 12G6530...

  • Page 345: Assembly 9: Paper Feed Input

    5060-2XX Assembly 9: Paper feed input Asm- Part Units Description index number 9–1 56P2101 Sensor, S2/NMS 56P2175 Sensor, transparency reflective (XPAR) 56P2174 Cable, S2/XPAR/NMS/MPF (without sensors) 56P1524 Paper out sensor MPF 56P2100 Cable assembly, S2/XPAR/NMS/MPF (with sensors) 7-15 Parts catalog...

  • Page 346: Assembly 10: Paper Size Sensing

    5060-2XX Assembly 10: Paper size sensing Asm- Part Units Description index number 10–1 56P1564 System board shield support with clips 12G6468 Paper size sensing bracket 12G6467 Paper size sensing spring Screw, paper size sensing assembly mounting PP 12G6531 Screw, paper size sensing card mounting PP 12G6531 56P1554 Media size sensing card assembly, 221/222 only 56P2504...

  • Page 347: Assembly 11: Paper Feed Transport

    5060-2XX Assembly 11: Paper feed transport Asm- Part Units Description index number 11–1 56P2194 Nip relief handle 56P2293 Kit, staging drive assembly, including - Staging motor assembly - Gear, reference plate - Gear, staging idler - Gear, staging reduction - Motor screws Staging motor assembly screw PP 12G6309 7-17 Parts catalog...

  • Page 348: Assembly 12: Multipurpose Feeder (Mpf)

    5060-2XX Assembly 12: Multipurpose feeder (MPF) 7-18 Service Manual...
  • Page 349 5060-2XX Assembly 12: Multipurpose feeder (MPF) Asm- Part Units Description index number 12–1 12G6452 MP feeder door cover 12G6460 Door hinge restraint Screw, PP 12G6533 12G6453 Frame bias latch 12G6455 Frame bias latch cover Screw, PP 12G6533 12G6454 Frame bias spring 12G6457 MPF support bracket cover 56P1525...

  • Page 350: Assembly 13: 500-Sheet Integrated Tray

    5060-2XX Assembly 13: 500-Sheet integrated tray Asm- Part Units Description index number 13–1 12G6416 500-Sheet tray assembly 12G6419 Back restraint latch 12G6418 Back restraint 12G6425 Tray bias bellcrank assembly Screw, PP 12G6533 12G6426 Tray bias spring 12G6568 Reflector label 12G6421 Wear strip 12G6420 Tray wear clip...

  • Page 351: Assembly 14: Autocompensator Assembly

    5060-2XX Assembly 14: Autocompensator assembly Asm- Part Units Description index number 14–1 12G6471 Tray interlock bellcrank 12G6558 Pick arm lift bellcrank 56P1526 Pick assembly 500-tray 12G6557 Bellcrank lift spring 12G6476 Paper level sensing assembly 12G6472 Tray interlock bracket 12G6461 Sensor, paper out/low Screw, pick roll mounting PP 12G6533 99A0070 Pick rolls (2 per pack)

  • Page 352: Assembly 15: Itu Assembly

    5060-2XX Assembly 15: ITU assembly Asm- Part Units Description index number 15-1 56P1513 ITU light shield assembly 56P1540 Printhead interlock cable assembly 56P1537 ITU assembly 7-22 Service Manual...

  • Page 353: Assembly 16: Itu Drive Assembly

    5060-2XX Assembly 16: ITU drive assembly Asm- Part Units Description index number 16–1 56P1560 ITU drive motor assembly 12G6385 #58 gear 56P0568 ITU motor drive Screw PP 12G6309 (ITU drive motor to ITU drive assembly) Screw, PP 12G6309 (ITU drive assembly lower frame) 7-23 Parts catalog...

  • Page 354: Assembly 17: Itu Loading

    5060-2XX Assembly 17: ITU loading 7-24 Service Manual...
  • Page 355 5060-2XX Assembly 17: ITU loading Asm- Part Units Description index number 17–1 56P1568 Yellow terminal contact assembly 12G6442 Terminal, contact spring Screw PP 12G6533 12G6353 Cartridge support roller 56P1495 Parts packet, ITU loading - yellow, including - Yellow BOR spring - Rear block guide - Rear transfer bellcrank - Front V block guide...

