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Lexmark T632 Service Manual

T63 series & 4060-series
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Revised: July 27, 2005
Lexmark™ T63x
(including Lexmark T630, Lexmark T632, Lexmark T634)
4060-xxx
(including 4060-000, 4060-010, 4060-200,
4060-210, 4060-400, 4060-410)
• 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 T632

  • Page 1 Revised: July 27, 2005 Lexmark™ T63x (including Lexmark T630, Lexmark T632, Lexmark T634) 4060-xxx (including 4060-000, 4060-010, 4060-200, 4060-210, 4060-400, 4060-410) • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered...
  • Page 2 Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 3: Table Of Contents

    4060-xxx Table of contents Laser notices ............ix Safety information .
  • Page 4 4060-xxx Power-On Self Test (POST) ........... . 2-34 Symptom tables .
  • Page 5 4060-xxx Diagnostic aids ..............Diagnostics mode .
  • Page 6 4060-xxx Maintenance page count ..........3-17 Setting configuration ID .
  • Page 7 4060-xxx Fuser cover removal ........... . . 4-25 Fuser exit sensor or fuser narrow media sensor removal .
  • Page 8 4060-xxx System board—non-network ..........5-10 System board—network .
  • Page 9: Laser Notices

    4060-xxx Laser notices 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 10 4060-xxx Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1.
  • Page 11 4060-xxx Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer.
  • Page 12 4060-xxx Laser-notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på...
  • Page 13 4060-xxx Japanese Laser Notice xiii Laser notices...
  • Page 14 4060-xxx Korean Laser Notice Service Manual...
  • Page 15: Safety Information

    4060-xxx Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 16 4060-xxx 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 4060-xxx 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

    4060-xxx 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 listed in this chapter, as well as general environmental and safety instructions.
  • Page 19: General Information

    4060-xxx 1. General information The Lexmark™ T63x laser printers are letter quality page printers designed to attach to IBM-compatible personal computers and to most computer networks. The Lexmark T63x laser printers are available in the following models: Model name Configuration...
  • Page 20: Options

    400-sheet universally adjustable tray – 2000-sheet high-capacity feeder – Envelope feeder – Duplex option—250-sheet (For Lexmark T630 and Lexmark T630n) – Duplex option—500-sheet (For Lexmark T632, Lexmark T632n, Lexmark T634, and Lexmark T634n) – Output expander – High-capacity output stacker – StapleSmart™ Finisher –...
  • Page 21: Print Speed And Performance Print Speed

    • Available printer memory • Media size and type • Resolution The following table specifies throughput based on resolution and media size. Lexmark T630, Lexmark T632, Lexmark T634, Lexmark T630n Lexmark T632n Lexmark T634n 300, 600, 300, 600, 300, 600,...
  • Page 22: Time To First Print

    Depending upon the options and features used, additional memory may be required to optimize performance. Available memory options Optional 8MB, 16MB, 32MB, 64MB, and 128MB SDRAM DIMMs are available from Lexmark. The memory options are 168-pin synchronous DRAM DIMMs. Flash memory options include 16MB and 32MB.
  • Page 23: Printer Specifications

    Lexmark T630 (base printer) 16.6 in. 19.6 in. 13.6 in. 38 lb (421 mm) (498 mm) (345 mm) (17 kg) Lexmark T632 (base printer) 17.2 in. 20.2 in. 16 in. 41.5 lb (436 mm) (513 mm) (406 mm) (19 kg) Lexmark T634 (base printer) 17.2 in.
  • Page 24: Operating Clearances

    Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts. Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Printing states T630 T630n T632 T632n T634 T634n Printing—average power Base model 429 W 432 W 523 W 527 W 584 W...
  • Page 25: Acoustics

    Idle (standby mode) 31 dBA 4.6 Bels Simplex printing 52 dBA 6.7 Bels Duplex printing 55 dBA N/M Bels Lexmark T632(n) Idle (standby mode) 32 dBA 4.7 Bels Simplex printing 54 dBA 6.8 Bels Duplex printing 57 dBA N/M Bels...
  • Page 26: Media Specifications

    4060-xxx Media specifications Media type Media type Paper Card stock Transparencies Envelopes Vinyl labels Paper labels Polyester labels Dual web labels Integrated labels Service Manual...
  • Page 27: Media Size

    4060-xxx Media size Media size supported A4 8.27 in. x 11.7 in. (210 mm x 297 mm) A5 5.83 in. x 8.27 in. (148 mm x 210 mm) JIS-B5 7.17 in. x 10.23 in. (182 mm x 257 mm) Letter 8.5 in. x 11 in. (216 mm x 279 mm) Legal 8.5 in.
  • Page 28 4060-xxx Media size supported Envelopes 7¾ Envelope 3.875 in. x 7.5 in. (98 mm x 191 mm) 9 Envelope 3.875 in. x 8.9 in. (98 mm x 225.4 mm) 10 Envelope 4.125 in. x 9.5 in. (105 mm x 241 mm) DL Envelope 4.33 in.
  • Page 29 4060-xxx Input media types and weights Media weights—input Media Type Weight Integrated trays and optional 500-sheet drawers Paper Xerographic or business paper 60 to 176 g/m grain long (16 to 47 lb bond) Card stock—maximum Index Bristol 163 g/m (90 lb bond) (grain long) 163 g/m (100 lb bond)
  • Page 30: Print Area

    28 lb bond envelopes are limited to 25% cotton content. Includes envelopes fed from the multipurpose feeder only. Information on whether your vinyl label converter has passed Lexmark’s criteria is available at Lexmark’s Web site (www.lexmark.com). Search for “converter list.” You can also check Lexmark’s Automated Fax...
  • Page 31: Envelopes

    4060-xxx • Unsuitable papers include: – Multi-part forms and documents – Chemically treated papers – Coated, synthetic, and thermal papers – A5 paper less than 80 g/m (21 lb) – Recycled paper less than 75 g/m (20 lb) – Preprinted paper requiring a high degree of registration •...
  • Page 32: Tools Required

    4060-xxx Tools required Flat-blade screwdrivers, various sizes Phillips screwdrivers, various sizes 7.0 mm nut driver 5.5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Flash light (optional) 1-14 Service Manual...
  • Page 33: Acronyms

    4060-xxx Acronyms BLDC Brushless DC motor Customer setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Digital multimeter Enhanced Data Out EEPROM Electrically Erasable Programable Read-Only Memory Electrophotographic process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT High-capacity Input Tray...
  • Page 34 4060-xxx 1-16 Service Manual...
  • Page 35: Diagnostic Information

    4060-xxx 2. Diagnostic information Start CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
  • Page 36: Messages And Error Codes

    4060-xxx Messages and error codes Service error codes Service error codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition. Service error code Error code Action 900 RIP Software Go to “900 Error Code service check”...
  • Page 37 4060-xxx Service error code (continued) Error code Action 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit. Go to “Fuser service checks” on page 2-52. 925 Fuser Error Wrong fuser lamp installed. Go to “Cold fuser service check” on page 2-52.
  • Page 38 4060-xxx Service error code (continued) Error code Action 954 NVRAM CRC Indicates the NVRAM experienced a CRC failure. Replace the interconnect board. Failure 955 Code CRC Replace the system board. Where <loc> = CRC Failure or ECC Failure on the system board.
  • Page 39: Sub Error Codes

    4060-xxx Service error code (continued) Error code Action 990 <device> Indicates an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure. Note: <device> can be one of the following: duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin.
  • Page 40: Base Printer Sub Error Codes

    4060-xxx Base printer sub error codes Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem.
  • Page 41 4060-xxx Base printer sub error codes First 6 bytes sub error code data (xx can be Explanation any value) 84 xx 00 x1 x2 This code indicates that the input sensor in the printer is still actuated from the first sheet and the second sheet is ready to arrive at the sensor.
  • Page 42 4060-xxx Base printer sub error codes (continued) First 6 bytes sub error code data (xx can be Explanation any value) 84 xx 17 There is an envelope or envelopes in the envelope feeder during warm up. An envelope may have partially fed from the envelope feeder. Remove any envelopes from the feeder and check the envelope feeder for correct operation.
  • Page 43 4060-xxx Base printer sub error codes (continued) First 6 bytes sub error code data (xx can be Explanation any value) 84 xx 22 x1 x2 This code indicates that the media activated the input sensor before the printer EP was ready. (x1=leading edge of media state, x2=trailing edge of media state) 84 xx 23 x1 x2 The transfer servo never started.
  • Page 44 4060-xxx Base printer sub error codes (continued) First 6 bytes sub error code data (xx can be Explanation any value) 8D 00 00 The fuser exit sensor was never activated by the leading edge of the media fed through the printer. •...
  • Page 45: Base Printer (Fuser) Sub Error Codes

    4060-xxx Base printer (fuser) sub error codes The following sub error codes could help in diagnosing fuser assembly failures: Base printer (fuser) sub error codes First 6 bytes sub error code data (xx can be Explanation any value) 920 Service - Fuser Error (under temperature while printing) EN 08 xx yy - 1 Actual fuser temperature EN- zz - - 2...
  • Page 46: Duplex Option Sub Error Codes

    4060-xxx Base printer (fuser) sub error codes (continued) First 6 bytes sub error code data (xx can be Explanation any value) 925 Service - Fuser Error (Wrong Fuser Lamp Installed) Note: The following sub error codes are only for an incorrect lamp being installed. EN 07 xx yy zz 1 This error code is generated anytime an incorrect lamp is detected.
  • Page 47: Envelope Feeder Sub Error Codes

    4060-xxx Envelope feeder sub error codes First 6 bytes sub error code data (xx can be Explanation any value) 84 xx 17 There is an envelope in the feeder during POST. 84 xx 1D x1 x2 The envelope feeder pass thru sensor activated but never deactivated. (x1=media size, x2=media source) This error can be caused by an envelope over the pass thru sensor.
  • Page 48: User Status Displays

    4060-xxx User status displays Each user status screen may also display a warning message. See “Warning messages (second lines)” on page 2-16 for additional information when they display. User status displays Status Action The printer is ready to receive and Press Menu to take the printer out of process data.
  • Page 49 4060-xxx User status displays Status Action Displayed until the current job is Press Go to print the contents of the terminated or until additional data is printer buffer, staple the accumulated Waiting <interpreter> received on the active link. (PCL, PS, sheets, or terminate the collation set.
  • Page 50 4060-xxx Warning messages (second lines) These second line warnings apply to the User status displays (see “User status displays” on page 2-14). For example, Ready <warning> If none of the conditions exist that are listed in the following table, line two is blank. If any of the messages in the table are displayed, the following actions can be taken: •...
  • Page 51: User Status Messages

    4060-xxx User status messages User status messages Status Action The printer is busy receiving or Press Stop to take the printer out of processing data, or printing data. Busy status. Not Ready displays. No Busy additional data processes, but the Note: The printer indicator light blinks printer processes all paper currently in while the printer is processing data.
  • Page 52 4060-xxx User status messages Status Action The flash memory is being formatted. No button actions are possible while this message displays. Formatting Flash (Do Not Power Off) The flash memory is being Do not perform any button actions programmed, which means fonts or while this message displays.
  • Page 53: User Attendance Messages

