Page 1 ™ Lexmark C760, C762 5060-4xx • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. ImageQuick, Optra Forms, and PrintCryption are trademarks of Lexmark International, Inc.
Page 3: Table Of Contents
5060-4xx Table of contents Notices and safety information ......... . . xi Laser notice .
Page 4 5060-4xx 132 error code ..............2-52 133 error code .
Page 5 5060-4xx Print quality service check ............2-130 Blank page (no image) .
Page 6 5060-4xx Diagnostics mode ..............3-13 Entering Diagnostics mode .
Page 7 5060-4xx EP SETUP ..............3-34 EP Defaults .
Page 8 5060-4xx Printhead removal and adjustments ..........4-60 Identifying the printheads .
Page 9 5060-4xx Parts catalog ................How to use this parts catalog .
Page 10 5060-4xx Registration and alignment ............B-8 Quick Test Page .
Page 11: Notices And Safety Information
5060-4xx Notices and safety information The following laser notice labels may be affixed to this printer as shown: Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Page 12 5060-4xx Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
Page 13 5060-4xx Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Page 14 5060-4xx Service Manual...
Page 15: Safety Information
5060-4xx Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
Page 16 5060-4xx Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
Page 17 5060-4xx Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 18: Preface
5060-4xx Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are, as well as general environmental and safety instructions. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs).
Page 19: General Information
5060-4xx 1. General information The Lexmark™ C76x is a network-capable color printer that uses electrophotographic technology to deliver high quality images, presentation graphics, line art, and text. It prints up to 25 pages per minute (ppm) for both four- color and monochrome print jobs.
Page 20: Options And Features
5060-4xx Options and features Lexmark C76x paper handling options support the Lexmark C750/C752/C76x printers, however the color of the covers do not match the C750 and C752 models. The C76x envelope drawer is not compatible with the C750. Note: Do not use Lexmark C750/C752 options on the Lexmark C76x printers.
Page 21: Toner Darkness
The toner darkness default setting is 4. Color level 4 and level 5 are the same. The toner darkness setting is available through the operator panel under the Print Quality menu or through the Lexmark PostScript driver. Setting Delta toner from default (mono)
Page 22: Printer Specifications
28.9 in. 132 lb (including duplex and optional (604.5 mm) (469.9 mm) (734.1 mm) (60 kg) 500-sheet drawer) Lexmark C762 with Finisher T 59.4 in. 28.1 in. 43.5 in. 274.5 lb (including duplex unit, optional (1508.8 mm) (713.7 mm) (1104.9 mm) (124.7 kg)
Page 23 Power and electrical specifications Average nominal power requirements for the base printer configuration (110 volt). (Power levels are shown in watts.) Maximum current shown in amp ergs. Printing states Lexmark C76x(n) Lexmark C76xdn Printing - average power Base model All options...
Page 24: Print Speed And Performance Print Speed
5060-4xx Environment Printer Temperature and Humidity • Operating – Temperature: 60 to 90° F (15.6 to 32.3° C) – Relative humidity: 8 to 80% – Maximum wet bulb temperature: 73° F (22.8° C) – Altitude: 10,000 ft. (0 to 3,048 meters) –...
Page 25 5060-4xx Media size—Tray 1 Smaller sizes, reduced throughput Nearly narrow (for example, More than 6.8 in., but less B5 or Exec) than 8.3 in. wide Narrow media (for Less than 6.8 in. wide example, A5). The first 25 narrow pages print at rated speed; subsequent pages print at the speed shown. Once the printer enters a reduced throughput mode as indicated, the printer remains at the given speed after the last sheet of smaller media, until the fuser return to standby temperature.
Page 26: Duty Cycle
Standby times may be longer if the toner control senses that toner flow needs to be checked or adjusted. Processor Lexmark C76x Lexmark C76x(n), dn Processor frequency (Mhz) Bus frequency (Mhz) Duty cycle •...
Page 27: Available Memory Options
5060-4xx Available memory options Optional 64MB, 128MB, 256MB and 512MB SDRAM DIMMs are available from Lexmark. The memory options are 168-pin synchronous DRAM DIMMs (dual in-line memory modules) meeting or exceeding the following specifications: • 100MHz or greater • 4KB refresh rate •...
Page 28: Media Specifications
The capacities listed below are based on plain paper at 75g/m Capacity (sheets) Media source or output Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark description C760 C760n C760dn C760dtn C762 C762n C762dn C762dtn Input Standard input sources Tray 1 Tray 2...
Page 29: Media Type
5060-4xx Capacity (sheets) Media source or output Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark description C760 C760n C760dn C760dtn C762 C762n C762dn C762dtn Output Standard output bin capacity Optional outputs 5-Bin mailbox (maximum of one) Output Expander Finisher S or T...
Page 30: Media Size
5060-4xx Media size Media size supported 5, 6, 7 A4 8.27 in. x 11.7 in. (210 mm x 297 mm) A5 5.83 in. x 8.27 in. (148 mm x 210 mm) JIS-B5 7.17 in. x 10.12 in. (182 mm x 257 mm) Statement 5.5 in.
Page 31 5060-4xx Media size supported Envelope 7 ¾ 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 32: Index
5060-4xx Input media types and weights Media Weight Integrated trays and optional 500-sheet drawer b, f Paper Xerographic or 16 to 19.9 lb bond (60 to 74.9 g/m grain long) business paper 20 to 47 lb bond (75 to 176 g/m grain long) Specialty papers Gloss 60 to 120 lb book (88 to 176 g/m...
Page 33: Output Media Types And Weights
Refer to the Converter Listing on Lexmark's Home Page and Automated FAX system (LEXFAX ) for information on whether your vinyl label converter has passed Lexmark's criteria. Refer to the Card Stock and Label Guide for more details. Lexmark transparency numbers 12A5940 and 12A5941 are supported from the standard tray, optional 500- sheet trays and the multipurpose feeder.
Page 34 Vinyl labels are supported only when printing environment and media are 20 to 23° C (68 to 90°F). Refer to the Converter Listing on Lexmark's Home Page and Automated FAX system (LEXFAX) for information on whether your vinyl label converter has passed Lexmark's criteria. Refer to the Card Stock and Label Guide for more details.
Page 35: Web Oiler Upgrade Kit And Replacements
56P1557 The installation of the web oiler upgrade kit converts a standard Lexmark C76x printer to an oil web capable printer. The web oiler upgrade kit includes an oiler fuser and web oiler. For replacements for the web oiler, see “Web oiler fusers and web oiler replacements”...
Page 36: Acronyms
5060-4xx Acronyms BLDC Brushless DC Motor Black Only Retract Cyan Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT High-Capacity Input Tray HCOF High-Capacity Output Finisher HVPS...
Page 37: Diagnostic Information
5060-4xx 2. Diagnostic information Start CAUTION: Unplug power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The printer weighs 47.7 kg (105 lb.) and requires at least two people to lift it safely.
Page 38: Por (Power-On Reset) Sequence
5060-4xx POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed. Power the machine on. +5V LED (Power ON) on the system board comes on. Operator Panel LED comes on solid.
Page 39: Symptom Tables
5060-4xx Symptom tables Symptom table - base printer Symptom Action Fuser fan fails to run or is noisy Go to “925 error code” on page 2-85. RIP fan fails to run or is noisy Go to “927 error code” on page 2-86.
Page 40: Symptom Table - 500-Sheet Drawer Option
5060-4xx Symptom Action Print quality: Poor color alignment Go to “Poor color alignment” on page 2-136. Print quality: Toner on the back of the page Go to “Toner is on the back of the printed page” on page 2-139. Print quality: Toner smears or rubs off the page Go to “Toner smears or rubs off the page with no error code displayed”...
Page 41: Symptom Table - 5-Bin Mailbox Option
5060-4xx Symptom table - 5-bin mailbox option Symptom Action Printer fails to recognize the option is installed. Paper Go to “The printer does not recognize one or more feeds into the standard bin. output options as installed.” on page 2-99. Ready Bin x Full displays and won’t clear Go to “Ready bin x full message - may be able to...
Page 42: Error Code Table
5060-4xx Error code table Error code Action 9xx service errors 900 RIP Software Error Go to “900 RIP Software Error” on page 2-83. 902 Service Engine Error 0 General Engine Software Errors 902 through 907 indicate an unrecoverable engine software error. The system board may cause this type of error.
Page 43 5060-4xx Error code Action 955 Code CRC <loc> System board - This error indicates that the Code ROM or NAND failed the CRC check. The location of the failure is indicated by <loc>. Replace the system board. See “System board” on page 4-72.
Page 44: 1Xx Service Errors
5060-4xx Error code Action 983 <device> comm Invalid command received by the specified device. Note: This message is used for multiple bin output devices. Note: Check the autoconnects above and below the failing option to make sure they are seated and connected correctly. Go to service check for the device indicated.
Page 45 5060-4xx Error code Action 107 Printhead Error Magenta printhead lost Hsync Check for the correct installation of all the cables to the system board assembly and to the printhead assembly; J11 and J12 on the system board. Go to “System board” on page 5-8.
Page 46 5060-4xx Error code Action 113 Printhead Error No first Hysnc - black Check for the correct installation of all the cables to the system board and in the printhead assembly; J12 and J13 on the system board. Go to “System board” on page 5-8.
Page 47 5060-4xx Error code Action 117 Printhead Error A yellow printhead servo error has been detected. Verify all packing material have been removed from the printer and the printhead. If error persists, see “Printhead diagnostics” on page 3-1. 120 Fuser Error Wrong fuser lamp - hot roll - replace the fuser assembly.