  • Page 356: Assembly 18: Waste Toner

    5060-2XX Assembly 18: Waste toner Asm- Part Units Description index number 18–1 12G6494 Waste toner container 12G6470 Waste container latch spring 12G6469 Waste container latch 7-26 Service Manual...

  • Page 357: Assembly 19: Bor Drive Assembly

    5060-2XX Assembly 19: BOR drive assembly Asm- Part Units Description index number 19–1 56P1536 BOR housing assembly with motor 7-27 Parts catalog...

  • Page 358: Assembly 20: Cartridge Contact Assembly

    5060-2XX Assembly 20: Cartridge contact assembly Asm- Part Units Description index number 20–1 56P0310 Cartridge contact assembly, complete cyan/magenta/yellow 12G6376 Rear hold down spring 12G6377 Rear hold down bellcrank 56P1561 Cartridge contact assembly, complete black 7-28 Service Manual...

  • Page 359: Assembly 21: Cartridge Drive Assembly

    5060-2XX Assembly 21: Cartridge drive assembly Asm- Part Units Description index number 21–1 56P1214 Cartridge drive assembly, cyan/magenta/black (one drive assembly per package) Screw, PP 12G6530 56P1215 Cartridge drive assembly, yellow 7-29 Parts catalog...

  • Page 360: Assembly 22: Electronics

    5060-2XX Assembly 22: Electronics 7-30 Service Manual...
  • Page 361 5060-2XX Assembly 22: Electronics Asm- Part Units Description index number 22–1 11A9095 Power cord set (LV)—U.S., Asia Pacific (English), Canada, Colombia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Taiwan, Venezuela, Virgin Islands 1339553 Power cord set (LV)—Japan 43H5544...
  • Page 362 5060-2XX Assembly 22.1: Electronics 7-32 Service Manual...
  • Page 363 5060-2XX Assembly 22.1: Electronics Asm- Part Units Description index number 22.1–1 56P1517 System board outer shield 56P1547 Cable clip 56P1518 System board shield assembly with clips 56P1545 Cable, ground 56P1564 System board shield support with clips Screw, PP 12G6531 56P2503 System board, network, 222/234 only 56P2502 System board, non-network, 221 only...
  • Page 364 5060-2XX Assembly 22.2: Electronics Asm- Part Units Description index number 22.2–1 12G6327 Transfer HVPS board Screw, PP 12G6309 (TFR HVPS board to frame) Screw, PP 12G6530 (TFR HVPS board to frame) 12G6541 Standoff, high voltage power supply - developer board Screw, PP 12G6540 56P2469 Developer HVPS board...
  • Page 365 5060-2XX Assembly 22.3: Electronics Asm- Part Units Description index number 22.3–1 56P1551 VTB fan, 60 mm 12G6490 VTB fan gap cover 56P1509 Fuser fan 12G6529 Screws, fuser fan mounting 56P1538 RIP fan, 80 mm 56P1500 RIP fan duct Screws, PP 12G6530 7-35 Parts catalog...

  • Page 366: Assembly 23: Electronics-Cabling Interconnections 1

    5060-2XX Assembly 23: Electronics—cabling interconnections 1 7-36 Service Manual...
  • Page 367 5060-2XX Assembly 23: Electronics—cabling interconnections 1 Asm- Part Units Description index number 23–1 56P1539 Cable, options - stacker with output bin sensor 56P1538 RIP fan assembly with cable 56P1536 Motor assembly, Lift/BOR 56P1550 Cable, oiler motor driver 12G6321 Cable, operator panel 56P1505 Yellow mirror motor (attached to yellow printhead) 56P1549...