    4060-xxx User attendance messages User attendance messages Primary message Secondary message Explanation Change Cartridge Select one of the following actions: Invalid Refill • Remove the toner cartridge and install a new cartridge. • Press and hold Select and press Return to display debug data for the engine and cartridge code.
  • Page 54 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation Check Duplex This messages displays for the following conditions: Connection • The duplex option may have been removed from the printer, possibly to clear a paper jam or to remove the option. •...
  • Page 55 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation Disk Corrupted The printer has detected there are errors on the hard Reformat? disk that cannot be corrected. The disk cannot be used until it is reformatted. Warning: All data on the disk will be lost if you format the disk.
  • Page 56 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation Insert <tray> <tray>=Tray 1, Tray 2, Tray 3, Tray 4, or Tray 5. The printer detects a tray needs to be inserted. The printer does not continue until it detects the tray is inserted.
  • Page 57 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation Install Tray x Tray x=Tray 2, Tray 3, Tray 4, Tray 5. or Cancel Job This message is displayed when a paper handling option has been hot unplugged. The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed.
  • Page 58 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation Reattach Bins x–y=Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10 Bins x–y This messages displays for the following conditions: • The specified output bins may have been removed from the printer, possibly to clear a paper jam or to remove the option.
  • Page 59 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 31 Defective Print Error code 31 displays when the top front cover is Cartridge closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective.
  • Page 60 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 37 Insufficient Memory Held Jobs may be lost This message displays when the printer memory used to restore the Print and Hold jobs from the disk and found that some or all of the jobs could not be restored. The printer ran out of memory while attempting to restore the jobs.
  • Page 61 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 53 Unformatted Flash This message displays when the printer detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues.
  • Page 62 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 56 Standard Parallel This error is displayed when data is sent to the printer Port Disabled across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset.
  • Page 63 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 59 Incompatible Tray x An incompatible tray is installed. For Tray x, x= 2, 3, 4, or 5. Remove the incompatible tray and press Go to clear the message. Note: If the user installed the incompatible device to satisfy a Check Device Connections/reattach message, the user should reinstall an associated compatible option or hot unplug the option.
  • Page 64 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 200 Paper Jam Leave Job in Finisher Primary: Paper is jammed at the printer input sensor. Remove Cartridge Open the printer upper front door and remove the print cartridge to access the paper jam area. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed...
  • Page 65 4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 235 Duplex Paper Jam - Leave Job in Finisher Primary: A piece of media is over the duplex double Front feed sensor. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets.
  • Page 66: User Line 2 Link Messages

    4060-xxx User attendance messages (continued) Primary message Secondary message Explanation 280 Paper Jam Leave Job in Finisher Primary: Paper is jammed in the finisher option. Open Check Finisher the finisher option side door or top cover to access the jammed pages. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed...
  • Page 67: Check Device Connection Messages

    4060-xxx Check device connection messages The messages in the following table display when the printer loses communications with one of the following devices. User status message Explanation Check Env Feeder Check envelope feeder connection. Connection Check Tray x Check tray x, where x=1, 2, 3, 4, or 5. Connection Check Duplex Check duplex option connection.
  • Page 68: Power-On Self Test (Post)

    4060-xxx Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: The LED comes on. The operator panel displays one and a half row of pels, and then clears. Diamonds scroll across the display, and then clear.
  • Page 69: Symptom Tables

    4060-xxx Symptom tables Base printer symptoms Symptom Action Dead machine Go to “Dead machine service check” on page 2-45. Operator panel—one or more buttons do Go to “Operator panel buttons service check” on page 2-70. not work. Operator panel—display is blank. Printer Go to “Operator panel service check”...
  • Page 70: Paper Tray Symptoms

    4060-xxx Paper tray symptoms Symptom Action Paper feed problem with 250-Sheet Paper Go to “Input tray(s) service check” on page 2-64. Tray. Paper feed problem with 500-Sheet Paper Go to “Input tray(s) service check” on page 2-64. Tray. Media fails to pass through from the lower Go to “Input tray(s) service check”...
  • Page 71: Staplesmart Finisher

    4060-xxx StapleSmart finisher Symptom Action Finisher does not staple. Go to “StapleSmart finisher service check” on page 2-86. Printer does not recognize StapleSmart Go to “StapleSmart finisher service check” on page 2-86. Finisher Option as being installed. Close Top Cover displayed. Unable to clear Go to “StapleSmart finisher service check”...
  • Page 72: Service Checks

    4060-xxx Service Checks Anytime the system board is replaced, the Configuration ID must be reset in NVRAM. Go to “Setting configuration ID” on page 3-18. Review the following information before performing any service checks. • Paper feed problems (especially paper jams): Go to “Viewing the error log”...
  • Page 73 4060-xxx The printer does not recognize one or more output options as installed. Service tip: 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 74 4060-xxx Ready Bin x Full displays—May be able to clear message and feed paper into bin selected. Action Bin x sensor Check the sensor and sensor cable for the bin that is displaying the Bin x sensor cable message to make sure the sensor is seated correctly in the side of Bin x sensor flag the tray and the cable is connected to the sensor and the control Control board...
  • Page 75: 900 Error Code Service Check

    Sub Error Codes on the display. Check the “Base printer sub error codes” on page 2-6. If none of the Sub Error Codes are listed, then call your next level of support or call Lexmark. 2-41 Diagnostic information...
  • Page 76 Configuration ID must be reset in NVRAM on the interconnect board. “Setting configuration ID” on page 3-18 Go to Replace the interconnect board. If this does not clear the message, contact the next level of support or Lexmark. 2-42 Service Manual...
  • Page 77: Charge Roll Service Check

    4060-xxx Charge roll service check Service tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 in.) apart, or spots on the page can be caused by a damaged or contaminated charge roll. Service tip: Make sure the right charge roll arm bushing is correctly installed and operates correctly. To remove the charge roll: Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.
  • Page 78: Cover Closed Switch/Cable Service Check

    4060-xxx Cover closed switch/cable service check Action Toner cartridge Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not loose or broken. Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring.
  • Page 79: Dead Machine Service Check

    4060-xxx Dead machine service check A dead machine is a condition where the display is blank, the LED on the operator panel is off, no fans turn, no motors turn, and the fuser lamp does not come on. If a high-capacity input tray is installed, remove the option and check the base printer for correct operation.
  • Page 80 4060-xxx Action LVPS Unplug the AC line cord from the LVPS and disconnect the interconnect card cable on the LVPS. Reconnect the AC line cord and measure the voltage on CN2-1 on the LVPS. The voltage should measure approximately +5 V dc. If the voltage is correct, go to step 6.
  • Page 81: Duplex Option Service Check

    4060-xxx Action Loads connected to the Turn the printer off and disconnect each cable connected to the system board system board and each option installed on the system board until the problem is located. Warning: When removing any card installed on the system board observe all ESD precautions when handling these options.
  • Page 82 4060-xxx Duplex does not recognize that the option is installed, or other options below the duplex are installed Action Autoconnect cables/ Check the top and bottom autoconnect connectors for signs of connections damage. If damaged, replace the duplex option. If not damaged, check the cables are correctly connected to the duplex system board at J9, J10, J11, and J12.
  • Page 83: Envelope Feeder Service Check

    4060-xxx Envelope feeder service check Service tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise verify the interconnect card is functioning properly.
  • Page 84 4060-xxx Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display Load Envelopes after envelopes are placed in the hopper. Service tip: The kick rolls rotate during the attempted feed cycles. Action Envelope out hopper Check the envelope out sensor flag for damage, correct installation...
  • Page 85 4060-xxx 260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls are rotating. Check the deflector gap adjustment before continuing this service check. Action Deflector gap adjustment Check the deflector gap adjustment. The adjustment may be too narrow.
  • Page 86: Fuser Service Checks

    4060-xxx Fuser service checks Cold fuser service check Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error indicates the wrong fuser lamp is installed.
  • Page 87 4060-xxx Action Fuser top cover assembly Disconnect the thermistor cable from the fuser control board at J6. (assembly includes thermistor and thermal fuses) Resistance: • HOT J2-1–J2-2 <10K ohms • COLD approximately 450K ohms If the resistance is incorrect, replace the fuser top cover assembly. If the resistance is correct, check each pin of J6 to ground.
  • Page 88: Hot Fuser Service Check

    4060-xxx Hot fuser service check Error Code 923: Indicates the fuser is too hot during printing or when the printer is idle. Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit. Note: Check the fuser sub error codes to help diagnose between a 923 and 924 error. CAUTION: The fuser may be hot, use caution before removing or servicing.
  • Page 89: Fuser Solenoid Service Check

    4060-xxx Fuser solenoid service check CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Service tip: Try changing the envelope enhance level setting.
  • Page 90: High-Capacity Feeder Input Tray Service Check

    4060-xxx High-capacity feeder input tray service check Note: Voltage measurements in the high-capacity feeder input tray service checks must be made with the high-capacity feeder attached to the base printer to obtain accurate results. Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.
  • Page 91 4060-xxx Action High-capacity feeder option Check the voltage on J8-1 (green). The voltage measures +24 V dc. control board If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high-capacity input for the high-capacity feeder to be recognized.
  • Page 92 4060-xxx Tray x empty displays when there is paper in the high-capacity feeder input tray. Action Paper out sensor flag Check the paper out sensor flag for correct operation and installation. If correct, replace the high-capacity feeder system board. (The paper out sensor is mounted on the high-capacity feeder system board.) Paper out sensor (on option system board)
  • Page 93 4060-xxx The elevator tray does not move up or down. The printer recognizes that the option is installed. Action DC drive motor high- Be sure the motor cable is correctly installed at J1 on the board. capacity feeder option Check the cables, damaged or loose wires. Disconnect the motor. system board Check for a short between each pin and the motor housing.
  • Page 94 4060-xxx Paper size switch not selecting paper size that is selected. Action Paper size switch Check for continuity between the common pin (J5-1) and the pin of High-capacity feeder option the paper size selected. control board Color Paper size J5-1 Black Common lead J5-2...
  • Page 95 4060-xxx Tray x Paper Low displays when the high-capacity feeder input tray is full or has adequate paper in the tray. Action Paper low switch Run the sensor diagnostics for tray x (x=the number that represents the high-capacity input tray). Paper low switch cable High-capacity feeder option If the test fails, check the voltage at J3-1 (gray).
  • Page 96: High-Capacity Output Stacker Service Check

    4060-xxx High-capacity output stacker service check Service tip: The majority of the mechanical components can be observed during operation by removing the left, right, and front covers. The high-capacity output stacker option functions without the covers installed. Determine which paper path stacker assembly is not functioning properly. Make sure the option(s) are installed correctly and the machine is configured correctly before attempting to service the high-capacity output stacker option.
  • Page 97 4060-xxx 202 Paper Jam Open Rear Door displays and a sheet of paper is jammed prior to the pass thru sensor flag or 202 Paper Jam Open Rear Door displays, a sheet of paper feeds out to the standard bin even though bin x is selected and paper exits half way out of the redrive assembly.
  • Page 98: Input Sensor Service Check

    4060-xxx Input sensor service check Service tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor. Action Input sensor flag Check the input sensor flag for damage and proper operation.
  • Page 99 4060-xxx Action Power takeoff shaft and Check these parts for broken or damaged parts, contamination on spring, bevel gear, feed roll the drive rollers or wear plate, and wear or damage to the drive shaft gear, drive roll assembly, bearings. Check the drive roll assembly and skewed backup roller for wear plate, drive shaft signs of wear, slick spots, material buildup, and oil or grease on the bearings, and skewed...
  • Page 100: Internal Tray Card/Paper Size Sensing Service Check