Page 48 5060-4xx Error code Action 141 Motor DC pick motor excessive PWM - registration (staging) motor - replace the “Registration motor” on page 4-69. If this does not fix the problem, replace the “System board” on page 4-72. 142 Motor DC pick motor, over speed - registration (staging) motor - replace the “Registration motor”...
Page 49 5060-4xx Error code Action 164 Motor Cyan cartridge BLDC motor mfg. unknown - go to “164 error code” on page 2-64. 165 Motor Yellow cartridge BLDC motor mfg. unknown - go to “165 error code” on page 2-65. 167 Motor The incorrect configuration ID.
Page 50: Programming Errors - P101 Through P116
5060-4xx Programming errors - P101 through P116 These error codes may be displayed whenever a new code upgrade has been attempted. It is possible that the wrong type of code, network versus non-network, or a corrupted file was probably sent to the printer. Verify that the correct type of code is being flashed to the printer.
Page 51: 2Xx Paper Jams
5060-4xx 2xx Paper Jams User primary User secondary Explanation message message 200 Paper Jam Leave sheets in Primary: This message indicates that a paper jam has Clear Paper Path Finisher area 5 occurred at or near the printer Input Sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.
Page 52 5060-4xx User primary User secondary Explanation message message 230 Paper Jam Leave Job in Primary: Paper has most likely jammed in the duplex option. Clear Paper Path Finisher area 5 Remove the duplex tray to access the jam. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam...
Page 53 5060-4xx User primary User secondary Explanation message message 272 Paper Jam Leave Job in Primary: Media is jammed in the 5-Bin Mailbox Option. Clear Paper Path Finisher area 5 Open the rear door of option to access the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the...
Page 54: Sub Error Code Table
5060-4xx Sub error code table Use this table to troubleshoot the printer when 9xx and 2xx Error Codes are displayed. When a 9xx or 2xx error code is displayed, press and hold Return and press Select to view the Sub error code. Sub error code Explanation 2D 00...
Page 55 5060-4xx Sub error code Explanation 2D 1D Fuser exit sensor obstructed. 2D 1E Duplex sensor(s) obstructed. 2D 1F Tray 2 sensor obstructed. 2D 20 Tray 3 sensor obstructed. 2D 21 Tray 4 sensor obstructed. 2D 22 Pass thru sensor in Stacker 1 obstructed. 2D 23 Pass thru sensor in Stacker 2 obstructed.
Page 56 5060-4xx Sub error code Explanation 2D 3E Tray 4 pick motor stall error detected. 2D 3F Tray 4 pick motor PWM error detected. 2D 40 Tray 4 pick motor Encoder error detected. 2D 41 Tray 4 feed motor stall error detected. 2D 42 Tray 4 feed motor PWM error detected.
Page 57: Understanding The Printer Operator Panel
5060-4xx Understanding the printer operator panel The operator panel has five buttons, a display, and a light that flashes when the printer is processing a job indicated by the Busy message. Operator panel buttons Button Function Press Go to: • Return to the Ready state if the printer is offline (the Ready message does not appear on the display).
Page 58 5060-4xx Select a menu or menu item for more details. Supplies Menu Job Menu Serial Menu PCL Emul Menu Color Menu <color> Toner Cancel Job PCL SmartSwitch Font Source Color Adjust Oiler Reset Printer PS SmartSwitch Font Name Color Balance Waste Bottle Print Buffer NPA Mode...
Page 59: Color Menu
5060-4xx Color Menu Use the Color Menu to adjust print quality and customize color printing. Note: Values marked by an asterisk (*) are the factory default settings. Menu Item Purpose Values Color Adjust To manually recalibrate the color No selections exist for this operation. conversion tables, adjusting for variations Pressing Select initiates this operation.
Page 60 5060-4xx Menu Item Purpose Values Color Saver To conserve toner. If selected, this setting Off* Prints using Toner Darkness setting. overrides Toner Darkness settings. Applies a lower Toner Darkness level. Toner Darkness setting is ignored. Manual Color To let users customize the RGB or CMYK RGB Image •...
Page 61: Utilities Menu
5060-4xx Menu Item Purpose Values Toner To lighten or darken printed output, or If Print Mode is Black & White, a Darkness conserve toner. setting of 5 increases toner density and darkness to all print jobs (PCL or Note: Setting Toner Darkness to values of PostScript).
Page 62 5060-4xx Menu Item Purpose Values Format Disk To format the printer hard disk. Deletes any data stored on the hard disk and prepares the device to Warning: Do not turn off the printer while receive new resources. the hard disk is formatting. Cancels the request to format the hard disk and leaves current resources stored on the disk.
Page 63: User Attendance Messages
5060-4xx User attendance messages Note: A secondary message only displays if the finisher option is installed. Use the “Sub error code table” on page 2-18 to help diagnose paper jam problems. User primary User secondary Explanation message message Setup Required This message is displayed when the printer has detected at POST, that packing material is still installed and must be removed.
Page 64 5060-4xx User primary User secondary Explanation message message Close Door This message is displayed when the printer upper front cover (door) is open. Close the upper front cover (door). Close <tray> Door This message is displayed when the HCIT (2000-sheet) option tray door is open.
Page 65 5060-4xx User primary User secondary Explanation message message Load Staples This message is displayed when the Staples Empty Alarm is activated and there are no staples in the staple unit or the staple unit is not installed. This message appears: •...
Page 66 5060-4xx User primary User secondary Explanation message message Install Tray x or This message is displayed when the printer requests the Cancel Job user to insert tray x before it can continue printing the job. The printer needs to pick media from the missing tray or the Install Bin x or trays below it.
Page 67 5060-4xx User primary User secondary Explanation message message 30 ITU Error This message is displayed when the ITU is not sensed. Check Area If the ITU is present, check the ITU Release Lever for Move Z Down correct operation. The ITU Release Lever is the black lever Power Off/On located on the left upper side frame above the ITU opening and can be seen by opening and lowering the MPF...
Page 68 5060-4xx User primary User secondary Explanation message message 34 Incorrect Change <source> This message is displayed when the printer detects a media Media <type><size> mismatch. Primary Message: 34 Incorrect Media. Secondary Message: <type>= Bond, Cardstock, Colored, Labels, Envelopes, Letterhead, Plain, Preprint, Transparency or Glossy.
Page 69 5060-4xx User primary User secondary Explanation message message 36 Printer Service This message is displayed when background toner prevents Required a completion of a TPS calibration cycle. Service is required to fix the problem. Press Go to clear the error. If the Service Printer message is displayed it means that a TPS failure has most likely occurred.
Page 70 5060-4xx User primary User secondary Explanation message message 37 Insufficient Held Jobs May Not This message displays when the printer has attempted to Memory Be Restored Print and Hold jobs from the disk and found that some or all of the jobs could not be restored. Each of the three Help Jobs May Not be 57 Configuration Held Jobs messages describe different Restored...
Page 71 5060-4xx User primary User secondary Explanation message message 40 <color> Invalid This message is displayed when the printer has detected a Refill refilled Return Program cartridge. <color> can be black, cyan, magenta, or yellow. Remove the toner cartridge and install a new cartridge. Press and hold Select and then press Return to display any secondary error codes that might help diagnose a problem.
Page 72 5060-4xx User primary User secondary Explanation message message 53 Unformatted Flash This message is displayed when the printer detects an unformatted flash at POST. Press Go to clear the message. The flash is marked bad and normal operation continues. Flash operations are not allowed until the flash is formatted. 54 Std Par ENA This message is displayed when the printer detects during Connection Lost...
Page 73 5060-4xx User primary User secondary Explanation message message 56 Std Parallel Port These messages may appear when data is sent to the Disabled printer across a parallel port, but the port is disabled. 56 Parallel Port x Note: Once the error is displayed the first time, reporting of Disabled further errors is suppressed until the printer is reset or menus are entered.
Page 74 5060-4xx User primary User secondary Explanation message message 58 Too Many Bins This message is displayed when too many optional bins are Attached attached to the printer or if an unsupported combination of bins is installed. 58 Too Many Disks This message is displayed when too many disks are Installed installed.
Page 75 5060-4xx User primary User secondary Explanation message message 63 Unformatted Disk This message is displayed when the printer detects an unformatted disk at POST. Press Go to clear the message. The disk is marked as bad and normal operation continues, however disk operation is not allowed until the disk is formatted.
Page 76 5060-4xx User primary User secondary Explanation message message 85 ITU Check printouts for excess toner. If present, replace the Maintenance suspect cartridge. Otherwise, replace the “ITU assembly” on page 4-44. Press Go to continue, however, the message persists until replacement. 86 ITU This message displays when the ITU reaches end of life.
Page 77: Service Checks
5060-4xx Service checks 100 ITU Error A 100 ITU error indicates that the printer did not detect the ITU belt home sensor. Before proceeding with this service check make sure that the Second Transfer Roll is correctly installed. After you reinstall the Second Transfer Roll, check to see if a 100 ITU error is still displayed.
Page 78 5060-4xx Step Action and questions Check the ITU Release Lever for correct operation. Go to step 3 Repair as The ITU Release Lever is the black lever located on the necessary left upper side frame above the ITU opening and can be seen by opening and lowering the MPF Assembly.
Page 79 5060-4xx Step Action and questions Check to see if the ITU Drive Roll Gear (A) is turning Go to step 10 Go to step 9 during POR. Observe the gear by opening the MFP door to its horizontal position. Observe the gear on the left end of the ITU Drive Roll.
Page 80: 104 Itu Error
5060-4xx 104 ITU Error The ITU has an optical sensor that watches for a piece of reflective tape on the inside of the image belt. This tape is read every revolution of the belt. If a signal is not received from the belt sensor within a certain time period, the printer posts an error due to the loss of signal.