  • Page 368: Assembly 24: Electronics-Cabling Interconnections 2

    5060-2XX Assembly 24: Electronics—cabling interconnections 2 7-38 Service Manual...
  • Page 369 5060-2XX Assembly 24: Electronics—cabling interconnections 2 Asm- Part Units Description index number 24–1 56P1565 Cable assembly, black terminal contact 56P1567 Cable assembly, cyan terminal contact 56P1568 Cable assembly, yellow terminal contact 56P1566 Cable assembly, magenta terminal contact 56P0174 Cable assembly, second transfer voltage 56P1502 Cable, HVPS control - transfer 7-39...

  • Page 370: Assembly 25: Electronics-Cabling Interconnections 3

    5060-2XX Assembly 25: Electronics—cabling interconnections 3 Asm- Part Units Description index number 25–1 56P1502 Cable assembly, HVPS control - developer 56P0310 Cartridge contact assembly, complete, cyan/magenta/yellow 56P1561 Cartridge contact assembly, complete, black 7-40 Service Manual...

  • Page 371: Assembly 26: Electronics-Cabling Interconnections 4

    5060-2XX Assembly 26: Electronics—cabling interconnections 4 Asm- Part Units Description index number 26–1 56P1503 Cable assembly, options bottom/paper size sensing 56P1560 ITU drive assembly with motor and waste toner full switch 7-41 Parts catalog...

  • Page 372: Assembly 27: Output Expander

    5060-2XX Assembly 27: Output expander 7-42 Service Manual...
  • Page 373 5060-2XX Assembly 27: Output expander Asm- Part Units Description index number 27–1 99A0107 Deflector, upper redrive, also order 99A0104 99A0104 Spring, upper diverter 99A0369 Shaft assembly, exit, also order PP 99A0572 99A0052 Shaft assembly, lower exit, also order PP 99A0572 56P0407 Shield, output option card 99A0915...
  • Page 374 5060-2XX Assembly 27.1: Output expander 7-44 Service Manual...
  • Page 375 5060-2XX Assembly 27.1: Output expander Asm- Part Units Description index number 27.1–1 56P0405 Door assembly, right jam access 99A0368 Shaft assembly, lower, also order PP 99A0572 99A0363 Pulley, drive 56P0410 Bracket, attach Screw, PP 56P0169 56P0400 Cover, front 99A0361 Belt, 160 gear 99A0362 Arm assembly, belt idler 99A0364...

  • Page 376: Assembly 28: 5-Bin Mailbox

    5060-2XX Assembly 28: 5-Bin mailbox 7-46 Service Manual...
  • Page 377 5060-2XX Assembly 28: 5-Bin mailbox Asm- Part Units Description index number 28–1 12G6409 Cover, redrive cap 99A1710 Cover, wire 56P0416 Cover, top bin 56P0423 Latch, rear access door 99A0104 Spring, upper diverter 56P0414 Door, front 56P0422 Latch, access door front 56P0415 Cover, right 99A1723...
  • Page 378 5060-2XX Assembly 28.1: 5-Bin mailbox 7-48 Service Manual...
  • Page 379 5060-2XX Assembly 28.1: 5-Bin mailbox Asm- Part Units Description index number 28.1–1 99A1741 Spring, diverter 99A1727 Frame asm, right side Screw, board mounting PP 12G6309 99A1728 Cam, diverter actuator 99A1731 Spring, diverter actuator 99A1729 Latch, diverter actuator 99A1730 Arbor, diverter actuator 99A1789 C-clip 56P0418...

  • Page 380: Assembly 29: 500-Sheet Tray Option

    5060-2XX Assembly 29: 500-Sheet tray option 7-50 Service Manual...
  • Page 381 5060-2XX Assembly 29: 500-Sheet tray option Asm- Part Units Description index number 29–1 56P0168 Drive assembly, 500 option 2 Screw, PP 12G6309 12G6550 500-Sheet option tray pick assembly 12G6565 Paper level sensing assembly 12G6471 Tray interlock bellcrank 12G6556 Cover, frame 12G6553 Pass thru sensor 12G6562...
  • Page 382 5060-2XX Assembly 29.1: 500-Sheet tray option 7-52 Service Manual...
  • Page 383 5060-2XX Assembly 29.1: 500-Sheet tray option Asm- Part Units Description index number 29.1–1 12G6416 500-Sheet tray assembly 12G6419 Back restraint latch 12G6418 Back restraint 12G6425 Tray bias bellcrank assembly Screw, PP 12G6533 12G6426 Tray bias spring 12G6568 Reflector label 12G6421 Wear strip 12G6420 Tray wear clip...