    4060-xxx Internal tray card/paper size sensing service check Before proceeding, check for the correct paper size loaded in the tray and that the tray has been set to accept the size paper loaded in the tray. Paper size sensing switch chart Paper tray size selection (X is activated) System Signal...
  • Page 101 4060-xxx The printer does not recognize the paper size selected. Action Back restraint Check all the paper size parts for damage or broken parts. make sure Side restraint the parts operate correctly. If a problem is found, repair as necessary. Snap-in plate If no problem is found, go to step 2.
  • Page 102: Main Drive Service Check

    4060-xxx Main drive service check Service tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board. Service tip: If there are equally spaced horizontal lines across the page, go to “Print quality— evenly spaced horizontal lines or marks”...
  • Page 103: Main Fan Service Check

    4060-xxx Main fan service check Check the cable connections at J7 on the system board and at the main fan assembly. The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode. Action Main fan Manually spin the fan and check that it rotates freely.
  • Page 104: Operator Panel Service Check

    4060-xxx Operator panel service check Operator panel buttons service check Before continuing with this service check do the “Button Test” on page 3-8. Action Operator panel assembly If any button fails the Button Test, replace the operator panel assembly. Operator panel assembly If no buttons work, replace the operator panel assembly.
  • Page 105: Options Service Check

    4060-xxx Options service check Service tip: When you have a problem with any of the options installed in the options slots on the interconnect board, switch the non operating option to one of the other option slots to isolate the failure.
  • Page 106: Output Bin Sensor Standard Tray Service Check

    4060-xxx Output bin sensor standard tray service check Service tip: If the output bin standard tray fills up and the bin full sensor fails to post the Remove Paper Standard Bin message: Enter the Diagnostics Mode. Select Output Bin Tests. Select Sensor Tests.
  • Page 107 4060-xxx Printer does not recognize one or more output expander options as being installed. Service tip: If more than a single output expander 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 expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option.
  • Page 108 4060-xxx Remove Paper - Output Bin x is displayed, POST incomplete, unable to clear the message. Action Dual output bin sensor flag Check the flag for correct operation, binding, broken parts, or interference from the sensor cable, If incorrect, repair as necessary. 271 Paper Jam - Check Bin x, POST incomplete Action Pass thru sensor and flag...
  • Page 109 4060-xxx Action Output expander control Disconnect the motor cable J4 and check the voltages at J4 on the board board. Note: Use caution not to short to adjacent pins on the connector. Status Voltage J4-1 (Motor Idle) +24 V dc J4-2 (Motor Idle) +24 V dc...
  • Page 110: Paper Feed Service Check

    4060-xxx Paper feed service check If you have a 936 Transport Motor Error go to “Main drive service check” on page 2-68. Action Alignment assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight. Check the alignment assembly for worn rollers, contaminated rollers, or binds.
  • Page 111: Parallel Port Service Check

    4060-xxx Double feeding paper Note: If double feeding paper occurs mostly from the bottom of the stack, check for missing or damaged restraint pads in the tray. Action Paper Paper is usually the primary cause of a double feeding paper problem.
  • Page 112: Printhead Service Check

    4060-xxx Printhead service check The printhead assembly does not contain any service replaceable parts or components. If service error code 930 displays, the wrong printhead is installed in the printer. See “Printhead 1 (000/010)” on page 7-10, “Printhead 2 (200/210)” on page 7-11, or “Printhead 3 (400/410)”...
  • Page 113 4060-xxx Measure all voltages from the connector to printer ground. All voltages measured during the print cycle are measured with the controller board removed while running the print test. Print quality—all black page Service tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
  • Page 114 4060-xxx Print quality—random marks Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll, or transfer roll. Symptom Action Random marks Check the print cartridge for loose or foreign material that might be on the photoconductor.
  • Page 115 4060-xxx Action Lines spaced 49.74 mm Replace the FRUs in the following order: (1.958 inch) apart • Redrive assembly • Fuser assembly There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task.
  • Page 116 4060-xxx Print quality—background Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background. Some problems occur with printers that run a large amount of graphics in a humid environment.
  • Page 117 4060-xxx Print quality—banding Service tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer, especially in the development and transfer process.
  • Page 118 4060-xxx Print quality—light print Service tip: Check the toner saver and print darkness settings first if the print is light. Action Transfer roll Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll. Right side transfer roll arm Check the right side transfer roll arm assembly bearing for wear or assembly...
  • Page 119: Smart Contact Assembly Service Check

    Note: If you are unable to clear a “32-Unsupported Cartridge” User Error message, be sure a Lexmark T63x print cartridge is correctly installed in the printer. The cartridge is easily identified by the contact board on the right side rear of the cartridge. Install another print cartridge before attempting to troubleshoot the printer.
  • Page 120: Staplesmart Finisher Service Check

    4060-xxx StapleSmart finisher service check Note: When removing the stapler mechanism from the option, first remove the staple supply cartridge. Note: When replacing staples in the supply cartridge, discard any old staples in the cartridge and replace with a fresh strip. Problems with static electricity buildup Action Top cover...
  • Page 121 4060-xxx Close Finished Side Door displayed—unable to clear or reset message. (POST incomplete) Action Side cover door Check the stapler access door for any signs of damage or broken parts. Make sure the door correctly actuates the stapler side access door switch.
  • Page 122 4060-xxx 990 Service Error Code - Check Bin x displayed—POST Incomplete • “Step 1—During POST the stapler option does not try to home.” on page 2-88. • “Step 2—During POST the stapler option tries to home.” on page 2-88. Step 1—During POST the stapler option does not try to home. Action Stapler card assembly Turn the printer off, disconnect the motor from J2 and check for...
  • Page 123 4060-xxx 281 Paper Jam—The paper feeds partway into the standard bin even if finisher is selected Note: When a 900 Service Error is displayed during POST the failure is usually in the stapler gearbox assembly or stapler cartridge. Action DC motor in drive gearbox Turn the printer off, disconnect the motor from J4 and check for assembly continuity between J4 pins 1, 2, 5, and 6 on the cable and the motor...
  • Page 124 4060-xxx 281 Paper Jam—paper jams into stapler output bin. Action Center stapler bail Check the center stapler bail for broken parts and that the bail moves freely on the upper exit shaft assembly. Upper exit shaft assembly Check the upper and lower shaft assembly for wear, binds, or damage.
  • Page 125 4060-xxx Action Stapler board Check the voltages on connector J3 on the board. Stapler assembly Note: All voltages are approximate values. Pin No. Voltage static Voltage feeding +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc...
  • Page 126 4060-xxx Paper feeds into finisher option output tray—Paper is not stapled—Paper does not align with the right side. Action Paper alignment wheel Check to make sure the gamma wheel aligner assembly is operating correctly and that the wheel is touching the paper. If the gamma Paper alignment pad wheel is not turning or touching the paper, go to step 2.
  • Page 127: Toner Sensor Service Check

    4060-xxx Stapled sheets are not transported to the output tray. Action Sol 2 (stapler gearbox Disconnect Sol 2 cable from J8 on the stapler card and measure the assembly) resistance of the solenoid across the cable connector. It should measure approximately 48 ohms (cold). If incorrect, replace the Stapler card assembly stapler/finisher option assembly.
  • Page 128: Transfer Roll Service Check

    4060-xxx Transfer roll service check Service tip: The transfer roll is 51.02 mm (2.009 inch) circumference. Any print quality problems such as lines that are spaced 51.02 mm apart indicate you should check the transfer roll for damage and check for toner or foreign material buildup. Service tip: The transfer roll assembly is part of the maintenance kit and is replaced when an 80 Scheduled Maintenance displays.
  • Page 129: Diagnostic Aids

    4060-xxx 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostics mode Entering Diagnostic Mode: Turn the printer off.
  • Page 130: Device Tests

    4060-xxx Device tests Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block.
  • Page 131: Flash Test

    4060-xxx Flash Test This test causes the file system to write and read data on the flash to test the flash. Warning: This test destroys all data on the flash because the flash is reformatted at the end of the test.
  • Page 132: Duplex Tests

    4060-xxx Duplex tests Duplex Quick Test This test is used to verify that 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 backside of the duplexed page.
  • Page 133: Duplex Motor Test

    4060-xxx Duplex Motor Test This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable. To run the Duplex Motor Test: Select Motor Test from the Duplex Tests menu. The duplex motor test continues to run until the printer is powered off.
  • Page 134: Duplex Feed 2 Test

    4060-xxx Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop position 2. To run the Duplex Feed 2 Test: Select Duplex Feed 2 from the Duplex Test menu. • The power indicator blinks while the paper is feeding. •...
  • Page 135: Printing The Error Log

    Sub error codes Next error code The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the error log: Select Print Log from the Error Log menu.
  • Page 136: Clearing The Error Log

    4060-xxx Clearing the error log Select Clear Log from the Error Log menu. ERROR LOG Clear Log Select YES to clear the Error Log or NO to exit the Clear Log menu. If YES is selected, Empty Error Log displays on the screen. Press Return/Stop to exit the Clear Log menu.
  • Page 137: Sdram Memory Test

    4060-xxx SDRAM Memory Test The purpose of this test is to check the validity of SDRAM, both standard and optional. The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly. To run the SDRAM Memory Test: Select SDRAM Memory Test from the menu.
  • Page 138: Input Tray Tests

    4060-xxx Input tray tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder.
  • Page 139: Output Bin Tests

    4060-xxx Output Bin Tests Output Bin Test—Standard Bin This test is used to verify if the standard bin sensor is working correctly. To run the Standard Bin Sensor Test: Select Output Bin Tests from the Diagnostic menu. Select Output Bin Tests - Sensor Tests. Select Sensor Tests - Standard Bin.
  • Page 140: Feed To All Bins Test

    4060-xxx Feed to All Bins Test This test can be used to verify that the printer can feed media to the standard bin or any installed output options. No information will be printed on the test pages as the printhead is not turned on during the feed test.
  • Page 141 4060-xxx Output Expander Select Output Bin Tests from the menu. Select Output Bin Tests - Sensor Tests. Select Sensor Tests for Output Bin x (x=number of the output option to be tested) The following screen is displayed: Output Bin x P=OP F=OP NF=OP P=Pass Thru Sensor F=Bin Full Sensor...
  • Page 142: Finisher Tests For Staplesmart Finisher

    4060-xxx 5-Bin Mailbox Option Select Output Bin Tests from the menu. Select Output Bin tests - Sensor Tests. Select Sensor Tests for Output Bin x (x=number of the output option to be tested). The following screen is displayed: Output Bin x P1=OP P2=OP L=NL P1=5-Bin Mailbox first pass thru sensor P2=5-Bin Mailbox second pass thru sensor...
  • Page 143: Staple Sensor Test

    4060-xxx There are four sensor tests that can be selected from the Sensor Tests: • Staple Sensors • Cover and Door sensor • Pass and Media Sensor • Bin Level Sensor Select the test for the sensors you want to test from the menu. The following appear on the display for each test selected.
  • Page 144: Base Sensor Test

    4060-xxx Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly. The following sensors can be checked: • Toner optical sensor • Input sensor • Output sensor (fuser exit) • Narrow media sensor (fuser) •...
  • Page 145: Printer Setup