Page 81: 120 Error Code
5060-4xx Step Action and questions Check the printer is setting on a solid, flat surface. Go to step 5 Inform the customer that the Is the printer setting on a solid flat surface? printer must be setting on a solid flat surface.
Page 82 5060-4xx 121 error code This error code displays whenever an incorrect fuser backup roll lamp is installed. Step Action and questions Check to make sure that the line voltage to the printer Go to step 2 Set the line matches the setting of the line voltage selection switch voltage selection on the LVPS.
Page 83 5060-4xx 124 error code Hot fuser Error code 124 displays whenever the printer detects a problem with the fuser running over temperature or the fuser lamps have been on too long. A problem could exist in the fuser assembly with the hot roll bearings, hot roll thermistor, or other hot roll parts.
Page 84 5060-4xx 126 error code Hot roll thermistor or thermistor circuits are open If error code 126 displays, the printer detects a problem in the fuser hot roll, back up roll lamp circuits, fuser hot roll thermistor, back up roll thermistor, system board, or LVPS fuser control circuits. Step Action and questions Turn the printer on and allow it to reach the Ready...
Page 85: 128 Error Code
5060-4xx 128 error code Fuser hot roll is under temperature during standby Step Action and questions Turn the printer on and allow it to reach a Ready Go to step 2 Replace the prompt. “System board” on page 4-72. Note: The printer may not complete POR and continue to display the 128 Error message.
Page 86: 130 Error Code
5060-4xx 130 error code Hot roll did not reach the correct standby temperature This error displays when the fuser hot roll does not reach the correct standby temperature. Step Action and questions Measure the voltage on connector J33-11 on the Replace the Go to step 2 system board.
Page 87: 131 Error Code
5060-4xx 131 error code Backup roll did not reach the correct standby temperature Step Action and questions Measure the voltage on connector J33-12 on the Go to step 2 Replace the system board. “Fuser assembly” on The voltage measures approximately 0.14 V dc to page 4-35 0.64 V dc as the back up roll lamp turns off and on.
Page 88: 132 Error Code
5060-4xx 132 error code Cold hot roll Step Action and questions Measure the voltage on connector J33-11 on the Go to step 2 Replace the system board. The voltage should measure “System board” approximately +0.13 V dc to +0.64 V dc as the hot roll on page 4-72 lamp turns off and on.
Page 89: 133 Error Code
5060-4xx 133 error code Cold backup roll Step Action and questions Measure the voltage on connector J33-12 on the Go to step 2 Replace the system board. The voltage should measure “System board” approximately +0.13 V dc to +0.64 V dc as the backup on page 4-72.
Page 90 5060-4xx 134 error code Hot fuser Error code 134 indicates that the fuser is running over temperature or the hot roll fuser lamp has been on too long. Error code 134 may also indicate a problem in the fuser assembly with the hot roll bearings, hot roll thermistor, LVPS, or the system board.
Page 91 5060-4xx Step Action and questions Do the gears stop and the fuser drive assembly gears Replace the Go to step 3 make a loud buzzing sound? FRUs in the order shown: 1. Fuser drive card. See “Fuser drive card assembly” page 4-37.
Page 92: Error Code
5060-4xx 148 error code Step Action and questions Connector J30 on the system board - Check for correct Go to step 2 Install the cable installation of the ITU drive motor cable from the ITU correctly drive motor to the system board connector J30. Is the cable connected correctly? ITU drive motor - Check for continuity between pin 4 of Replace the drive...
Page 93: Error Code
5060-4xx 150 error code Black cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Indicates the black cartridge drive motor has either Go to step 2 Install the cable...
Page 94: 151 Error Code
5060-4xx 151 error code Magenta cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Indicates that the magenta cartridge drive motor has Go to step 2 Install the cable...
Page 95: Error Code
5060-4xx Step Actions and questions Replace the system board. Problem solved Call your next level support Does this fix the problem? 153 error code Yellow cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect”...
Page 96: Error Code
5060-4xx 154 error code ITU belt motor Step Action and questions Connector J30 on the system board - Check for correct Go to step 2 Install the cable installation of the ITU drive motor cable from the ITU correctly drive motor to the system board connector J30. Is the cable connected correctly? ITU drive motor - Check for continuity between pin 4 of Replace the drive...
Page 97 5060-4xx 156 error code Black cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Error code 156 - The black cartridge drive motor has Go to step 2 Install the cable...
Page 98: 157 Error Code
5060-4xx 157 error code Magenta cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions The magenta cartridge drive motor has either failed to Go to step 2 Install the cable...
Page 99: 159 Error Code
5060-4xx 159 error code Yellow cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions The yellow cartridge drive motor has either failed to Go to step 2 Install the cable...
Page 100: 162 Error Code
5060-4xx 162 error code Black cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Black cartridge drive assembly - Error code 162 Go to step 2 Problem solved...
Page 101: 165 Error Code
5060-4xx 165 error code Yellow cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-17. If this procedure is not performed, error code 168 is displayed. Step Actions and questions Yellow cartridge drive assembly - Error code 165 Go to step 2 Problem solved...
Page 102: Paper Jam—Tray 1
5060-4xx 200 Paper Jam—Tray 1 Obtain the sub error code from the operator panel. Press and hold Return and press Select to view the sub error code. Compare the sub error code to the list below and go to the appropriate service check. Sub error code Service check 2D 1B “S2 or narrow media sensor obstructed”...
Page 103 5060-4xx S2 sensor late • 2D 11—S2 sensor late • 2D 03—S2 sensor late Note: See “Printer sensors” on page 5-3. Step Action and questions Check the tray for proper edge guide setting and media Go to step 2 Properly load loading.
Page 104: Paper Jam—Options And Multipurpose Feeder
5060-4xx S2 or narrow media sensor did not break in time • 2D 04—S2 sensor did not break in time • 2D 06—Narrow media sensor did not break in time Note: See “Printer sensors” on page 5-3. Step Action and questions Make sure the media installed in the tray meets Go to step 2 Inform the...
Page 105: Duplex Option
5060-4xx Multipurpose feeder Step Action and questions Does the media feed correctly from tray 1? Go to step 2 Go to “200 Paper Jam— Tray 1” on page 2-66. Verify that the media is loaded properly in the Replace the Properly load the multipurpose feeder.
Page 106: Paper Jam
5060-4xx 201 Paper Jam Step Action and questions Remove fuser from printer, remove oiler housing from Clear the jam. Go to step 2 fuser, and pivot the paper guide up. Is paper jammed inside the fuser? Check fuser entry guide for toner buildup. Replace the Go to step 3 “Fuser...
Page 107: Paper Jam
5060-4xx 202 Paper Jam Step Action and questions Remove the fuser from the printer. Remove the oiler Clear the jam Go to step 2 housing from the fuser, and pivot the paper guide up. from the fuser. Is media jammed inside the fuser? Check fuser exit sensor flag.
Page 108 5060-4xx Step Action and questions If the duplex option is in use, check the lower right door Go to step 8 Replace the paper path. “Lower right door assembly” Does media pass freely between the door and the on page 4-18.
Page 109: Paper Jam
5060-4xx 230 Paper Jam Step Action and questions Thoroughly examine the duplex paper path for torn Go to step 2 Clear the paper paper that may be blocking the sensors or paper path. path. Is the duplex paper path clear? Check the lower right door paper path.
Page 110 5060-4xx 24x Paper jam 500-sheet drawer option Media does not reach the pass thru sensor Step Action and questions Is Tray x a HCIT 2000-sheet option? Go to “HCIT” on Go to step 2 page 2-75 Make sure the media installed in the tray meets Go to step 3 Inform the specifications.
Page 111 5060-4xx Step Action and questions Check the autocompensator cable for correct Replace the Install the cable installation to Tray x system board. option or replace correctly the following Is the cable connected correctly? parts in the order until the error is cleared: •...
Page 112 5060-4xx Step Action and questions Check the pick motor cable to HCIT system board Replace the Install the cable cable connected to CN4 for correct installation. following FRUs in correctly the order shown: Is the cable connected correctly? 1. HCIT system board 2.
Page 113 5060-4xx Envelope feeder Before proceeding with this service check, make sure the envelope option is installed correctly. Step Action and questions Make sure the envelopes installed in the tray meet Inform the Go to step 2 specifications. customer of the problems with the Some guidelines that can be used in selection of envelopes that do...
Page 114: 250 Paper Jam
5060-4xx 250 Paper Jam Unable to clear the message—Multipurpose feeder loaded Note: A 250 Paper Jam displays when using a multipurpose feeder. Step Action and questions Make sure the media in the MPF meets specifications. Go to step 2 Inform user that the media in the Does media meet specifications? MPF does not...
Page 115 5060-4xx Displayed with no media in MPF A 250 Paper Jam indicates that the MPF tried to feed a sheet of media from the MPF tray. A 250 Paper Jam may occur when there is no paper in the MPF, MPF is selected as the paper source, or the MPF sensor is malfunctioning.
Page 116: Paper Jam - Check Bin 1
5060-4xx 271 Paper Jam - check bin 1 Output bin POST complete, first sheet of paper feeds into output bin x. Note: Before proceeding with this service check run the Output Bin x Sensor Test and check for the failing sensor.
Page 117: Paper Jam - Check Bin X
5060-4xx 272 Paper Jam - check bin x 5-bin mailbox Step Action and questions Bottom pass thru sensor flag - Make sure the flag is Fix or replace the Go to step 2 operating correctly and is not binding, broken, and flag there is no interference from the sensor cable.
Page 118: 280 Paper Jam
5060-4xx 280 Paper Jam Use the table below to determine where to check for jams in the printer and to diagnose a 280 Paper Jam. Check the area indicated to find the jam and the problem. If this does not fix the problem, contact the next level ow support.