  • Page 384: Assembly 30: Duplex Option

    5060-2XX Assembly 30: Duplex option 7-54 Service Manual...
  • Page 385 5060-2XX Assembly 30: Duplex option Asm- Part Units Description index number 30–1 56P0480 Back cover 99A2540 Redrive bearing 56P0447 Duplex entry shaft assembly Screw PP 12G6533 56P0434 Right side front tray guide 56P0483 Deflector actuator assembly 56P2038 Deflector follower assembly 56P0432 Duplex front jam tray assembly 56P0457...
  • Page 386 5060-2XX Assembly 30.1: Duplex option 7-56 Service Manual...
  • Page 387 5060-2XX Assembly 30.1: Duplex option Asm- Part Units Description index number 30.1–1 56P0456 Duplex support plate 56P0462 Autoconnect cable assembly 56P0463 DC forward/reverse motor assembly 56P0464 DC duplex feed motor Screw PP 12G6309 12G6510 Cable tie (6 in pack) 56P0459 Back support 56P0430 Duplex card assembly...
  • Page 388 5060-2XX Assembly 31: High-capacity input tray (HCIT) 7-58 Service Manual...
  • Page 389 5060-2XX Assembly 31: HCIT Asm- Part Units Description index number 31–1 56P0561 Paper size sensor box assembly 56P0519 Flag, paper size R 56P0520 Flag, paper size F 56P0518 Flag, paper size C 56P0522 Spring, paper size flag 56P0516 Sensor, photo interrupter 56P0511 Paper size sensors cable 56P0494...

  • Page 390: Assembly 31: High-Capacity Input Tray (Hcit)

    5060-2XX Assembly 31.1: High-capacity input tray (HCIT) 7-60 Service Manual...
  • Page 391 5060-2XX Assembly 31.1: HCIT Asm- Part Units Description index number 31.1–1 56P0505 Rear cover 56P0503 Right side cover 56P0491 Caster, movable Screws PP 12G6533 56P0493 F adjuster 56P0500 Front cover 56P0501 Cover, main CA 56P0492 Caster, fixed 56P0504 Left side cover 56P0508 Upper left side jam cover 56P0507...

  • Page 392: Assembly 32: Finisher

    5060-2XX Assembly 32: Finisher 7-62 Service Manual...
  • Page 393 5060-2XX Assembly 32: Finisher Asm- Part Units Description Index number 32–1 56P0321 Top cover (tall finisher) 56P1287 Scanner plate (short finisher) 56P0569 Rear cover (tall finisher) 56P1285 Rear cover (short finisher) 56P0573 Upper right side cover (tall finisher) 56P1286 Upper right side cover (short finisher) 56P0574 Lower tray cover 56P0576...
  • Page 394 5060-2XX Assembly 32.1: Finisher 7-64 Service Manual...
  • Page 395 5060-2XX Assembly 32.1: Finisher Asm- Part Units Description index number 32.1–1 56P0324 Motor assembly elevator tray 56P0357 Actuation assembly 56P1471 HCOF control board assembly 56P0325 Motor assembly paper feed 56P0332 Accumulator paper feed belt (40S3M900) 56P2294 Accumulator drive belt (B30S2M334) 56P0315 Punch assembly 56P0345...
  • Page 396 5060-2XX Assembly 32.2: Finisher 7-66 Service Manual...
  • Page 397 5060-2XX Assembly 32.2: Finisher Asm- Part Units Description index number 32.2–1 56P0355 Guide vertical paper 56P0385 Solenoid drop assembly 56P0347 Jogger fence homing sensor (EE-SX1235A-P2) 56P0384 Accumulator belt (hook) 56P2294 Accumulator drive belt (B30S2M334) 56P0319 Accumulator w/o stapler 56P0348 Drop timing sensor (OS-535223-602) 56P0349 Accumulator homing sensor (OS-311D-A5) 56P0316...
  • Page 398 5060-2XX Assembly 33: Finisher cables Service Manual...