    4060-xxx Printer setup Setting the page count This lets the servicer change the page count from the Diagnostics Menu. This is used whenever the system board is replaced because this board contains the printer NVRAM Memory where the page count is stored. To set the page count: Select Page Count from the Diagnostic menu.
  • Page 146: Setting Configuration Id

    4060-xxx Setting configuration ID The configuration ID is used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration ID is originally set at the factory when the printer is manufactured, however it requires resetting whenever you replace the interconnect board and can be set on the operator panel.
  • Page 147: Print Tests

    4060-xxx Print Contrast The print contrast setting controls the developer voltage offset. The print contrast can be adjusted to: LOW, MEDIUM, HIGH Charge Roll The charge roll can be adjusted to: LOW, MEDIUM, HIGH Print tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options.
  • Page 148: Print Quality Test Pages

    4060-xxx Print quality test pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality test consists of three pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. If duplex is turned on, the pages are duplexed.
  • Page 149: Theory

    4060-xxx Theory Autocompensator operation The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels.
  • Page 150: Duplex Option

    4060-xxx Duplex Option The duplex option interface is a six pin autoconnector that provides a +24 V dc, +24 V dc return, serial interface transmit signal, serial interface receive signal, and two ground pins. The duplex option receives the +24 V dc from the base printer for the duplex motors and also converts the voltage to +5 V dc for duplex electronics.
  • Page 151: Paper Jams-Base Printer

    4060-xxx Paper jams—base printer Error Message 200 Paper Jam - Remove Cartridge This message indicates that paper is jammed at the printer input sensor. This condition can be caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper over the sensor, or paper arriving at the sensor too late.
  • Page 152: Paper Jams-Options

    4060-xxx Paper jams—options Error Message 23x Paper Jam - Check Duplex Option 231 Paper Jam Input Sensor 232 Paper Jam Stage 1 Location Stage 2 Location 235 Paper Jam 234 Paper Jam Doublefeed Sensor 236 Paper Jam 235 Paper Jam 233 Paper Jam Exit Sensor 237 Paper Jam...
  • Page 153: Error Message 24X (X=Tray 1 Through 5) Paper Jam Check Tray X

    4060-xxx Error Message 24x (x=tray 1 through 5) Paper Jam Check Tray x The paper has not cleared the pass thru sensor or reached the pass thru sensor of the option above tray x. Note: When the StapleSmart Finisher option is installed, a secondary message may be displayed which advises whether or not to remove the job from the finisher.
  • Page 154: Error Message 282 - Check Stapler

    4060-xxx Error Message 282 - Check Stapler This message indicates that a staple jam has been detected during normal operation, when printing and stapling jobs. The printer alternately flashes the primary and secondary message to indicate that all accumulated sheets should be removed during the jam clearance procedure. Error Message 283 - Check Stapler This message indicates that a staple jam has been detected during a stapler priming operation.
  • Page 155: Repair Information

    4060-xxx 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: •...
  • Page 156: Adjustment Procedures

    4060-xxx Adjustment procedures Duplex motor drive belt adjustment Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor or loosen the motor or drive belt idler pulley. Service tip: Excessive belt tension can result in stalling the duplex motor. Too little belt tension can result in belt slippage.
  • Page 157: Gap Adjustment

    4060-xxx Gap adjustment The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the printer. This adjustment reduces the printer overall performance, such as pages per minute, but can help in reducing the amount of curl of some printed medias, thus improving media stacking in the output bin.
  • Page 158: Paper Alignment Assembly Adjustment

    4060-xxx Paper alignment assembly adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one.
  • Page 159 4060-xxx Step B Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in “Print registration” on page 3-16. The reference screw can be adjusted without loosening the locknut. Turn the screw a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin.
  • Page 160: Screw Identification Table

    4060-xxx Screw identification table The following table contains screw types, locations, and quantities necessary to service the printer. Each screw callout in the removal procedure graphic displays the screw reference number listed in the table. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly.
  • Page 161 4060-xxx Reference Screw type Location Purpose number M3x6 mm Taptite outer shield mounting inner redrive deflector mounting interconnect board to center pan mounting system board to interconnect board ground attach system board to inner shield mounting system board (back) mounting lower stacker duct mounting ground cables to ground (center pan—front)
  • Page 162 4060-xxx Reference Screw type Location Purpose number M3x28 mm Taptite developer drive ground (bottom hole) attach Panhead M3.5x8 mm Plastite autocompensator mounting Thread Forming M3.5x10 mm right side cover mounting Plastite Thread Forming right side frame to pan attach left side frame to pan attach right side frame to right side cover attach...
  • Page 163: Removal Procedures

    4060-xxx Removal procedures CAUTION:Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
  • Page 164: Right Cover Removal

    4060-xxx Right cover removal Remove the redrive cap Remove the redrive assembly. Open the upper and lower front covers. Remove the print cartridge. Remove the right cover mounting screw (A) and release the cover latch (B). A(324) Remove the right side cover mounting screw (C). C(324) 4-10 Service Manual...
  • Page 165 4060-xxx Remove the right side cover. Cover retainers Note: When replacing the right side cover, make sure the cover retainers are correctly located in the appropriate slots in the right side frame. 4-11 Repair information...
  • Page 166: Upper Front Cover Removal

    4060-xxx Upper front cover removal Raise the upper front cover. Remove the upper front cover mounting screws (A). A(323) 4-12 Service Manual...
  • Page 167 4060-xxx While holding the two upper front cover latches, lift off the cover. Note: When removing the cover, hold the upper and lower latch and spring to prevent them from falling into the printer. Note: Use caution to avoid scratching or damaging the operator panel lens cover. Set aside the operator panel overlay.
  • Page 168: Laser Cover Removal

    4060-xxx Laser cover removal Remove the left door. Remove the right cover. See “Right cover removal” on page 4-10. Remove the paper support. Remove the redrive cap. Press the fuser wiper cover latch and remove the cover. Loosen screw (A) and remove the two screws (B) on the right side. B(102) A(323) Remove the mounting screws (C) from the left side.
  • Page 169 4060-xxx Remove the paper bin full sensor flag assembly from the mounting bracket. See “Paper bin full sensor flag assembly removal” on page 4-54. Unlatch the front right and front cover posts (left) and remove cover. Remove fan grill cover. Note: Be sure to reseat the fan grill cover before replacing the laser assembly cover.
  • Page 170: Bevel Gear Removal

    4060-xxx Bevel gear removal Open the left door. Remove the inner shield. Remove the gear guard. Remove the power takeoff shaft and spring (A) through the bottom of the printer. Place your thumb on the top of the gear and press firmly down and away. Note: You need to exert firm pressure to snap the bevel gear out.
  • Page 171: Installation

    4060-xxx Installation Remove any washer that may be present (A) and discard. Lubricate areas (A) that engage the journal (B) with grease, from the provided packet. Place the new washer (C) on the bevel gear shaft. Insert the bottom portion and press or pull into position. Note: You should hear two distinct snaps.
  • Page 172: Communications Board Removal

    4060-xxx Communications board removal Remove the outer shield. See “Outer shield removal” on page 4-52. Remove features and options from the interconnect board only if they block access. Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESD-sensitive parts” on page 4-1.
  • Page 173: Cover Closed Switch/Cable Removal

    4060-xxx Cover closed switch/cable removal Note: Pay careful attention to the cable routing through the printer before you remove the cover closed switch and cable assembly. Remove the left cover, upper front cover, and outer system board shield. Disconnect the cover closed switch cable from the system board (J3). Remove the screw (A) that attaches the cover closed switch.
  • Page 174: Developer Drive Assembly Removal

    4060-xxx Developer drive assembly removal Remove the inner shield. See “Inner shield removal” on page 4-34. Remove the developer drive assembly mounting screws (A). Remove the developer drive assembly. Note: Be sure the developer drive shaft and coupler aligns with the hub on the main drive assembly when reinstalling the assembly.
  • Page 175 4060-xxx Remove the paper alignment assembly. See “Paper alignment assembly removal” on page 4-52. Remove the left side frame mounting screws (A). A(102) Place the printer on its back and remove the left side frame mounting screws (B). B(104) Remove the left side frame. 4-21 Repair information...
  • Page 176: Right Side Frame

    4060-xxx Right side frame CAUTION: Unplug the printer before you begin. Remove the right side cover. See “Right cover removal” on page 4-10. Remove the laser cover. See “Laser cover removal” on page 4-14. Remove the LVPS. See “Low voltage power supply removal” on page 4-42.
  • Page 177: Fuser Assembly Removal

    4060-xxx Fuser assembly removal CAUTION: Unplug the printer before you begin. Remove the redrive assembly. See “Redrive assembly removal” on page 4-57. Remove the fuser mounting screws (A). Disconnect the AC fuser lamp cable (C) from the fuser lamp connector (D). Pull the fuser assembly out far enough to remove the fuser lamp cable.
  • Page 178 4060-xxx Installation When you reinstall the fuser, be sure to route the fuser lamp cable through the channel (F) on the right side frame above the LVPS, under the clip (G), and through the notch in the frame (H) Route the fuser lamp cable through the opening in the fuser as shown (J). 4-24 Service Manual...
  • Page 179: Fuser Cover Removal

    4060-xxx Fuser cover removal CAUTION: Unplug the printer before you begin. Remove the fuser assembly. See “Fuser assembly removal” on page 4-23. Note the thermistor cable (A) routing. Clip the cable tie (B) and disconnect the thermistor cable (C) from the fuser board. 4-25 Repair information...
  • Page 180 4060-xxx Disconnect the AC fuser lamp cable (A) from the top left side of the fuser cover. Remove the two screws (C) from the right side fuser lamp contact cover. Release the latch (D) and remove the cover. C(202) 4-26 Service Manual...
  • Page 181 4060-xxx Remove screw (A) that attaches the fuser lamp contact to the fuser cover. Remove the two screws (B), one on each side of the fuser, that attach the fuser upper cover assembly to the fuser frame. Remove the fuser laser cover. 4-27 Repair information...
  • Page 182: Fuser Exit Sensor Or Fuser Narrow Media Sensor Removal

    4060-xxx Fuser exit sensor or fuser narrow media sensor removal Remove the fuser. See “Fuser assembly removal” on page 4-23. Cut the cable tie (A). Narrow Media Sensor Exit Sensor Unplug the sensor from the fuser control board. Remove the sensor from the lower exit guide assembly. Fuser lamp removal Remove the fuser assembly.
  • Page 183 4060-xxx Remove the left lamp contact assembly. Remove the fuser lamp. Warning: The lamp is under spring tension and care must be used when removing the lamp from the fuser. Grip the lamp by the ceramic end piece and remove it from the fuser assembly.
  • Page 184: Fuser Transfer Plate Removal

    4060-xxx Fuser transfer plate removal Remove the upper paper deflector. See “Upper paper deflector assembly removal” on page 4-63. Remove the transfer roll. Remove the inner paper deflector. See “Inner paper deflector assembly removal” on page 4-33. Lift the left side of the fuser transfer plate (A) and move the plate to the left to clear the right side from its mounting.
  • Page 185: High Voltage Power Supply Removal

    4060-xxx High voltage power supply removal CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Remove the inner paper deflector.
  • Page 186 4060-xxx Remove the HVPS mounting screws (C). C(235) Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS. 4-32 Service Manual...
  • Page 187: Inner Paper Deflector Assembly Removal