Page 119: 900 Rip Software Error
5060-4xx Explanation Paper detected at punch timing sensor too long. Dirty or failed punch timing sensor. Paper not detected at punch timing sensor within timeout. Jam near input, misdirected sheet (diverter stuck or misaligned), sensor failure. Finisher internal software error. Intermittent sensor might cause this error. Unexpected sheet detected at punch timing sensor.
Page 120 5060-4xx Step Action and questions Turn the printer off. Remove any options from the Go to step 5 Determine which system board, such as additional memory, hard disk option is causing drives, or option cards. the 900 error. Does the 900 error persist when the printer is turned Restore factory defaults from the Configuration Menu.
Page 121: 925 Error Code
5060-4xx 925 error code Fuser fan (main fan) Step Actions and questions Turn the power off and manually spin the fan and check Go to step 2 Replace the that it rotates freely. “Fuser fan” on page 4-38 Does the fan rotate freely? Check the fuser fan cable connection to the system Go to step 3 Install the cable...
Page 122: Error Code
5060-4xx 927 error code RIP Fan service check Step Actions and questions Turn the power off and manually spin the fan and check Go to step 2 Replace the “RIP that it rotates freely. fan” on page 4-69 Does the fan rotate freely? Check the RIP fan cable connection to the system Go to step 3 Install the cable...
Page 123: Error Code
5060-4xx 940 error code Cyan toner metering cycle (TMC) The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed. Replacement of the cartridge may fix the problem temporarily if the problem is with the printer.
Page 124 5060-4xx Step Actions and questions Go to “BASE SENSOR TEST” on page 3-30 Replace the Go to step 4 check the cyan TMC sensor. When you press the TMC cartridge. pin in the cyan cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.
Page 125: Error Code
5060-4xx 941 error code Magenta toner metering cycle (TMC) The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed. Replacement of the cartridge may fix the problem temporarily if the problem is with the printer.
Page 126 5060-4xx Step Actions and questions Go to “BASE SENSOR TEST” on page 3-30 Replace the Go to step 4 check the magenta TMC sensor. When you press the cartridge. TMC pin in the magenta cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.
Page 127: Error Code
5060-4xx 942 error code Yellow toner metering cycle (TMC) The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed. Replacement of the cartridge may fix the problem temporarily if the problem is with the printer.
Page 128 5060-4xx Step Actions and questions Go to “BASE SENSOR TEST” on page 3-30 Replace the Go to step 4 check the yellow TMC sensor. When you press the cartridge. TMC pin in the yellow cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS.
Page 129: Error Code
5060-4xx 943 error code Black toner metering cycle (TMC) Toner metering cycle (TMC) is where the code and electronics in the printer sense an addition of toner in the cartridge developing area. If the printer is expecting a toner addition cycle but one is not detected, a 94x TMC Error is displayed.
Page 130 5060-4xx Step Actions and questions Go to “BASE SENSOR TEST” on page 3-30 Replace the Go to step 4 check the black TMC sensor. When you press the TMC cartridge. pin in the black cartridge contact assembly make sure it actuates the TMC switch on the developer HVPS. When the TMC pin is pressed in you hear a click when the switch actuates.
Page 131: 956 Service Error
5060-4xx 956 service error Service <xxxx> System Board Step Action and questions Remove all option boards from the system board. Turn Replace the Go to step 2 on the printer. system board. “System Does the error continue? board” on page 4-72.
Page 132: Output Expander
5060-4xx 500-sheet drawer option For 990 Service Error - Tray x, x=Tray 2, 3, 4 or 5, this is the tray that has a problem or needs service. Note: Verify the autoconnect housing is correctly snapped into the printer and all options, and is plugged into the system board correctly.
Page 133 5060-4xx Step Actions and questions Output expander control board check - Disconnect the Replace the Replace the motor cable J4 and check the voltages at J4 on the output expander mechanical board. control board linkage/DC motor assembly Warning: Be careful not to short to adjacent pins on the connector.
Page 134: 5-Bin Mailbox Option Service Check
5060-4xx 5-bin mailbox option service check Note: Before proceeding with this service check make sure the option(s) are installed correctly before attempting to service the unit. Make sure the machine is configured correctly. The majority of the mechanical components can be observed during operation by removing the left and right side covers. Step Symptoms Problems with excessive static electricity buildup.
Page 135 5060-4xx Step Symptoms 990 Service Error Go to 950 Error Call your next Code service level support check. The printer does not recognize one or more output options as installed. Note: If more than a single output option is installed, check each one to see if the printer recognizes any single option as being installed.
Page 136 5060-4xx Ready bin x full message - may be able to clear message and will feed paper into bin selected. Note: This sensor is normally in a open position with the flag out of the sensor slot. Step Action and questions Bin x sensor (bin x=Sensor 1 through 5) - Make sure Go to step 2 Install the sensor...
Page 137 5060-4xx Ready - bin x full displays and paper feeds into bin x Step Action and questions Bin x sensor flag - Make sure the bin x sensor flag is Replace the bin x Repair or replace not in the up position and is operating correctly. sensor.
Page 138: 500-Sheet Drawer Option Service Check
5060-4xx 500-sheet drawer option service check If the paper does not feed from the 500-sheet option, see “Autocompensator service check” on page 2-107. Whenever the 500-Sheet Tray is removed, use care as the autocompensator may be in its down position which could result in damage to the autocompensator assembly.
Page 139 5060-4xx Tray x autocompensator fails to retract, stays in down position. Step Action and questions Use care when removing a tray assembly when the Go to step 2 Go to step 3 autocompensator is in its down position. Remove the tray and manually reset the autocompensator to its uppermost position by actuating the pick arm lift bellcrank.
Page 140 5060-4xx The printer detects paper out in tray x when adequate paper is installed in the tray. Step Action and questions Run Tray x Sensor Test from the Diagnostics Menu. Go to step 5 Go to step 2 Does the test pass for Sensor L1? Check the cable connection for the paper level sensing Go to step 3 Install the cable...
Page 141: Ac And Dc Power Service Check
5060-4xx AC and DC power service check Before proceeding with this service check remove or disconnect any options that may be installed. Turn the machine on. If it operates correctly, reattach one option at a time until the failing option is located. Note: Set the voltage range switch to the proper power setting for the geographic area you are in.
Page 142: Dc Power Service Check
5060-4xx Step Actions and questions Low voltage power supply - Turn the power off and Replace the Replace the disconnect the LVPS at J35 on the system board. “System board” “LVPS Measure the voltages on J35-3 and J35-4. The voltage on page 4-72 assembly”...
Page 143: Autocompensator Service Check
5060-4xx Step Actions and questions Turn off the printer and plug in the cable for the Check the cable If printer comes component that is related to the error presented. For and component to Ready, connect the example, for the 114 Service Printhead error, plug in that was last the black printhead J11 and J12.
Page 144 5060-4xx Step B Step Action and questions Check Tray 1 for damage to the pick arm lift bellcrank Replace tray 1 Go to step 2 activation tabs on the rear of the tray. Is there any damage to the tray? Check the following parts for damaged, loose, or Repair or replace Go to step 3...
Page 145: Black Only Retract (Bor) Service Check
5060-4xx Step D Step Action and questions Enter the Diagnostics Mode and select INPUT TRAY Call your next Go to step 2 TESTS, Sensor Test, and Tray 1. You can activate the level support paper level sensor inside the printer. The paper level sensor is a dual sensor and checks the following levels for Tray 1.
Page 146: Close Door/Hvps/Printhead Interlock Switch Service Check
5060-4xx Close door/HVPS/printhead interlock switch service check Note: There are two separate cables that contain microswitches and a cable. These cable/switches provide separate interlocks for the printhead and HVPS. One switch in the Printhead/cover open cable is mounted in the front access door support and the other switch in the printhead/open cover cable is mounted on the ITU light shield assembly.
Page 147 5060-4xx POR complete, printer feeds blank page This symptom is usually associated with the upper switch mounted on the front access door support. Step Action and Questions Make sure that the ITU light shield is not broken. Replace the ITU Go to step 2 light shield Is the ITU light shield broken?
Page 148: Duplex Option Service Check
5060-4xx Duplex option service check Before proceeding with this service check: Check for any pieces of media or obstructions in the duplex paper path that might cause a paper jam. Check for correct installation of the front duplex jam tray and right side clearance tray. Check the duplex option for any signs of loose, damaged, contaminated, or warped parts that might cause a jam.
Page 149 5060-4xx Step Action and questions Check the voltages on the bottom options cable Go to step 8 Replace the connector. The voltages are with the printer in standby bottom options mode. cable in the printer Note: All voltages are approximate values. Connector pin Voltage J37-1 +5 V dc...
Page 150: Envelope Feeder Option Service Check
5060-4xx Envelope feeder option service check Note: Except for the tray and pick tires, the envelope feeder option is a complete assembly with no other internal parts that can be replaced. If a 24x paper jam (x=envelope feeder) is displayed, go to “Envelope feeder”...
Page 151 5060-4xx Envelopes do not feed from the tray or do not feed correctly Step Action and questions Check the envelope feeder tray to make sure it is Go to step 2 Install the tray installed correctly. correctly Is the tray installed correctly? Check the tray to make sure it has been setup correctly Go to step 3 Set the tray up...
Page 152: Finisher Service Check
5060-4xx Finisher service check If a failure is detected by the system board, an error may be displayed. The LEDs on the HCOF system board can help in diagnosing the errors. HCOF error code table LEDs lit by number Description Error detected by Punch Timing Sensor Error detected by Inverter Jam Sensor Error detected by Drop Timing Sensor...