  • Page 399: Assembly 33: Finisher Cables

    5060-2XX Assembly 33: Finisher cables Asm- Part Units Description index number 33–1 56P0340 Communications cable 56P0341 Power cord 56P0359 Harness cable assembly H2 - system board to drop solenoid 56P0360 Harness cable assembly H3 - system board to harness cable assembly H4/drop timing sensor/punch motor homing sensor/inverter timing sensor 56P0361 Harness cable assembly H4 - harness cable H3 to punch timing sensor...

  • Page 400: Assembly 34: Envelope Option

    5060-2XX Assembly 34: Envelope option 7-70 Service Manual...
  • Page 401 5060-2XX Assembly 34: Envelope option Asm- Part Units Description index number 34–1 56P1569 Envelope option (complete) 56P2237 Envelope tray assembly 7-71 Parts catalog...

  • Page 402: Assembly 35: Options

    5060-2XX Assembly 35: Options 7-72 Service Manual...
  • Page 403 Card assembly, ImageQuick™ 56P2298 Card assembly, PRESCRIBE 56P1433 MarkNet X2031e Ethernet 10/100BaseTX - 3 Port External Server 56P1434 MarkNet X2030t Token-Ring External Server 56P1742 MarkNet N2101e Ethernet 10/100BaseTX Internal Server 56P9932 Lexmark Forms hard disk, 5GB or larger w/adapter 7-73 Parts catalog...

  • Page 404: Assembly 36: Miscellaneous

    5060-2XX Assembly 36: Miscellaneous Asm- Part Units Description index number Screw type 323, PP 12G6309 Screw type 324, PP 12G6530 Screw type 232, PP 12G6531 Screw type 102, PP 12G6532 Screw type 312/322/412/423, PP 12G6533 Screw type 484, PP 12G6534 Screw, 500-sheet tray, PP 12G6538 Screw type 124, PP 12G6539 Screw type 121, PP 12G6540...

  • Page 405: Appendix A-Service Tips

    5060-2XX Appendix A—Service tips Printhead diagnostics If you get a printhead error, follow this diagnostic to find the specific failure. Verify all the printhead cables are properly seated. If the printhead cables are properly seated and the error remains, record the error code. Continue to the next step.
  • Page 406 5060-2XX Install the printhead diagnostic tool and determine the problem. The following procedure shows the yellow and cyan switch as an example. Turn off the printer. Unplug the printhead cables from the system board and connect them to the printhead diagnostic tool.
  • Page 407 5060-2XX Turn on the printer and note the new error codes. • If an automatic calibration begins, 36 Printer Service Required may appear. The printhead and system board are working correctly and the printhead cable connections should be checked. Press Go to clear the error. •...

  • Page 408: Identifying The Printheads

    5060-2XX Identifying the printheads Black (K) Magenta (M) Cyan (C) Yellow (Y) Front Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost. Notes: •...

  • Page 409: Redrive Belt Routing

    5060-2XX Redrive belt routing If the redrive belt has been removed, use the diagram and information to properly route the belt. The idler gear roller in these photos is only visible because the printer has been disassembled to the frame. The gear will have to be located by feel to ensure proper installation.