    4060-xxx Inner paper deflector assembly removal Remove the paper tray. Remove the upper paper deflector assembly. See “Upper paper deflector assembly removal” on page 4-63. Place the printer on its side. Remove the MPT deflector assembly. See “Inner paper deflector assembly removal” on page 4-33.
  • Page 188: Inner Shield Removal

    4060-xxx Inner shield removal Remove the left door. Remove the outer system board shield. See“Outer shield removal” on page 4-52. Remove all features or option boards from the interconnect board. Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESD-sensitive parts”...
  • Page 189: Integrated Tray Autocompensator Assembly Removal

    4060-xxx Integrated tray autocompensator assembly removal Remove the paper tray. Remove the left door. Remove the outer shield. See “Outer shield removal” on page 4-52. Disconnect the autocompensator motor cable from the system board (J28). Cut cable tie (A) on left side. Place the printer on its back.
  • Page 190 4060-xxx Locate the integrated tray autocompensator assembly (A) on the bottom of the printer and disconnect the autocompensator arm bias spring (B). Note: When you remove the spring, note the larger loop attaches to the side frame. Remove the C-clip (C) that rests against the right side frame from the autocompensator pivot shaft.
  • Page 191 4060-xxx Disconnect the autocompensator sensor cable (D) from the assembly. Remove the autocompensator assembly mounting screw (E). Remove the integrated tray autocompensator assembly. Note: When you reinstall the assembly, reinstall the cable tie. 4-37 Repair information...
  • Page 192: Integrated Tray Autocompensator Pick Roll Assembly Removal

    4060-xxx Integrated tray autocompensator pick roll assembly removal Remove the integrated tray and look underneath the printer for the autocompensator arm. Pull the arm down. Press on the end of the tab and pull the pick roll off the arm. Repeat this step for the pick roll on the other side.
  • Page 193 4060-xxx Installation Remove the new pick rolls from their packaging. Pull the autocompensator arm down. Locate the recessed area on the pick roll and align it with the tab on the arm. There are two arrows on each pick roll. Make sure the bottom arrow faces you as you align the recessed area with the tab.
  • Page 194: Interconnect Board Assembly Removal

    4060-xxx Interconnect board assembly removal CAUTION: Unplug the printer before you begin. Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESD- sensitive parts” on page 4-1. Note: Any time the interconnect board assembly is replaced, the Configuration ID must be reset in NVRAM on the new interconnect board.
  • Page 195: Internal Tray Card (Itc)/Paper Size Sensing Board Removal

    4060-xxx Place the printer on its side and remove the mounting screws (A). A(202) Remove the interconnect board assembly. Internal tray card (ITC)/Paper size sensing board removal Remove the paper size sensing board mounting screw (A). Disconnect the paper size sensing board cable (B) from the board. Remove the paper size sensing board from the ITC latch (C).
  • Page 196: Low Voltage Power Supply Removal

    4060-xxx Low voltage power supply removal CAUTION: Unplug the printer before you begin. Remove the right side cover. See “Right cover removal” on page 4-10. Remove fuser assembly. See “Fuser assembly removal” on page 4-23. Remove the LVPS mounting screws (A) from the rear of the bottom pan. A(203) Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser lamp cable.
  • Page 197 4060-xxx Remove the LVPS access plate. Disconnect the interconnect card cable from the LVPS (A). Remove the LVPS. 4-43 Repair information...
  • Page 198: Main Drive Assembly Removal

    4060-xxx Main drive assembly removal Remove the inner shield. See “Inner shield removal” on page 4-34. Remove the gear guard (A). Remove the developer drive assembly. See “Developer drive assembly removal” on page 4-20. 4-44 Service Manual...
  • Page 199 4060-xxx Remove the power takeoff shaft and spring (A) through the bottom of the printer. Remove all cables from the cable clamps (B) on the main drive assembly. Remove the ground cable screw (C). Remove the main drive assembly mounting screws (D). Remove the link from the rear of the main drive assembly.
  • Page 200: Main Fan Removal

    4060-xxx Main fan removal Remove the laser cover. See “Laser cover removal” on page 4-14. Remove the inner shield. See “Inner shield removal” on page 4-34. Remove the fan grill cover. Note the routing of the main fan cable (A) and disconnect the cable from the system board at connector J7.
  • Page 201: Multipurpose Tray/Lower Deflector Assembly Removal

    4060-xxx Multipurpose tray/lower deflector assembly removal Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts.
  • Page 202: Operator Panel Assembly Removal

    4060-xxx Operator panel assembly removal Remove the upper front cover. Remove the operator panel overlay (A) and set it aside. Gently press the operator panel lens tabs to loosen the operator panel. Disconnect the operator panel cable and remove the operator panel. 4-48 Service Manual...
  • Page 203: Operator Panel Bezel Removal

    4060-xxx Operator panel bezel removal Remove the upper front cover. See “Upper front cover removal” on page 4-12. With the upper front cover upside down on a soft, non-scratching surface, release the clips and remove the operator panel lens cover. Note: Use caution to avoid scratching or damaging the operator panel lens cover.
  • Page 204: Operator Panel Cable Removal

    4060-xxx Operator panel cable removal Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable. Remove the left cover. See “Left door removal” on page 4-9. Remove the upper front cover. See “Upper front cover removal”...
  • Page 205: Optional 250 Or 500-Sheet Paper Tray Assembly Removal

    4060-xxx Optional 250 or 500-sheet paper tray assembly removal Note: Remove the printer and other paper feed options to access the failing optional paper tray assembly. Paper tray autocompensator assembly removal Remove the printer and other paper feed options. Disconnect the autocompensator assembly bias spring from the tray frame. Disconnect the autocompensator assembly motor cable.
  • Page 206: Outer Shield Removal

    4060-xxx Outer shield removal Remove the left door. See “Left door removal” on page 4-9. Loosen the outer shield mounting screws (A) and remove the shield. A(202) A(202) Paper alignment assembly removal Remove the upper paper deflector assembly. See “Upper paper deflector assembly removal” on page 4-63.
  • Page 207 4060-xxx Remove the paper alignment assembly mounting screws (A). Locate the paper alignment assembly reference adjustment screw (B) through the left frame and remove the screw. Remove the paper alignment assembly. Note: Do the “Paper alignment assembly adjustment” on page 4-4 when you reinstall the assembly.
  • Page 208: Paper Bin Full Sensor Flag Assembly Removal

    4060-xxx Paper bin full sensor flag assembly removal Remove the left door. Remove the right cover. Remove the rear paper deflector. Press the fuser wiper cover latch and remove the cover. Loosen screw (A) and remove the two screws (B) on the left side. B(102) A(323) Remove the mounting screws (C) from the right side.
  • Page 209: Pick Roll Removal (Mpt)

    4060-xxx Lift the right corner of the laser assembly cover to access the flag. Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting bracket. Pick roll removal (MPT) Remove the upper paper deflector. See “Upper paper deflector assembly removal”...
  • Page 210: Printhead Removal

    4060-xxx Printhead removal Remove the laser assembly cover. See “Laser cover removal” on page 4-14. Disconnect the printhead cables (A) from the printhead assembly. Remove the printhead mounting screws (B) and remove the printhead. Note: Do the “Printhead assembly adjustment” on page 4-3 whenever you remove or replace the printhead assembly or loosen the mounting screws.
  • Page 211: Redrive Assembly Removal

    4060-xxx Redrive assembly removal Remove the redrive door assembly. Remove the redrive exit cover. Remove the redrive assembly mounting screws (A). Release the redrive assembly mounting latches (B) and remove the redrive assembly. 4-57 Repair information...
  • Page 212: Smart Contact Assembly Removal

    4060-xxx Smart contact assembly removal Remove the print cartridge. Remove the left side door. See “Left door removal” on page 4-9. Remove outer system board shield. See “Outer shield removal” on page 4-52. Disconnect smart cartridge cable from connector J19 on the system board. Remove smart cartridge contact assembly mounting screw (B).
  • Page 213 4060-xxx Remove the five system board mounting screws (A). Remove the USB screw (B) A(232) A(102) Remove the system board. Remove the communications board mounting screw (C). D(201) C(232) Remove the communications board shield mounting screw (D). The communications board is held in place by a ground clip (E) that attaches the communications board shield to the side frame.
  • Page 214 4060-xxx System board installation Note: The replacement system board assembly contains a communications board connected to the system board. To install, you need to separate the boards. Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESD- sensitive parts” on page 4-1.
  • Page 215: Toner Sensor Removal

    4060-xxx Toner sensor removal Remove the right side cover. See “Right cover removal” on page 4-10. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable and remove the toner sensor. A(102) Transfer roll assembly removal Open the upper front cover and remove the print cartridge. Unsnap the transfer roll assembly from the left pivot arm.
  • Page 216: Upper Front Cover Hinge Assembly Removal

    4060-xxx Upper front cover hinge assembly removal Remove the upper front cover. See “Upper front cover removal” on page 4-12. Remove the laser cover assembly. See “Laser cover removal” on page 4-14. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and remove the pins.
  • Page 217: Upper Paper Deflector Assembly Removal

    4060-xxx Upper paper deflector assembly removal Open the multipurpose tray and remove the tray from the two mounting posts. Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right. Remove the upper deflector assembly. 4-63 Repair information...
  • Page 218 4060-xxx 4-64 Service Manual...
  • Page 219: Connector Locations

    4060-xxx 5. Connector locations Autoconnect Connector Pin no. Signal (static) Bottom autoconnect +24 V dc 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc Front autoconnect 0 V dc 0 V dc 0 V dc +5 V dc 0 V dc +24 V dc...
  • Page 220: Envelope Feeder Board

    4060-xxx Envelope feeder board Connector Pin no. Signal Ground Tx (EOC) Ground Rx (EOC) +24 V dc Return +24 V dc Ground Paper Present +5 V dc Ground Paper Present +5 V dc Motor - Phase B- Motor - Phase A- Motor - Phase B+ Motor - Phase A+ Fuser Board...
  • Page 221: High-Capacity Output Stacker Board

    4060-xxx High-capacity output stacker board Connector Pin no. Signal +24 V dc Autoconnect Ground +5 V dc Prtxdin Ground prtrxd Ground +24 V dc Autoconnect Ground +5 V dc prtxdout Ground prtrxd Ground J3 Pass thru Ground sensor Paper Present RVsnsr J4 DC motor mtrout1...
  • Page 222: High Voltage Power Supply

    4060-xxx High voltage power supply Connector CN no. Signal CN1 System board Developer PWM +24 V dc Return Charge PWM T302 +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT Service Manual...
  • Page 223: Interconnect Board

    4060-xxx Interconnect board Connector Pin no. Signal 200/210/400/410 J1 System board (comm board) J2 LVPS +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc BAR CODE AREA +24V Ground Ground Ground Ground J3 LVPS Ground Ground Ground 000/010...
  • Page 224: Low Voltage Power Supply

    4060-xxx Low voltage power supply CN pin Connector Signal CN1 Fuser lamp AC AC fuser lamp Not used AC fuser lamp CN2 DC output +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc...
  • Page 225: Output Expander Control Board

    4060-xxx Output expander control board Connector Pin no. Signal +24 V dc Autoconnect Ground +5 V dc Prtxdin Ground prtrxd Ground +24 V dc Autoconnect Ground +5 V dc prtxdout Ground prtrxd Ground J3 Pass thru Ground sensor Paper Present RVsnsr J4 DC motor mtrout1...
  • Page 226: Staplesmart Finisher