Page 153 5060-4xx Check Finisher displayed, unable to clear message Step Action and questions Check for correct printer and finisher installation. Make Go to step 2 If not installed, sure the magnetic bracket is mounted on the printer. install the bracket Is the magnetic bracket mounted? Is the pin on the magnetic bracket actuating the joint Go to step 3 Find out why the...
Page 154 5060-4xx Finisher is inoperative, or not recognized This problem can be caused by a problem with the autoconnect system between the finisher and the printer. It also can be caused by a problem with the power system in the finisher. Step Action and questions Check the AC line cord to the finisher to make sure the...
Page 155 5060-4xx Step Action and questions Check the voltage at J2-5 on the system board. The Replace the top Replace the voltage measures approximately +5 V dc. options cable system board Is the voltage correct? Front door is open, no indication on display Step Action and questions Make sure the front door is activating the cover switch.
Page 156 5060-4xx No indication that the chad box is full, no message Step Action and questions Make sure the chad box is correctly installed in the Go to step 2 Install the chad finisher. box correctly Is the chad box correctly installed? Make sure the chad box cable S5 is properly Go to step 3 Install the cable...
Page 157: Hcit 2000-Sheet Option Service Check
5060-4xx HCIT 2000-sheet option service check HCIT system board LED error code table If a failure is detected by the system board, an error code may be displayed. If the system board LED is on solid, the HCIT detects that the tray or side door is not closed. The LED on the system board may blink.
Page 158 5060-4xx Printer does not recognize that the HCIT 2000-sheet option is installed. Step Action and questions Is the HCIT 2000-sheet option the only paper input Go to step 5 Go to step 2 option that is not recognized? Make sure that the printer and any option above the Go to step 3 Install the options HCIT 2000-sheet option are installed correctly.
Page 159 5060-4xx HCIT inoperative Before proceeding with this service check make sure the 2000-sheet tray option is properly connected to AC power. • If a finisher is installed: The AC jumper should go from the HCIT to the finisher. The finisher AC power cord should attach to the AC voltage source.
Page 160: Fuser Drive Assembly Noise Check
5060-4xx HCIT 2000-sheet option does not recognize the size paper selected. Step Action and questions Make sure the media loaded in the tray meets Go to step 2 Load the media specifications. properly or inform the customer that Is the media loaded properly and meet specifications? the media does not meet specifications...
Page 161: Operator Panel Lcd/Status Led/Buttons Service Check
5060-4xx Operator panel LCD/status LED/buttons service check Use this service check to check both the operation of the panel buttons and to test the LCD display for correct operation. • Replace the operator panel assembly if the LCD display functions normally, but the LED does not come on. •...
Page 162 5060-4xx Step Action and questions Operator panel cable (operator panel connection) - Go to step 9 Seat the cable Make sure that the operator panel cable is seated correctly correctly in the connector on the operator panel board. Is the cable seated correctly? Operator panel cable - Check continuity of the operator Replace the Go to...
Page 163: Output Expander Option Service Check
5060-4xx Output expander option service check Note: The majority of the mechanical components can be observed during operation by removing the covers. The output expander functions without the covers installed. Make sure the option is correctly installed before attempting to service the unit. Step Symptoms The printer does not recognize one or more output...
Page 164 5060-4xx Printer does not recognize that one or more output options as being installed. Step Actions and questions Excessive static electricity buildup - Check the output Go to step 2 1. Attach the expander control board cover to make sure the ESD ground cable if brush ground lead is firmly attached to the output not installed...
Page 165 5060-4xx No indication that bin x is full or no indication that bin x is near full. Step Actions and questions Sensor cable installation - Check for correct installation Go to step 2 Install the cable of the sensor cable at J5 on the control board. correctly Is the cable installed correctly? Dual output bin x sensor assembly...
Page 166: Print Quality Service Check
5060-4xx Print quality service check Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install an ITU, fuser assembly, second transfer roll, or print cartridge. Check the following before proceeding with any of the print quality service checks.
Page 167: Entire Page Is Mostly One Color-Full Bleed Planes In One Color
5060-4xx Entire page is mostly one color—Full bleed planes in one color Some printing may appear in other colors. This applies to black, cyan, magenta and yellow. Step Action and questions Using a piece of paper, block the laser path between Go to step 2 Go to step 4 the printhead and cartridge for the color that is...
Page 168: Missing Colors-Complete Or Partially Missing Color Planes
5060-4xx Missing colors—Complete or partially missing color planes • If a color or colors are missing, or a color is partially missing, go to “If cyan, magenta, and yellow is missing, go to “Black and white only—cyan, magenta, and yellow are missing” on page 2-133.” on page 2-132.
Page 169: Black And White Only-Cyan, Magenta, And Yellow Are Missing
5060-4xx Step Action and questions Perform a continuity check on the developer HVPS Replace in order: Replace the cable. developer HVPS 1. Developer cable. Does the cable check out? HVPS board. “Developer HVPS board” on page 4-31. 2. System board. See “System board”...
Page 170: Vertical Lines Or Streaks
5060-4xx One color has light print over the entire page Step Action and questions Print cartridge - Make sure the cartridge is seated Go to step 2 Remove the properly and all packaging material is removed from packaging the cartridge. material and seat the cartridge.
Page 171: Low Image Density
5060-4xx Step Action and questions Print cartridge(s) - Enter the Diagnostics Mode. Replace the Go to step 3 Remove one print cartridge at a time and run a Test “Cartridge Page to isolate the faulty print cartridge. contact assembly for the Have you isolated the failing print cartridge? failing color on page...
Page 172: Poor Color Alignment
5060-4xx Poor color alignment Step Action and questions Print cartridge - Make sure that the print cartridges are Go to step 2 Install the properly inserted and are seated properly in their cartridge(s) respective V blocks. correctly Are the cartridges seated correctly? Front cover and cartridge contact block - Check the Go to step 3 Replace any...
Page 173: Negative Ghosting Or Faded Image
5060-4xx Negative ghosting or faded image The print has a negative ghost on the page or the image is faded, particular with text. This problem may happen with any color and can be mistaken as toner smudges on the page. Step Action and questions Check the bellcranks of the color that is having the...
Page 174: Toner Smears Or Rubs Off The Page With No Error Code Displayed
5060-4xx Toner smears or rubs off the page with no error code displayed Note: This type of problem is associated with improper fusing or incorrect settings for media type being used. Step Action and questions Media settings - Check to see if the printer is set for Set the printer for Go to step 3 light paper.
Page 175: Toner Is On The Back Of The Printed Page
5060-4xx Toner is on the back of the printed page Do the following steps before proceeding with this service check: Enter the Diagnostics Mode. Select Print Test, Tray 1, Continuous from the menu. Run at least 20 pages of text and see if the problem remains. •...
Page 176: White Streak In Color Plane
5060-4xx White streak in color plane A white streak appears in one particular color plane. This problem may be caused by a contaminated developer roll in the print cartridge. Step Action and questions Check to see which color is having the problem and go to step 2.
Page 177: Second Transfer Roll Service Check
5060-4xx Second transfer roll service check Note: The second transfer roll is 51.03 mm (2.009 inches) in circumference. Any print quality problems such as lines that are spaced apart indicate you should check the second transfer roll for damage, toner, or foreign material.
Page 178: Tray 1 Service Check
5060-4xx Step Actions and questions Transfer terminal contact assembly and ITU transfer Repair or replace Replace the bellcrank - Check the transfer terminal contact, transfer as necessary. If FRUs in order: cable, and ITU transfer bellcrank assemblies to make this does not 1)“Transfer sure they are installed correctly, not loose, or broken.
Page 179: Tray 1 Paper Size Sensing Service Check
5060-4xx Step Action and questions Check to see if there is anything in the printer that Repair as Replace the tray might be interfering with the tray being correctly necessary assembly. installed. Is there anything in the printer that might cause the tray from installing correctly? Tray 1 paper size sensing service check The printer does not sense the size of the media installed in Tray 1.
Page 180 5060-4xx 2-144 Service Manual...
Page 181: Diagnostic Aids
5060-4xx 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. There are different test menus that can be accessed to identify problems with the printer. Diagnostic aids Printhead diagnostics “Printheads”...
Page 182 5060-4xx Install the printhead diagnostic tool and determine the problem. The following procedure shows the yellow and cyan switch as an example. Turn off the printer. Unplug the printhead cables from the system board in the printer and connect them to the printhead diagnostic tool.
Page 183 5060-4xx Turn on the printer and note the new error codes. • If an automatic calibration begins, 36 Printer Service Required may appear. The printhead and system board are working correctly and the printhead cable connections should be checked. Press Go to clear the error. •...
Page 184: Print Quality Defect Locator Chart
5060-4xx Print quality defect locator chart The print quality locator chart is copied below, but the tool is a transparent sheet available with this printed book. Use the tables and rulers to determine the source of repeating defects. Using the chart Measure repeating horizontal lines from the reference lines at the top to determine what may have caused the lines to form in that pattern.
Page 185 5060-4xx Printing the chart The printer has an internal copy of the defect locator chart under the Help Menu. Verify the proper image size by measuring any of the marks on the chart and comparing them to the corresponding measurement in the chart. Use Step 2 if adjustments are needed.
Page 186: Partial Print Test
5060-4xx Partial Print Test Diagnostic procedure for missing or faded planes Turn the printer off. Remove all cartridges and the ITU. Inspect the bellcranks. Enter the Configuration Menu. See “Configuration Menu” on page 3-8. Select Prt Quality Pgs and press Select. Open the vacuum transport belt (VTB) jam access door and watch the test pages pass from left to right over the VTB.
Page 187 5060-4xx Interpreting the results If the developed images are not visible on one of the PC drums, the following components should be checked: • Toner cartridge - Switch cartridges to determine if the problem stays with the slot or cartridge. •...