  • Page 410: Finisher Alignment

    5060-2XX Finisher alignment This tip provides detailed instructions for aligning the finisher to the printer. The sides of the finisher must be parallel with the printer and at the same height, or you may have paper feeding problems. There are four locations where adjustments can be made to correctly align the finisher with the printer. There are two adjustment casters on the left (the side closest to the printer) and two on the right, underneath the platform cover.
  • Page 411 5060-2XX • Tall finisher – Printer – Optional duplex unit – One additional 500-sheet drawer – Optional 2000-sheet drawer – Finisher Appendix A—Service tips...
  • Page 412 5060-2XX Step 1: Secure the printer Completely stabilize the printer before the finisher alignment process is started. How this is done depends on whether you have a short or tall finisher. Short finisher Attach caster brakes (A) to the two back legs of the printer caster base. Screw the caster brakes onto the legs of the caster base.
  • Page 413 5060-2XX Step 2: Align the pin Adjust the two casters on the left side (closest to the printer) to raise or lower the finisher as needed, so the pin (D) on the printer properly aligns with the hole in the finisher (the pin should freely slide into the hole). Short finisher Insert the Allen wrench (E) into either caster bolt (F).
  • Page 414 5060-2XX Tall finisher Loosen or tighten the wingnuts (G) to adjust the height of the finisher (clockwise raises the finisher). Step 3: Align the bumper pads Adjust the two casters on the right side (under the platform cover) to raise or lower the finisher as needed so the two bumper pads on the finisher lightly touch the printer.
  • Page 415 5060-2XX Short and tall finisher Lift the platform cover. Insert the Allen wrench (D) into either caster bolt (J). Rotate the wrench in the appropriate direction to adjust the height of the finisher (clockwise raises the finisher). Repeat with the other caster bolt. Step 4: Adjust the tilt If necessary, adjust the tilt of the finisher so that the front is flush with the front of the printer.
  • Page 416 5060-2XX Step 5: Connect the finisher and printer Push the finisher against the printer, making sure the gap in the front is the same as the gap in the back. When adjoining the finisher and the printer, make sure that the finisher cable is out of the way of the paper path. If the cable folds itself between the finisher and the printer, disconnect the cable, twist it one time, and then reconnect it.

  • Page 417: Duplex Option Deflector Button Replacement

    5060-2XX Duplex option deflector button replacement 230 Paper Jam - duplex deflector fails During a duplex job, the duplex option fails to actuate the deflector in the fuser and the paper is diverted away from the duplex. The duplex option does not receive the sheet and prompts a 230 Paper Jam message. Replace the rubber deflector button with the enclosed compression spring deflector button.
  • Page 418 5060-2XX Place the new button into the cam. Verify the new button moves freely by pressing the button firmly down and watching it snap back. Note: Leave the button in the up position. A-14 Service Manual...

  • Page 419: Appendix B-Print Quality Samples

    5060-2XX Appendix B—Print quality 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 420: Print Menus-Page Two Of Two

    5060-2XX Print Menus—Page two of two Service Manual...

  • Page 421: Print Tests

    5060-2XX Print tests Print Quality Pages—Title page (total of five) Appendix B—Print quality samples...

  • Page 422: Print Quality Pages-Page 1 (Total Of Five

    5060-2XX Print Quality Pages—Page 1 (total of five) Service Manual...

  • Page 423: Print Quality Pages-Page 2 (Total Of Five

    5060-2XX Print Quality Pages—Page 2 (total of five) Appendix B—Print quality samples...

  • Page 424: Print Quality Pages-Page 3 (Total Of Five

    5060-2XX Print Quality Pages—Page 3 (total of five) Service Manual...

  • Page 425: Print Quality Pages-Page 4 (Total Of Five

    5060-2XX Print Quality Pages—Page 4 (total of five) Appendix B—Print quality samples...

  • Page 426: Registration

    5060-2XX Registration Quick Test Service Manual...

  • Page 427: Miscellaneous Test Pages

    5060-2XX Miscellaneous test pages Printhead mechanical alignment test page Appendix B—Print quality samples...

  • Page 428: Printhead Electronic Alignment Test Page-Magenta (One Of Two

    5060-2XX Printhead electronic alignment test page—Magenta (one of two) B-10 Service Manual...

  • Page 429: Printhead Electronic Alignment Test Page-Cyan (Two Of Two

    5060-2XX Printhead electronic alignment test page—Cyan (two of two) Warning: B-11 Appendix B—Print quality samples...
  • Page 430 5060-2XX B-12 Service Manual...