    4060-xxx StapleSmart finisher Connector Pin no. Signal Staple card assembly J1A Bottom +24 V dc autoconnect Ground +5 V in J14B J1B Bottom rtxdin J14A autoconnect Ground prtrxd Ground Ground J2 Feed motor fdmtr1 fdmtr2 Ground Ground tachft 5Vptt J3 Stepper stpmtr- motor stpmtr-...
  • Page 227 4060-xxx Connector Pin no. Signal Staple card assembly (continued) J7 Right side Ground sensor board Bottom J14B Ground J14A J8 Solenoid Sol2- +24 V dc J9 Bin empty Ground sensor bnempty- 5Vsnsr2 J10 Left side Ground sensor board full+ NRFull+ Ground J12 Pass thru Ground...
  • Page 228: System Board-Non-Network

    4060-xxx System board—non-network J15 J19 49 100 5-10 Service Manual...
  • Page 229: System Board-Network

    4060-xxx System board—network J15 J19 49 100 5-11 Connector locations...
  • Page 230 4060-xxx System board—non-network and network (see “System board—non-network” on page 5-10 “System board—network” on page 5-11) Connector Pin no. Signal J1 (not used) J2 Printhead (laser cable) Video Level 2+ Video3* Ground +5PHead LPOW LADJ* LPOW FB LENA* J3 Cover closed switch Cov Closed Ground +5V dc...
  • Page 231 4060-xxx System board—non-network and network (see “System board—non-network” on page 5-10 “System board—network” on page 5-11) Connector Pin no. Signal J13 USB connector J1 G12 Ground USB +5 USB MINUS 2 USB PLUS 3 Ground J1 G2 Ground J14 Fuser DC NARMEDIA* Ground THERM...
  • Page 232 4060-xxx System board—non-network and network (see “System board—non-network” on page 5-10 “System board—network” on page 5-11) Connector Pin no. Signal J22 HVPS ATSERVO TXCURPWM TXENABLE TDXPWM +24V dc CHGPWM Ground DEVB input sensor Ground INSENSE cartridge sensor +5V dc TONER WHEEL Ground J23 (not used for non-network model) 49 100...
  • Page 233 4060-xxx System board—non-network and network (see “System board—non-network” on page 5-10 “System board—network” on page 5-11) Connector Pin no. Signal J25 Autocomp motor +5V_TRAY1 +5v_SWITCHED PAPER_OUT-IN AUTOCOMP_ENC PAPER_LOW_IN Ground Ground Ground AUTOCOMP_OUT1 AUTOCOMP_OUT2 J26 MPF paper out MPF POUT Ground MPF LED J27 (not used) J28 Autocompensator...
  • Page 234 4060-xxx System board—non-network and network (see “System board—non-network” on page 5-10 “System board—network” on page 5-11) Connector Pin no. Signal J34 Paper size sensor PSIZE2 Ground PSIZE1 PSIZE3 Ground TRAY1 POUT TRAY1 PLOW* +3.3V dc autocomp motor ENCODER +5V dc J35 System board edge connector J36 (not used)
  • Page 235: 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 No requirements for this printer. Scheduled maintenance The operator panel displays the message “80 Scheduled Maintenance” at each 300K page count interval.
  • Page 236 4060-xxx Service Manual...
  • Page 237: Parts Catalog

    The parts catalog uses the last three digits of the type to identify model specific replacement FRUs. Model name Configuration Machine type Parts catalog Lexmark T630 Non-network 4060-000 Lexmark T630n Network 4060-010 Lexmark T632 Non-network 4060-200 Lexmark T632n Network 4060-210 Lexmark T634 Non-network 4060-400 Lexmark T634n Network...
  • Page 238: Assembly 1: Covers

    4060-xxx Assembly 1: Covers Service Manual...
  • Page 239 Hinge, upper front cover 56P1306 Cover, right side, 250-sheet output, 000/010 56P1307 Cover, right side 500-sheet output, 200/210/400/410 99A0007 Label, TLI/ID/serial number—blank 56P1303 Upper front cover with Lexmark logo 56P1308 Latch, upper cover 56P1309 Cover assembly, lower front 99A0004 Spring, latch 56P1356...
  • Page 240: Assembly 2: Frame 1

    4060-xxx Assembly 2: Frame 1 Service Manual...
  • Page 241 4060-xxx Assembly 2: Frame 1 Asm- Part Units Description index number 2—1 56P1322 Frame, EP module, 000/010 56P1347 Frame, EP module, 200/210/400/410 56P1320 Right side frame assembly 99A1540 Nut plate, frame extension, 200/210/400/410 99A0263 Parts packet, screw 99A1518 Frame extension, right, 200/210/400/410 99A1538 Contact, RSF ground 99A1517...
  • Page 242: Assembly 3: Frame 2

    4060-xxx Assembly 3: Frame 2 Service Manual...
  • Page 243 4060-xxx Assembly 3: Frame 2 Asm- Part Units Description index number 3—1 99A1857 Upper redrive deflector 99A0104 Upper diverter spring 99A2151 Redrive assembly, 250 in/250 out, 000/010 56P1328 Redrive assembly, 500 in/500 out, 200/210/400/410 56P1318 Duct, main cap 99A0263 Parts packet, screw 99A2021 Support, right stacker plate, 000/010 56P1319...
  • Page 244 4060-xxx Assembly 3 (cont.): Frame 2 Service Manual...
  • Page 245 4060-xxx Assembly 3 (cont.): Frame 2 Asm- Part Units Description index number 3—34 99A1596 Contact, LSF ground 56P1317 Duct, left stacker, 250-sheet, 000/010 99A2016 Duct, left stacker, 500-sheet, 200/210/400/410 56P1351 Door assembly, redrive 250-sheet 56P1329 Door assembly, redrive 500-sheet 99A1613 Flag, output paper level, 000/010 56P1316 Flag, output paper level, 200/210/400/410...
  • Page 246: Assembly 4: Printhead 1 (000/010)

    4060-xxx Assembly 4: Printhead 1 (000/010) 000/010 Asm- Part Units Description index number 4—1 56P1386 Cable, laser 99A0263 Parts packet, screw (printhead mounting) 56P1396 Printhead assembly (includes all cables), 000/010 56P1387 Cable, HSYNC 56P1388 Cable, mirror motor, 000/010 7-10 Service Manual...
  • Page 247: Assembly 5: Printhead 2 (200/210)

    4060-xxx Assembly 5: Printhead 2 (200/210) View Bottom View 200/210 Asm- Part Units Description index number 5—1 56P1386 Cable, laser 99A0263 Parts packet, screw (printhead mounting) 56P1443 Printhead assembly (includes all cables), 200/210 56P1387 Cable, HSYNC 7-11 Parts catalog...
  • Page 248: Assembly 6: Printhead 3 (400/410)

    4060-xxx Assembly 6: Printhead 3 (400/410) View Bottom View 400/410 Asm- Part Units Description index number 6—1 56P1386 Cable, laser 99A0263 Parts packet, screw (printhead mounting) 56P1854 Printhead assembly (includes all cables), 400/410 56P1387 Cable, HSYNC 7-12 Service Manual...
  • Page 249: Assembly 7: Paper Feed-Autocompensator

    4060-xxx Assembly 7: Paper feed—autocompensator Asm- Part Units Description index number 7—1 56P1325 Pick arm assembly (500-sheet), 200/210/400/410 56P1326 Pick arm assembly (250-sheet), 000/010 56P1337 Parts packet, bellcrank and spring for 250 tray, 000/010 56P1331 Parts packet, bellcrank and spring for 500 tray, 200/210/400/410 99A0070 Pick roll assembly 56P1324...
  • Page 250: Assembly 8: Paper Feed-Multipurpose Feeder

    4060-xxx Assembly 8: Paper feed—multipurpose feeder 7-14 Service Manual...
  • Page 251 4060-xxx Assembly 8: Paper feed—multipurpose feeder Asm- Part Units Description index number 8—1 99A0075 Screw, socket set M4X5 mm 99A0071 Arm assembly, MPF 99A0076 Pick roll assembly 99A0084 Flag, MPT paper out 56P1352 MPF pad/separator arm assembly, includes: • Pad, restraint •...
  • Page 252: Assembly 9: Paper Feed-Alignment

    4060-xxx Assembly 9: Paper feed—alignment 7-16 Service Manual...
  • Page 253 4060-xxx Assembly 9: Paper feed—alignment Asm- Part Units Description index number 9—1 56P1327 Alignment assembly paper feed 99A0263 Parts packet, screw (clip ref ground mounting) 56P1349 Clip, reference ground 56P1346 Parts packet (reference adjust) • Screw, paper reference adjust • Washer, paper reference adjust •...
  • Page 254: Assembly 10: Integrated Paper Tray-250-Sheet

    4060-xxx Assembly 10: Integrated paper tray—250-sheet 7-18 Service Manual...
  • Page 255 4060-xxx Assembly 10: Integrated paper tray—250-sheet Asm- Part Units Description index number 10—1 99A1536 Tray, integrated 250-sheet 99A1601 Latch, back restraint 99A2160 Restraint, back 250-sheet tray 99A0120 Restraint pad 99A1894 Restraint, side 250-sheet tray 56P1229 Wear strips 99A1812 Label, tray option number 99A0121 Clip, 250-sheet tray wear 99A0126...
  • Page 256: Assembly 11: Integrated Paper Tray-500-Sheet

    4060-xxx Assembly 11: Integrated paper tray—500-sheet 7-20 Service Manual...
  • Page 257 4060-xxx Assembly 11: Integrated paper tray—500-sheet Asm- Part Units Description index number 11—1 99A1576 Tray assembly 500-sheet 99A1895 Restraint, side 99A0292 Strip, wear 99A1812 Label, tray option number 99A1583 Plate, 500-sheet tray wear 99A0126 Finger, autosize 99A0124 Plate, snap-in 99A1582 Slider, autosize 500-sheet 99A0120 Restraint pad...
  • Page 258: Assembly 12: Drives-Main Drive And Developer Drive

    4060-xxx Assembly 12: Drives—Main drive and developer drive 7-22 Service Manual...
  • Page 259 4060-xxx Assembly 12: Drives—Main drive and developer drive Asm- Part Units Description index number 12—1 56P1330 Gearbox, w/motor, 000/010 56P1332 Gearbox, w/motor, 200/210 56P1858 Gearbox, w/motor, 400/410 99A0134 Shaft, power takeoff 250, 000/010 99A1569 Shaft, power takeoff 500, 200/210/400/410 99A0275 Spring, power takeoff shaft 56P2162 Gear, bevel with grease packet and washer...
  • Page 260: Assembly 13: Hot Roll Fuser

    4060-xxx Assembly 13: Hot roll fuser 7-24 Service Manual...
  • Page 261 4060-xxx Assembly 13: Hot roll fuser Asm- Part Units Description index number 13—1 56P2542 Fuser assembly w/115V lamp, 000/010/200/210 56P2543 Fuser assembly w/100V lamp, 000/010/200/210 56P2544 Fuser assembly w/220V lamp, 000/010/200/210 56P2545 Fuser assembly w/115V lamp, 400/410 56P2546 Fuser assembly w/220V lamp, 400/410 56P2547 Fuser assembly w/100V lamp, 400/410 99A1658...
  • Page 262: Assembly 14: Transfer/Charging