Page 188: Configuration Menu
5060-4xx Configuration Menu The Configuration Menu contains a set of menus, settings and operations which are infrequently used by a user. Generally, the options made available in this menu are used to configure a printer for operation. Note: An asterisk(*) in the value list in the following menus indicates the default value. The following are available from the Configuration Menu: ITU Cnt Value Fuser Cnt Value...
Page 189: Itu Count Value
5060-4xx ITU Count Value This is the page count of the current ITU. It cannot be reset unless a new ITU is installed. Press Select to view the count value. Fuser Cnt Value Enter the Configuration Menu and select Fuser Cnt Value. The value can be reset in Reset Fuser Cnt.
Page 190: Size Sensing
5060-4xx SIZE SENSING Automatic size sensing can be disabled or enabled in this menu. Only paper sources that support Auto Size Sensing are displayed. Select SIZE SENSING from the Config Menu. Select a tray. Only those trays with size sensing display. One of the following is displayed: Tray 1 Sensing Tray 2 Sensing Tray 3 Sensing...
Page 191: Energy Conserve
5060-4xx Energy Conserve When Energy Conserve is on, the customer does not have access to disable the Power Saver function. When Energy Conserve is off, Disable appears as an additional menu item in the Power Saver menu. This setting only affects the values that are displayed in the Power Saver Menu.
Page 192: Paper Prompts
5060-4xx Paper Prompts Setting Paper Prompts controls which tray a change prompt is directed to when paper is sensed to be the wrong size. Select Paper Prompts from the Config Menu. Select Auto, MP Feeder, or Manual Paper. Env Prompts Env Prompts controls which tray a change prompt is directed to when the envelopes are sensed to be the wrong size.
Page 193: Diagnostics Mode
5060-4xx Diagnostics mode To run the printer diagnostic tests described in this chapter, put the printer in Diagnostics mode. The tests display on the operator panel in the order shown: REGISTRATION ALIGNMENT MENU TOP FINE MARGIN ADJ MISC TESTS PRINT TESTS HARDWARE TESTS DUPLEX TESTS (if installed) INPUT TRAY TESTS...
Page 194: Registration
5060-4xx REGISTRATION Use REGISTRATION to align the black image on the page. Use ALIGHNMENT to align the individual colors. The black image should be aligned before the individual colors are aligned. To set Registration: Select REGISTRATION from the Diagnostics Mode. T=sxx* B=sxx* L=sxx*...
Page 195: Alignment Menu
5060-4xx Enter the values. The Top margin sign/value pair blinks. This indicates it is the margin value being changed. • To select the margin value to change, press Select until the margin value pair you want to change is blinking. •...
Page 196: Drift Sensors
5060-4xx Press Go to reprint the Alignment Test Pages to confirm your adjustments on page 1. Repeat steps 4 through 6 if required. Continue until all three colors are aligned. Press Return to exit the ALIGNMENT MENU. Drift Sensors This check is used to display the status of the thermal system used to compensate for printhead drift. The following screen is displayed when the test is selected: Com=aaaa M=bb...
Page 197: Misc Tests
5060-4xx MISC TESTS Motor Detect This test initiates an Automated Motor Detection. It must be performed if the NVRAM contents are lost during the replacement of a paper size sensing board. This test must also be performed anytime the ITU motor, fuser motor, or cartridge drive motors are replaced.
Page 198: Belt Tracking (Itu 4Th Point Adjustment)
5060-4xx Belt Tracking (ITU 4th point adjustment) This test is used to determine the need for the ITU Shim to correct 4th point alignment following the ITU replacement. Note: Remove all cartridges before initiating this test and note the belt position. Select Belt Tracking from the menu.
Page 199: Print Tests
5060-4xx PRINT TESTS The Print Tests consist of the following tests: Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) MP Feeder Print Quality Pgs For examples of the Print Quality Pages, see “Print tests”...
Page 200: Hardware Tests
5060-4xx HARDWARE TESTS The following hardware tests can be selected from this menu: LCD Test Button Test DRAM Test CASCHE Test ROM Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 2 Wrap (if available) Serial 3 Wrap (if available) LCD Test This test verifies the operator panel LCD function.
Page 201: Dram Test
5060-4xx DRAM Test This test checks the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: Select DRAM Test from HARDWARE TESTS in the Diagnostics mode.
Page 202: Rom Test
5060-4xx ROM Test The ROM memory test is used to check the validity of the controller board code and fonts. To run the ROM Test: Select ROM Test from HARDWARE TESTS in the Diagnostics mode. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in progress.
Page 203: Serial Wrap Test
5060-4xx Serial Wrap Test Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. To run the Serial Wrap Test: Disconnect the serial interface cable and install the wrap plug. Select the appropriate Serial Wrap Test from HARDWARE TESTS in the Diagnostics mode.
Page 204: Duplex Tests
5060-4xx DUPLEX TESTS Duplex Quick Test This test verifies if the Duplex Option Top Margin is set correctly. This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the back of the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages (Continuous) until Return or Stop is pressed.
Page 205: Input Tray Tests
5060-4xx INPUT TRAY TESTS Feed Test This test lets you observe the paper path as media is feeding through the printer. The upper front door, used to access the print cartridge, cannot be opened during the feed test. To observe the paper path, you must open the lower front door, used to access the paper jams on the vacuum transport belt.
Page 206: Output Bin Tests
5060-4xx For 2000-sheet trays This test can also be used to determine if the 2000-sheet tray sensors are working correctly. Select Sensor Test from INPUT TRAY TESTS in the Diagnostics mode. for the tray you want to test. The following is displayed: <input tray>...
Page 207: Sensor Test
5060-4xx Sensor Test This test verifies if the output bin sensors are working correctly. The following output sources, if installed, are supported by this test. Standard Bin Output Expander 5-Bin Mailbox To run the Output Bin Sensor Test: Select Sensor Test from OUTPUT BIN TESTS in the Diagnostics mode. Select the bin you want to test.
Page 208: Finisher Tests
5060-4xx FINISHER TESTS Staple Test This test verifies the operation of the staple mechanism in the finisher. To run the Staple Test: Select Staple Test from FINISHER TESTS in the Diagnostics menu. The printer feeds eight pieces of media to the finisher and accumulates all eight pieces in the accumulator.
Page 209: Hole Punch Test
5060-4xx • If you select Media 2 from the menu the following is displayed and the sensors polled: Media Path 2 Testing.... Once the sensors are polled the following is displayed and the sensors are ready to test. Media Path 2 S3=OP S4=OP =Inverter Jam Sensor =Drop Timing Sensor...
Page 210: Base Sensor Test
5060-4xx BASE SENSOR TEST Use the Base Sensor Test to determine that the sensors located inside the printer are operating correctly. The following sensors can be checked using this test: Input S1 Input S2 In-Line Media Fuser exit sensor K TMC sensor (black) C TMC sensor (cyan) M TMC sensor (magenta) Y TMC sensor (yellow)
Page 211: Disk Test/Clean
5060-4xx Disk Test/Clean Warning: This test destroys all data on the disk and should not be attempted on a good disk. This test may run approximately 1½ hours depending on the disk size. To run the Disk Test/Clean Test: Select Disk Test/Clean from DEVICE TESTS in the Diagnostics mode. Files will be lost/Go or Stop? is displayed to warn the user.
Page 212: Printer Setup
5060-4xx PRINTER SETUP Defaults This setting is used by the printer to determine whether US or non-US factory defaults should be selected. The following printer settings have different US and non-US values: Default values Printer setting US value Non-US value Paper size (paper feeding sources which do not have Letter hardware size sensing capabilities)
Page 213: Serial Number
5060-4xx Viewing the permanent page count The permanent page count can only be viewed from the operator panel and cannot be changed. Select Perm Page Count from PRINTER SETUP in the Diagnostics mode. A screen similar to the following screen displays when permanent page count is selected: Perm Page Count =1234567* Press Return to return to PRINTER SETUP in the Diagnostics mode.
Page 214: Reset Calibration
5060-4xx Reset Calibration The Reset Calibration resets the TPS NVRAM values when initiated. Select Reset Calibration from PRINTER SETUP in the Diagnostics mode and the following screen displays: PRINTER SETUP Reset Calibration Then the following screen is displayed: Resetting Calibration The printer returns to the previous screen when calibration is complete.
Page 215: Error Log
5060-4xx ERROR LOG Display Log The error log provides a history of printer errors. The error log contains the 12 most recent errors. The most recent error appears in position 1 and the oldest error appears in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded.
Page 216: Clear Log
5060-4xx Clear Log To clear the Error Log: Select Clear Log from ERROR LOG in the Diagnostics mode. Select Yes to clear the Error Log or No to exit the Clear Log menu. If Yes is selected, the Empty Error Log displays on the screen. Press Return or Stop to exit the Clear Log menu.
Page 217: Repair Information
5060-4xx 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...
Page 218: Screw Identification Table
5060-4xx Screw identification table The following table contains screw types, locations, and quantities necessary to service the printer. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly. Reference Screw type Location...
Page 219 5060-4xx Reference Screw type Location Purpose number M3x6 mm Taptite Ground cable to right front cover support Attach Metal Thread and upper frame. Forming Blank INA covers to system card shield Mounting Rear V-block plate to upper frame Mounting Transfer HVPS to card shield Attach Media size card to support plate Attach...
Page 220 5060-4xx Reference Screw type Location Purpose number M3.5x8 mm Left lower cover to lower frame Attach Plastite Thread Left upper cover asm to lower frame Attach Forming Left upper cover asm to upper frame Attach (continued) Left lower pivot to lower frame Attach Left upper pivot lower frame Attach...