  • Page 431: Index

    5060-2XX Index Numerics BOR drive assembly 7-27 parts catalog 2-40 1565 Emul Error Load 4-27 removal 1xx service errors BOR drive motor, location 2-13 error code table – 3-20 Button Test 2-41 2-65 error-specific service checks – 2000-sheet input tray option diagnostics cabling 7-58...
  • Page 432 5060-2XX 5-28 3-20 HCOF system board LCD Test 5-20 3-22 HVPS Parallel Wrap Test 5-20 3-22 HVPS board ROM Test 5-23 3-23 LVPS Serial Wrap Test 5-25 paper size sensing board Input Tray Tests 3-25 system board Feed Test 3-25 Sensor Test Misc Tests 3-35...
  • Page 433 5060-2XX 7-58 7-60 9xx service errors parts catalog 2-18 2-118 sub error code tables,9xx and 2xx service checks 2-27 3-36 user attendance errors standalone test mode 3-11 3-29 Error Log, configuration menu Hole Punch Test 3-31 Error Log, diagnostics mode HVPS, see developer HVPS or transfer HVPS 3-31 clearing the error log...
  • Page 434 5060-2XX 7-74 miscellaneous 7-18 7-19 multipurpose feeder (MPF) 4-65 narrow media sensor (NMS) cable, removal 7-72 options 4-66 narrow media sensor (NMS), removal 7-42 7-44 output expander nip relief handle 7-15 paper feed input 7-17 parts catalog 7-14 paper feed output (redrive) 4-46 removal 7-17...
  • Page 435 5060-2XX 4-64 registration motor 4-64 RIP fan 3-30 Quick Disk Test S2/narrow media/transparency/mutipurpose feeder 4-65 cables S2/narrow media/transparency/mutipurpose feeder rear bellcrank 4-66 sensors 4-59 4-61 removal 4-66 second transfer roll redrive assembly 4-67 system board belt routing 4-68 transfer HVPS board 7-14 parts catalog 4-70...
  • Page 436 5060-2XX 2-84 fans print quality - missing colors 2-114 finisher print quality - multiple horizontal lines 2-121 fuser drive assembly noise check print quality - poor color registration 2-118 HCIT print quality - toner on the back of the page 2-118 HCIT 2000-sheet option print quality - toner smears or rubs off the page...

  • Page 437: Part Number Index

    5060-2XX Part number index Description Page 11A9095 Power cord set (LV)—U.S., Asia Pacific (English), Canada, Colombia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Japan, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Taiwan, Venezuela, Virgin Islands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 12G6301 Fuser assembly, 115V 500W - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12G6302 Fuser assembly, 220V 500W - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 438 5060-2XX 12G6412 Front left handle cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12G6416 500-Sheet tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-20 7-53...
  • Page 439 5060-2XX 12G6530 Parts packet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12G6530 Screw (long), parts packet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57 12G6530 Screw, parts packet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 440 5060-2XX 56P0317 Staple cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 56P0318 Box, chad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-65...
  • Page 441 5060-2XX 56P0380 Harness cable assembly D2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-69 56P0381 Harness cable assembly D3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-69...
  • Page 442 5060-2XX 56P0472 Pass thru shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55 56P0473 Brake pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55...
  • Page 443 56P1427 Lexmark Forms 32MB Flash DIMM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 444 5060-2XX 56P1505 Cyan mirror motor (attached to cyan printhead) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 56P1505 Magenta mirror motor (attached to magenta printhead - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37...
  • Page 445 56P9932 Lexmark Forms hard drive, 5GB or larger w/adapter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 446 5060-2XX 7371549 Kit, relocation package assembly printer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-74 99A0052 Shaft assembly, lower exit, also order PP 99A0572 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43...
  • Page 447 5060-2XX 99A1741 Spring, diverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49 99A1742 Sensor, 5-bin mailbox pass thru - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47...
  • Page 448 5060-2XX I-18 Service Manual...

  • Page 452: Nip Shock

    2.02 Transfer to Fuser 319.4 12.57 Fuser Nip to First Redrive 50.0 1.97 Fuser Nip to Exit Sensor 58.2 2.29 Fuser Nip to Exit Tray Nip 420.3 16.55 M to 2 Xfer Lexmark International, Inc. Revision 2.1 December 17, 2003...

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