    4060-xxx Assembly 14: Transfer/charging 7-26 Service Manual...
  • Page 263 4060-xxx Assembly 14: Transfer/charging Asm- Part Units Description index number 14—1 99A0512 Parts kit, charge roll link asm, left side 99A1017 Roll assembly, charge 99A1555 Bushing, charge roll 99A0513 Parts kit, charge roll link asm, right side 56P1357 Transfer roll assembly 99A0349 Arm, transfer roll assembly right 99A0184...
  • Page 264: Assembly 15: Electronics-Power Supplies

    4060-xxx Assembly 15: Electronics—power supplies 7-28 Service Manual...
  • Page 265 4060-xxx Assembly 15: Electronics—power supplies Asm- Part Units Description index number 15—1 56P1369 LVPS, 110 V ac, 000/010 56P1371 LVPS, 110 V ac, 200/210/400/410 56P1372 LVPS, 220 V ac, 000/010 56P1374 LVPS, 220 V ac, 200/210/400/410 56P1365 Fuse, for 110 V ac LVPS 5 a/250V (fuse F1), 000/010 56P1367 Fuse, for 220 V ac LVPS 3.15 a/250V (fuse F1), 200/210/400/410 56P1366...
  • Page 266: Assembly 16: Electronics-Card Assemblies

    4060-xxx Assembly 16: Electronics—card assemblies 7-30 Service Manual...
  • Page 267 4060-xxx Assembly 16: Electronics—card assemblies Asm- Part Units Description index number 16—1 56P2410 System board assembly (non-network), 000 includes 56P1444 56P2412 System board assembly (non-network), 200 includes 56P1444 56P2414 System board assembly (non-network), 400 includes 45P1444 56P2411 System board assembly (network), 010 includes 56P1445 56P2413 System board assembly (network), 210...
  • Page 268: Assembly 17: Electronics-Shields

    4060-xxx Assembly 17: Electronics—shields 7-32 Service Manual...
  • Page 269 4060-xxx Assembly 17: Electronics—shields Asm- Part Units Description index number 17—1 99A0263 Parts packet, screw (INA cover mounting) 99A1611 Shield, Ethernet (blank) 99A0263 Parts packet, screw (outer shield mounting) 99A0263 Parts packet, screw (inner shield mounting) 56P1341 Cover, INA flat (blank) 56P2404 Shield, INA flat non-network 56P2405...
  • Page 270 4060-xxx Assembly 18: Cabling diagrams 1 7-34 Service Manual...
  • Page 271: Assembly 18: Cabling Diagrams 1

    4060-xxx Assembly 18: Cabling diagrams 1 Asm- Part Units Description index number 18—1 56P1408 Cartridge fan 56P1360 Fan, main w/cable 56P1391 Sensor, standard bin level with cable 56P1382 Int. card/autocomp card cable (paper low/out sensors) 56P1326 Pick arm assembly (250-sheet) 000/010 56P1325 Pick arm assembly (500-sheet) 200/210/400/410 56P1383...
  • Page 272 4060-xxx Assembly 19: Cabling diagrams 2 7-36 Service Manual...
  • Page 273: Assembly 19: Cabling Diagrams 2

    4060-xxx Assembly 19: Cabling diagrams 2 Asm- Part Units Description index number 19—1 56P1394 Cable assembly, operator panel 56P1385 Cable, front harness (HVPS/input sensor/toner sensor) 56P1395 Switch, cover closed w/cable 56P1398 Sensor, MPF cable 56P2407 MPF solenoid w/cable 56P1399 Smart contact assembly w/cable 56P1389 Cable, deflector 7-37...
  • Page 274 4060-xxx Assembly 20: Cabling diagrams 3 400/410 200/210 000/010 7-38 Service Manual...
  • Page 275: Assembly 20: Cabling Diagrams 3

    4060-xxx Assembly 20: Cabling diagrams 3 Asm- Part Units Description index number 20—1 56P1386 Cable, laser 56P1387 Cable, HSYNC 56P1390 Cable, system board to fuser board 56P1403 Exit sensor 56P1402 Narrow media sensor 56P1405 Cable, AC fuser lamp to LVPS 56P1388 Cable, mirror motor, 000/010 7-39...
  • Page 276: Assembly 21: 250-Sheet Paper Tray

    4060-xxx Assembly 21: 250-sheet paper tray 7-40 Service Manual...
  • Page 277: Assembly 22: 500-Sheet Paper Tray

    4060-xxx Assembly 21: 250-sheet paper tray Asm- Part Units Description index number 21—1 99A0445 Stud assembly, 250-sheet frame 99A0448 Arm, paper out 250-sheet 99A0263 Parts packet, screw (auto comp mounting) 99A1054 Pick arm assembly 99A0277 Wear plate, pass thru 99A0263 Parts packet, screw (wear plate mounting) 99A0276 500 Drive roll assembly...
  • Page 278 4060-xxx Assembly 21 (cont.): 250-sheet paper tray 7-42 Service Manual...
  • Page 279 4060-xxx Assembly 21 (cont.): 250-sheet paper tray Asm- Part Units Description index number 21—36 99A1536 Tray assembly, 250-sheet option 99A0892 Restraint, side 250-sheet tray 99A0119 Wear strips 99A1829 Label, tray option number 99A0121 Clip, 250-sheet tray wear 99A0126 Finger, autosize 99A0127 Slider, autosize 250-sheet 99A0124...
  • Page 280 4060-xxx Assembly 22: 500-sheet paper tray 7-44 Service Manual...
  • Page 281 4060-xxx Assembly 22: 500-sheet paper tray Asm- Part Units Description index number 22—1 99A0350 Sensor, paper low 99A0263 Parts packet, screw (auto comp mounting) 99A0405 Pick arm assembly 99A0070 Pick roll assembly 56P2540 Spring, bellcrank 500-sheet option tray 56P1337 Parts packet, bellcrank and spring 99A1636 Base, 500-sheet tray 99A0058...
  • Page 282 4060-xxx Assembly 22 (cont.): 500-sheet paper tray 7-46 Service Manual...
  • Page 283 4060-xxx Assembly 22 (cont.): 500-sheet paper tray Asm- Part Units Description index number 22—42 99A0286 Spring, backup roller 99A1664 Bellcrank, roller release 99A0273 Gear, bevel 99A0279 Bearing, drive shaft 99A0281 Cable, 250-sheet autoconnect 99A1702 Stud assembly, 500 frame 99A1645 Arm, paper out 500 99A0452 Washer, frame mounting 99A1665...
  • Page 284: Assembly 23: Duplex Option

    4060-xxx Assembly 23: Duplex option 7-48 Service Manual...
  • Page 285 4060-xxx Assembly 23: Duplex option Asm- Part Units Description index number 23—1 56P1414 250 duplex assembly 56P1416 500 duplex assembly 7-49 Parts catalog...
  • Page 286: Assembly 24: Envelope Feeder

    4060-xxx Assembly 24: Envelope feeder 7-50 Service Manual...
  • Page 287 4060-xxx Assembly 24: Envelope feeder Asm- Part Units Description index number 24—1 99A0389 Paper weight assembly 99A1694 Guide, edge 99A1696 Cover, top 99A0485 Sensor, envelope pass thru 99A0393 Clutch, restraint/gear 99A1697 Cover, right side 99A0390 Support, slide out 99A0488 Roller, support 99A0382 Motor, stepper DC 99A1666...
  • Page 288: Assembly 25: Output Expander

    4060-xxx Assembly 25: Output expander 7-52 Service Manual...
  • Page 289 4060-xxx Assembly 25: Output expander Asm- Part Units Description Index Number 25—1 99A1857 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 Screw, PP 99A0263 99A0915 Board, output expander DC motor...
  • Page 290 4060-xxx Assembly 25 (cont.): Output expander 7-54 Service Manual...
  • Page 291 4060-xxx Assembly 25 (cont.): Output expander Asm- Part Units Description Index Number 25—22 99A1748 Door assembly, rear access 99A0368 Shaft assembly, lower, also order PP 99A0572 99A0363 Pulley, drive 99A0371 Cover, right side 99A0361 Belt, 160 gear 99A0362 Arm assembly, belt idler 99A0364 Spring, belt tensioner 99A0351...
  • Page 292: Assembly 26: High-Capacity Output Expander

    4060-xxx Assembly 26: High-capacity output expander 7-56 Service Manual...
  • Page 293 4060-xxx Assembly 26: High-capacity output expander Asm- Part Units Description Index Number 26-1 99A1748 Door asm, rear access 99A1785 Latch, rear door 99A1783 Frame, right 99A1778 Pulley, output tray 99A1782 Shaft, pulley 99A1790 Guide, output tray 99A1779 Spring, output tray 99A1746 Cover, right 99A1747...
  • Page 294 4060-xxx Assembly 26 (cont.): High-capacity output expander Asm- Part Units Description Index Number 26-14 99A0107 Deflector, upper, also order 99A0104 99A0104 Spring, upper diverter 99A0369 Shaft asm, exit upper stacker asm 99A0052 Shaft asm, stacker lower exit upper stacker asm Bearings, shaft PP 99A0572 99A1749 Board asm, high-capacity output stacker...
  • Page 295 4060-xxx Assembly 26 (cont.): High-capacity output expander Asm- Part Units Description Index Number 26-29 99A0913 Shaft, 40T middle output stacker 99A0368 Shaft asm lower 99A0363 Pulley, drive 99A0361 Belt, 160G upper stacker asm 99A0362 Arm asm, belt idler 99A0364 Spring, belt tensioner 99A1791 Stacker asm, paper path lower 99A1792...
  • Page 296: Assembly 27: 5-Bin Mailbox

    4060-xxx Assembly 27: 5-bin mailbox 7-60 Service Manual...
  • Page 297 4060-xxx Assembly 27: 5-bin mailbox Asm- Part Units Description Index Number 27-1 99A1512 Cover, redrive cap 99A1710 Cover, wire 99A1711 Cover, top bin 99A1785 Latch, rear access door 99A0104 Spring, upper diverter 99A1714 Door, rear access 99A1723 Shaft asm, drive 99A1724 Shaft asm, drive w/gear 99A1708...
  • Page 298 4060-xxx Assembly 27 (cont.): 5-bin mailbox 7-62 Service Manual...
  • Page 299 4060-xxx Assembly 27 (cont.): 5-bin mailbox Asm- Part Units Description Index Number 27-30 99A1741 Spring, diverter 99A1727 Frame asm, right side 99A1728 Cam, diverter actuator 99A1731 Spring, diverter actuator 99A1729 Latch, diverter actuator 99A1730 Arbor, diverter actuator 99A1789 C-clip 99A1720 Bracket, attach 99A1732 Solenoid, diverter...
  • Page 300: Assembly 28: High-Capacity Feeder 1

    4060-xxx Assembly 28: High-capacity feeder 1 7-64 Service Manual...
  • Page 301 4060-xxx Assembly 28: High-capacity feeder 1 Asm- Part Units Description index number 28—1 99A0660 Frame, printer support frame 2 99A0675 Parts packet, screw (printer support 2 frame mounting) 99A0698 Clamp, feed frame 99A0675 Parts packet, screw (feed frame clamp) 99A0691 Bearing, Nyliner leadscrew top 99A0656 Cover, left side...
  • Page 302: Assembly 29: High-Capacity Feeder 2