Page 221 5060-4xx Reference Screw type Location Purpose number M3.5x10 mm Transfer HVPS/RIP fan asm to RIP shield Attach Plastite Thread Front left light shield to left upper cover asm Attach Forming and top cover Front right light shield to right front cover Attach support and top cover Cartridge drive assemblies to upper frame...
Page 222: Removal Procedures
5060-4xx Removal procedures CAUTION: Remove the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The C76xn weighs approximately 47.7 kg (105 lb) and requires at least two people to lift it safely.
Page 223 5060-4xx Remove the right light shield. Unsnap the bottom of the operator panel bezel and remove. Remove the top cover mounting screws (D) from the front of the printer. Repair information...
Page 224 5060-4xx Remove the top cover screws (E) type “323” on page 4-4 from the rear of the printer. Open the MPF and remove the top cover screw (F) type “323” on page 4-4 from the left side of the printer. Remove four screws (G) holding the outer system board shield.
Page 225 5060-4xx Disconnect the cable from J2 (H) on the system board and pull the cable through the inner system board shield. Remove the top cover. Repair information...
Page 226: Front Lower Left Cover
5060-4xx Front lower left cover Go to “Front lower left cover” on page 7-3 for part numbers. Remove the paper tray. Open the front cover. Open the paper path access door and carefully remove screw (A) type “323” on page 4-3, and close the door.
Page 227: Paper Path Access Door Cover
5060-4xx Remove the front lower left cover with the paper path door attached. Paper path access door cover Go to “Paper path access door” on page 7-3 for part numbers. Remove the front lower left cover. See “Front lower left cover” on page 4-10.
Page 228: Front Lower Right Cover
5060-4xx Front lower right cover Remove tray. Remove front right handle cover assembly. See “Front right handle cover assembly” on page 4-13. Open the paper path access door and remove the left lower cover screw (A) type “323” on page 4-3.
Page 229: Front Right Handle Cover Assembly
5060-4xx Remove the screw (C) from the front lower right cover. Remove the assembly. Front right handle cover assembly Go to “Front right handle cover assembly” on page 7-3 for part number. Open the front cover. Remove the four front right handle cover assembly screws (A) type “323”...
Page 230: Front Cover Assembly
5060-4xx Front cover assembly Go to “Front cover assembly” on page 7-3 for part number. Open the front cover assembly. Remove the detent post tension spring (A). Unsnap the bottom of the operator panel bezel and remove. 4-14 Service Manual...
Page 231 5060-4xx Hold the front cover and remove the two screws (B) from the upper front pivot cover. Remove the front cover assembly. 4-15 Repair information...
Page 232: Rear Cover
5060-4xx Rear cover Go to “Rear cover” on page 7-5 for part number. Remove the outer system board shield. See “Outer system board shield” on page 4-54. Remove 12 rear cover screws (A) type “232” on page 4-3 and type “323”...
Page 233 5060-4xx Remove two screws (B). Remove tabs (C) from slots (D). Remove the rear cover. Note: Make sure the toroid (E) is positioned at the edge of the inner system board shield. 4-17 Repair information...
Page 234: Lower Right Door Assembly
5060-4xx Lower right door assembly Go to “Lower right door assembly” on page 7-3 for part number. Open the lower right door assembly. Remove the front lower right cover. See “Front lower right cover” on page 4-12. Loosen the two screws (A). Remove the lower right door assembly.
Page 235: Lower Jam Access Door Assembly
5060-4xx Lower jam access door assembly Go to “Cover, left lower” on page 7-5 for part number. Remove the paper path access door cover. See “Paper path access door cover” on page 4-11. Remove the front left handle cover assembly. See “Front left handle cover assembly”...
Page 236: Autocompensator Pick Assembly
5060-4xx Autocompensator pick assembly Remove the ITU assembly. See “ITU assembly” on page 4-44. Remove tray 1. Remove the transfer plate. Lifting and rotating the right edge of the plate up to a 45° angle releases the transfer plate. Remove the grounding strap (A) attached to the bottom of the transfer plate. 4-20 Service Manual...
Page 237 5060-4xx Remove the black mylar piece by removing the two screws (B) or cutting the cable tie. Remove the front lower left cover. See “Front lower left cover” on page 4-10. Remove the three screws (C) type “323” on page 4-3 to remove the front left handle cover assembly.
Page 238: Left Side View
5060-4xx Remove the MPF swing arm assembly (E). Remove the paper level sensor. There are two screws located under the back VTB belt. Remove both of them along with a third that is located at the rear pivot point for the transfer plate (F). This allows the paper level assembly to drop into the cavity that the tray is inserted into.
Page 239 5060-4xx Paper Level Sensor Disconnect the pick motor connector (G). 4-23 Repair information...
Page 240 5060-4xx Remove four screws (H) holding the pick assembly in place. Push the bellcrank (I) in to allow the pick arm to fall to the bottom of the tray. 4-24 Service Manual...
Page 241 5060-4xx Disconnect the spring clip (J) from the pick arm. Be sure not to let the spring come off of the lower frame. Also identify which pegs the spring clip is sitting on. These pegs are typically marked with white paint. Leaving the pick arm down, lift the pick assembly and slide it toward the back of the machine and drop it through the holes located next to the brackets.
Page 242 5060-4xx Put the new pick assembly into the printer. Make sure the pick motor connector is placed through the holes before you insert the brackets. Make sure the boss (K) on the pick arm is on top of the bellcrank so it can raise and lower the arm.
Page 243 5060-4xx Reattach the spring clip to the pick arm. Make sure the pick arm rotates freely from top to bottom in the machine. Once the pick assembly is in place, put the four screws for the pick assembly back into place. Placing the front side screw in first makes it easier to put in the rest of the screws.
Page 244: Bor Drive Assembly
5060-4xx BOR drive assembly “Motor assembly, Lift/BOR” on page 7-27 for part numbers. Open the front cover. Remove the yellow toner cartridge. Remove the front right light shield cover. See “Front right light shield” on page 4-34. Remove the BOR housing assembly screw (A) type “323”...
Page 245: Cartridge Contact Assembly
5060-4xx Cartridge contact assembly Go to “Cartridge contact assembly” on page 7-28 for part numbers. Warning: Do not remove printheads. Open the front cover. Remove the toner cartridges. Remove the ITU assembly. See “ITU assembly” on page 4-44. Remove the top cover assembly. See “Top cover assembly”...
Page 246: Cartridge Drive Assembly
5060-4xx Cartridge drive assembly Note: Drive assemblies must be removed in the following order until the desired assembly can be removed: • Black • Magenta • Cyan • Yellow Go to “Cartridge drive assembly, cyan/magenta/black (one drive assembly per package)” on page 7-29 part number.
Page 247: Developer Hvps Board
5060-4xx Developer HVPS board Go to “Developer HVPS board” on page 7-34 for part numbers. Remove inner system board shield. See “Inner system board shield” on page 4-43. Remove four top machine screws (A) type “323” on page 4-3 and four bottom screws (B) type “121”...
Page 248 5060-4xx Remove connectors (D) from the right board. Remove the developer HVPS boards. Note: If you have a one piece Developer HVPS board, you can ignore steps 5 and 6. Reconnect the HVPS boards. Installation note: Disconnect the cable between boards. Note: You have a one piece Developer HVPS board.
Page 249: Friction Buckler
5060-4xx Friction buckler Go to “Friction buckler” on page 7-19 for part numbers Press the multipurpose feeder (MPF) latch to disconnect the MPF. Use needlenose pliers to remove the buckler housing (A). Replace the friction buckler (B). 4-33 Repair information...
Page 250: Front Right Light Shield
5060-4xx Front right light shield Go to “Front right light shield cover” on page 7-3 for part numbers Open the top cover. Remove the front right light shield screws (A) and (B). Unlatch the alignment stud (C). 4-34 Service Manual...
Page 251: Fuser Assembly
5060-4xx Fuser assembly CAUTION: Be sure the fuser assembly has cooled before you remove it. Go to “Fuser assembly” on page 7-7 for part numbers. Open the lower right door assembly and redrive door. Unlatch the two fuser latches (A). Remove the fuser assembly.
Page 252: Fuser Bottom Duct
5060-4xx Fuser bottom duct Go to “Fuser bottom duct” on page 7-5 for part number. Remove the fuser assembly. See “Fuser assembly” on page 4-35. Remove the fuser top duct. See “Fuser top duct” on page 4-39. Remove the redrive belt cover duct (A). Remove fuser left duct (B).
Page 253: Fuser Drive Assembly
5060-4xx Fuser drive assembly Go to “Fuser drive assembly” on page 7-10 for part number. Remove the fuser bottom duct. See “Fuser bottom duct” on page 4-36. Swing lever (A) and disengage VTB shaft. Remove the fuser drive assembly screws (A) type “323”...
Page 254: Fuser Fan
5060-4xx Fuser fan Go to “Fuser fan assembly with cable” on page 7-35 for part number. Remove rear cover. See “Rear cover” on page 4-16. Disconnect the fuser fan cable from connector J31 on the system board. Remove the fuser fan screws (A) and remove the fan. 4-38 Service Manual...
Page 255: Fuser Top Duct
5060-4xx Fuser top duct Go to “Fuser top duct” on page 7-5 for part number. Remove the rear cover. See “Rear cover” on page 4-16. Remove the fuser top duct screw (B) and disconnect tab (A). Remove the top duct. 4-39 Repair information...
Page 256: Fuser Web Oiler Motor Assembly And Card
5060-4xx Fuser web oiler motor assembly and card “Fuser assembly” on page 7-7. Open the front cover. Remove the yellow print cartridge. Remove the front lower right cover. See “Front lower right cover” on page 4-12. Remove screw (A) from the top front support bracket. Swing bracket to the right. 4-40 Service Manual...