    4060-xxx Assembly 29: High-capacity feeder 2 7-66 Service Manual...
  • Page 303 4060-xxx Assembly 29: High-capacity feeder 2 Asm- Part Units Description index number 29—1 99A0188 Guide, rear paper, use with 99A0219 99A0675 Parts packet, screws (including): • Top frame mounting (6) • Base mounting (2) • Power supply board mtg (2) •...
  • Page 304: Assembly 30: High-Capacity Feeder 3

    4060-xxx Assembly 30: High-capacity feeder 3 7-68 Service Manual...
  • Page 305 4060-xxx Assembly 30: High-capacity feeder 3 Asm- Part Units Description index number 30—1 99A0687 Parts packet, mounting feet 99A0672 Parts packet, foot (stabilizer) 99A1793 Parts packet, screw w/washer (motor mt) 99A1795 Motor assembly, DC 99A1798 Plate, drive pulley 99A1794 Parts packet, nut and washer (drive pulley plate) 99A1796 Belt, DC motor drive 99A1797...
  • Page 306: Assembly 31: High-Capacity Feeder 4

    4060-xxx Assembly 31: High-capacity feeder 4 7-70 Service Manual...
  • Page 307 4060-xxx Assembly 31: High-capacity feeder 4 Asm- Part Units Description index number 31—1 99A0281 Cable, 250-sheet autoconnect 99A0279 Bearing, drive shaft 99A0273 Gear, bevel 99A0276 500 Drive roll assembly 99A0263 Parts packet, screw (frame mounting) 99A0451 Roll, skewed backup 99A0267 Parts packet, retainer (roller) 99A0675 Parts packet, screw (wear plate mounting)
  • Page 308: Assembly 32: High-Capacity Feeder 5

    4060-xxx Assembly 32: High-capacity feeder 5 7-72 Service Manual...
  • Page 309 4060-xxx Assembly 32: High-capacity feeder 5 Asm- Part Units Description index number 32—1 99A0263 Parts packet, screw (auto comp assembly mounting) 99A1055 Arm assembly, pick 2000 99A0070 Roll assembly, pick 99A0692 Base, 2000 option 99A0263 Parts packet, screw (deflector mounting) 99A0678 Deflector, base 99A0288...
  • Page 310: Assembly 33: Kiosk-Vertical Paper Adapter

    4060-xxx Assembly 33: Kiosk—vertical paper adapter 7-74 Service Manual...
  • Page 311 4060-xxx Assembly 33: Kiosk—vertical paper adapter Asm- Part Units Description index number 33—1 99A0231 Bail, support 99A1646 Arm assembly, pivot 99A1819 Mounting, frame assembly 99A0240 Parts packet, retainer 99A0234 Parts packet, screw 99A1705 Gear, idler 99A1704 Gear, idler 99A0197 Shaft, drive rear 99A0079 Tray assembly, backup roller 99A0208...
  • Page 312: Assembly 34: Kiosk-Horizontal Paper Adapter

    4060-xxx Assembly 34: Kiosk—horizontal paper adapter 7-76 Service Manual...
  • Page 313 4060-xxx Assembly 34: Kiosk—horizontal paper adapter Asm- Part Units Description index number 34—1 99A0231 Bail, support 99A1646 Arm assembly, pivot 99A1819 Mounting, frame assembly 99A0240 Parts packet, retainer 99A0234 Parts packet, screw 99A1705 Gear, idler 99A1704 Gear, idler 99A0197 Shaft, drive rear 99A0079 Tray assembly, backup roller 99A0208...
  • Page 314: Assembly 35: Staplesmart Finisher I

    4060-xxx Assembly 35: StapleSmart finisher I 7-78 Service Manual...
  • Page 315 4060-xxx Assembly 35: StapleSmart finisher 1 Asm- Part Units Description index number 35—1 99A2505 Cover, top assembly 99A2510 Clip, brush ground 99A2506 Top cover bail/plate, right side 99A2512 Door, rear access 99A1785 Latch, rear access door 99A2501 Cover, right base assembly 99A2503 Cover, stapler access 99A2502...
  • Page 316: Assembly 36: Staplesmart Finisher 2

    4060-xxx Assembly 36: StapleSmart finisher 2 7-80 Service Manual...
  • Page 317 4060-xxx Assembly 36: StapleSmart finisher 2 Asm- Part Units Description index number 36—1 99A2575 Stapler cartridge holder 321-C 99A2526 Stapler assembly 99A2556 Bracket, attach 99A0263 Parts packet, screws 99A1820 Belt, 185G 99A2544 Card assembly, right stapler bin level 99A0362 Arm assembly, belt idler 99A2545 Spring, swing arm 99A2548...
  • Page 318: Assembly 37: Staplesmart Finisher 3

    4060-xxx Assembly 37: StapleSmart finisher 3 7-82 Service Manual...
  • Page 319 4060-xxx Assembly 37: StapleSmart finisher 3 Asm- Part Units Description index number 37—1 99A0263 Parts packet, screws 56P1747 System card assembly, stapler option 99A2531 Switch assembly, top cover open 99A2539 Flange, pulley 99A0104 Spring, upper diverter 99A2540 Bearing, redrive 99A2517 Shaft assembly, upper exit 99A2516 Deflector, upper...
  • Page 320: Assembly 38: Staplesmart Finisher 4

    4060-xxx Assembly 38: StapleSmart finisher 4 7-84 Service Manual...
  • Page 321 4060-xxx Assembly 38: StapleSmart finisher 4 Asm- Part Units Description index number 38—1 99A2559 Paper alignment wheel 99A2480 Kit, maintenance StapleSmart wheels 99A2525 Sensor, stapler pass thru 99A2530 Cable assembly, right stapler bin level 99A2534 Ground cable, stapler tray bar 99A2524 Cable, stapler 99A2532...
  • Page 322: Assembly 39: Options

    4060-xxx Assembly 39: Options Asm- Part Units Description index number 56P0695 8MB memory option 56P0696 16MB memory option 56P0697 32MB memory option 56P0698 64MB memory option 56P0699 128MB memory option 56P1417 16MB Flash card 56P1418 32MB Flash card 56P1850 Card assembly, Bar Code 56P2468 Card assembly IPDS and SCS/TNe 56P1851...
  • Page 323 4060-xxx Assembly 39 (cont.): Options Asm- Part Units Description index number 56P1427 Optra Forms 32MB Flash card 56P1428 Optra Forms 16MB Flash card 56P1429 Simplified Chinese font card 56P1430 Traditional Chinese font card 56P1438 Japanese font card 56P1101 Cable assembly, 6’ parallel, A-C 56P0161 Cable assembly, SER+PAR 1284C INA 56P0162...
  • Page 324: Assembly 40: Miscellaneous

    4060-xxx Assembly 40: Miscellaneous Asm- Part Units Description index number 99A1633 Parts packet, screw 99A0585 Parts packet, contact kit 99A0267 Parts packet, retainers 99A0268 Parts packet, springs paper feed 99A0269 Parts packet, duplex option fan mounting 99A0299 Parts packet, duplex option cam follower assembly 99A0271 Parts packet, envelope option gears 99A0404...
  • Page 325: Index

    4060-xxx Index Numerics autocompensator, integrated tray parts catalog 7-13 1565 Emul Error Load Emul Option 2-32 pick roll installation 4-39 200 Paper Jam - Remove Cartridge 2-30 removal 4-35 201 Paper Jam - Remove Cartridge 2-30 autoconnect connections, top 202 Paper Jam - Open Rear Door 2-30 231 Duplex Paper Jam - Rear 2-30...
  • Page 326 4060-xxx diagnostic aids device tests envelope feeder disk test/clean connections flash test parts catalog 7-50 quick disk test service check 2-49 diagnostic mode sub error codes 2-13 duplex tests EP frame removal 4-20 duplex feed 1 test error codes duplex feed 2 test error log duplex motor test ESD-sensitive parts...
  • Page 327 4060-xxx maintenance ESD-sensitive parts inner paper deflector removal 4-33 lubrication inner shield maintenance kit parts catalog 7-32 preventive removal 4-34 safety inspection guide input sensor removal 4-34 maintenance approach input tray feed test 3-10 maintenance kits input tray sensor test 3-10 maintenance page count 3-17...
  • Page 328 4060-xxx printhead 000/010 7-10 packaging 7-88 200/210 7-11 page count, setting 3-17 400/410 7-12 paper and media specifications StapleSmart finisher 7-79 paper bin full sensor flag assembly 4-54 transfer⁄ charging 7-26 paper deflector assembly pick roll (MPT) removal 4-55 inner 4-33 pick rolls, integrated tray autocompensator 4-38...
  • Page 329 4060-xxx lower deflector assembly 4-47 duplex option 2-47 main drive assembly 4-44 envelope feeder 2-49 main fan 4-46 fuser 2-52 multipurpose tray/lower deflector assembly 4-47 fuser solenoid 2-55 operator panel assembly 4-48 high-capacity feeder input tray 2-56 operator panel bezel 4-49 high-capacity output stacker 2-62...
  • Page 330 4060-xxx output expander option 2-36 paper trays 2-36 StapleSmart finisher 2-37 system board connectors 5-10, 5-11 installation 4-60 parts catalog 7-30 removal 4-58 toner sensor removal 4-61 tools 1-14 transfer roll assembly parts catalog 7-26 removal 4-61 service check 2-94 unique tools 1-14 upper front cover hinge assembly removal...
  • Page 331: Part Number Index

    ..... 7-3 56P1303 Upper front cover with labels w/Lexmark logo ........7-3 56P1305 Hinge, upper front cover .
  • Page 332 4060-xxx 56P1316 Flag, output paper level, 200/210/400/410 ......... . .7-9 56P1317 Duct, left stacker, 250-sheet, 000/010 .
  • Page 333 4060-xxx 56P1383 Cable, autoconnect bottom ............7-35 56P1384 Cable, main drive motor .
  • Page 334 4060-xxx 56P1755 Kit, operator panel overlay-Czech and Hungarian ........7-3 56P1756 Kit, operator panel overlay-Danish, Finnish, Norwegian, and Swedish .
  • Page 335 4060-xxx 99A0070 Pick roll assembly ........... 7-13 7-41 7-45 99A0070 Roll assembly, pick...
  • Page 336 4060-xxx 99A0263 Parts packet, screw (hanger) ........... .7-13 99A0263 Parts packet, screw (INA cover mounting) .
  • Page 337 4060-xxx 99A0362 Arm asm, belt idler ............7-59 99A0362 Arm assembly, belt idler .
  • Page 338 4060-xxx 99A0491 Bracket, stack limiter ............7-51 99A0494 Spring, cam clutch .
  • Page 339 4060-xxx 99A0677 Parts packet, washers high-capacity feeder ......... 7-88 99A0678 Deflector, base .
  • Page 340 4060-xxx 99A1541 Clip, external ground ............7-9 99A1544 Developer drive assembly .
  • Page 341 4060-xxx 99A1712 Tray, paper cap ............. . . 7-61 99A1713 Support, paper tray .
  • Page 342 4060-xxx 99A1788 Retainer, R-ring ............. . .7-63 99A1789 C-clip .
  • Page 343 4060-xxx 99A2503 Cover, stapler access ............7-79 99A2504 Cable assembly, left stapler bin level .
  • Page 344 4060-xxx I-20 Service Manual...