Page 257 5060-4xx Remove screws (B) for motor and screws (C) for the web oiler card. Remove the fuser web oiler motor assembly and card. 4-41 Repair information...
Page 258: Installation Notes
5060-4xx Installation notes Note: When you reinstall the web oiler motor assembly, route the cable along the right side frame and through the cable clip (A). Note: Make sure the cables from the drive assembly are routed along the lower frame and are not in contact with the drive assembly gears.
Page 259: Inner System Board Shield
5060-4xx Inner system board shield Go to “System board shield assembly with clips” on page 7-33 for part number. Remove the top cover assembly. See “Top cover assembly” on page 4-6. Remove the rear cover. See “Rear cover” on page 4-16.
Page 260: Itu Assembly
5060-4xx ITU assembly Go to “ITU assembly” on page 7-22 for part number. Open the front cover. Remove the toner cartridges. Open the MPF to the lowest position. Raise the ITU release lever (A) and slide the ITU from the printer. ITU drive assembly Go to “ITU drive assembly with motor and waste toner full switch”...
Page 261: Itu Drive Motor
5060-4xx Cut the two cable ties (B). Remove the three ITU drive assembly mounting screws (C) and disconnect the ITU drive motor cable (D). Move the bottom of the ITU drive assembly toward you as you rotate the top of the assembly out of the printer.
Page 262: Lvps Assembly
5060-4xx LVPS assembly Go to “LVPS, 115V/230V switchable” on page 7-31 for part number. Note: Set the voltage range switch to the proper power setting for the geographic area you are in. Remove the fuser drive assembly. See “Fuser drive assembly” on page 4-37.
Page 263 5060-4xx Remove the screw (C) type “121” on page 4-2 from the top of the LVPS and remove the LVPS from the printer. Installation notes • When installing the new power supply, set the voltage range switch to the proper power setting for the geographic area you are in.
Page 264: Multipurpose Feeder (Mpf)
5060-4xx Multipurpose feeder (MPF) Go to “Multipurpose feeder (MPF)” on page 7-19 for part numbers. Open the MPF to the lowest position. Remove the MPF cable cover screw (A). Place flatblade screwdriver in the slot (B) on the MPF cable cover and gently pry open the cover. 4-48 Service Manual...
Page 265 5060-4xx Disconnect the MPF switch cable from the MPF sensor (C). Pull the MPF cable free of the enclosure and out from under the cable retainer (D). Remove the MPF strap screw (E) type “412” on page 4-5. 4-49 Repair information...
Page 266: Nip Relief Handle
5060-4xx Release the MPF latch (F) and remove the MPF. Nip relief handle Go to “Nip relief handle” on page 7-17 for part number. Remove the left lower cover to access the nip relief handle. See “Left lower cover” on page 4-18.
Page 267 5060-4xx Pull down the lower portion of the broken handle as far as it goes. Rotate the handle to slide off the post. Installation notes Rotate the new nip relief handle into place to connect it to the nip relief link (A). Using a screwdriver, gently pry the nip relief lever (B) toward the rear of the machine and insert lower portion of the handle so that it is between the nip relief lever and the reference edge plate (C).
Page 268 5060-4xx Holding the handle in place, use a flathead screwdriver to gently pry up on the top portion of the nip relief lever allowing the handle to snap into place onto the post using moderate force. Once the handle snaps onto the post, press the upper portion of the handle to the right and rotate the handle into its home position.
Page 269: Operator Panel
5060-4xx Operator panel Go to “Operator panel assembly” on page 7-3 for the part number. Open the front cover assembly. Unsnap the bottom of the operator panel bezel and remove. Unlatch the operator panel latches (A). 4-53 Repair information...
Page 270: Outer System Board Shield
5060-4xx Disconnect the operator panel cable from the operator panel and remove the panel. Outer system board shield Go to “System board outer shield” on page 7-33 for part number. Remove four screws (A). Remove outer system board shield. 4-54 Service Manual...
Page 271: Paper Size Sensing Assembly
5060-4xx Paper size sensing assembly Go to “Paper size sensing” on page 7-16 for part numbers associated with this assembly. Enter Diagnostics mode. Power up the printer in Diagnostics mode (holding Go and Return until Performing Self Test appears.). Print the Quick Test Page, if possible. Retain this sheet to verify the installation. Select REGISTRATION.
Page 272 5060-4xx Gently twist and remove the paper size sensing assembly. As shown, the assembly touches at the spring (D), the fingers (E), the bottom (F), and the right side (G). This also occurs when replacing the assembly. Replacing the paper size sensing assembly Press on the back of the paper size sensing assembly fingers (H).
Page 273: Paper Size Sensing Board
5060-4xx Move the assembly down to the bottom of the aligning hole. Be careful with the exposed fingers. Do not allow them to press against the black plastic frame. Gently wiggle the entire assembly and press in and around the corner to the right. Grasp the rectangular piece (J) of the paper size sensing assembly and move up and to the left until the screw hole (K) lines up.
Page 274: Paper Size Sensing Board
5060-4xx Remove the paper size sensing board screws (A). Remove the board. Replace the new board Power up the printer in Diagnostics mode (holding Go and Return until Performing Self Test appears.) Verify the model name to make sure the correct paper size sensing board is installed. Select PRINTER SETUP from the Diagnostics mode.
Page 275: Pick Rolls
5060-4xx Pick rolls Go to “Pick roll tires” on page 7-53 for part number. Front roll Wipe any toner or debris from the bottom pan to avoid contaminating the pick rolls. Pull the pick assembly down into the bottom pan and remove the screw. Note: Do not attempt to remove either the shaft or the clutch races.
Page 276: Printhead Removal And Adjustments
5060-4xx Printhead removal and adjustments Identifying the printheads A color version of this sheet is available in the appendix. See“Identifying the printheads” on page A-4. Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost.
Page 277: Printhead Mechanical Alignment
5060-4xx Printhead mechanical alignment Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost. Install two printhead alignment assemblies, one in the front and another in the rear (see Figure 2 and Figure 3), by aligning the locating pin on the printhead alignment bracket (see Figure 1) with the hole in the printer frame.
Page 278 5060-4xx Turn the thumbwheel (see Figure 1) until the end of the thumbwheel just touches the printhead mounting beam for both the front and rear alignment assemblies. Remove the old printhead and install a new printhead assembly. Do not tighten the printhead screws yet. Note: Make sure the right rear screw goes through the printhead spacer located at the right rear of the printer frame.
Page 279: Printhead Electronic Alignment
5060-4xx Print the Printhead Mechanical Alignment Test page to determine the printhead alignment. Note: To see a printhead mechanical alignment test in color page, see “Printhead mechanical alignment test page” on page B-9. Loosen the printhead screws before making any adjustments to the thumbwheel. Turn each thumbwheel the appropriate number of clicks as indicated by the test page.
Page 280: Rear Bellcrank (Cyan, Magenta, Yellow)
5060-4xx Rear bellcrank (cyan, magenta, yellow) Power off the printer. Remove the four toner cartridges and leave the front door open. Remove the ITU assembly. See “ITU assembly” on page 4-44. Check each of the rear bellcranks for cracks or breakage. Remove the spring (A).
Page 281 5060-4xx Rotate the contact end of the bellcrank down (B) and remove. Be careful not to lose the contact spring (C). Installation note Replace the bellcranks by reversing the order of removal. Note: Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu. 4-65 Repair information...
Page 282: Rear Bellcrank (Black)
5060-4xx Rear bellcrank (black) Power off the printer. Remove the four toner cartridges and leave the front door open. Remove the ITU assembly. See “ITU assembly” on page 4-44. Check each of the rear bellcranks for cracks or breakage. Remove the spring. Remove the stop screw (A) and two washers (B).
Page 283 5060-4xx Rotate the contact end of the bellcrank down (C) and remove. Be careful not to lose the spring (D). Installation note Replace the bellcranks by using reverse order of removal. Note: Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu. 4-67 Repair information...
Page 284: Redrive Assembly
5060-4xx Redrive assembly Go to “Redrive assembly” on page 7-14 for part number. Remove the redrive door. See “Redrive door” on page 4-19. Remove the fuser bottom duct. See “Fuser bottom duct” on page 4-36. Remove the redrive assembly screw (A) type “323”...
Page 285: Registration Motor
5060-4xx Registration motor Remove the system board shield. Remove the registration motor mounting screws (B), cut the cable tie (A), and remove the assembly. RIP fan Go to “RIP fan, 92 mm” on page 7-35 for part number. Remove the rear cover. See “Rear cover”...
Page 286: S2/Narrow Media/Transparency/Multipurpose Feeder Cable
5060-4xx S2/narrow media/transparency/multipurpose feeder cable Remove the J21 connector cable to allow space. Note the route it shares with the sensor cable assembly through the frame. Route the new cable connector through the rectangular opening in the upper frame and out through the opening in the lower frame.
Page 287: S2/Narrow Media/Transparency/Multipurpose Feeder Sensors
5060-4xx S2/narrow media/transparency/multipurpose feeder sensors Replace only the necessary sensors. Second transfer roll Go to “Second transfer roll” on page 7-12 for part number. Remove the ITU assembly. See “ITU assembly” on page 4-44. Lift the transfer roll from the front bearing and remove the transfer roll. 4-71 Repair information...
Page 288: System Board
5060-4xx System board Go to “System board, non-network, 401/421 only” “System board, network, 402/422 only” on page 7-33. Remove the outer system board shield. See “Outer system board shield” on page 4-54. Disconnect all the cables from the system board. Remove the USB screw (A) and parallel port cover (B), if applicable.
Page 289: Transfer Hvps Board
5060-4xx Transfer HVPS board Go to “Transfer HVPS board” on page 7-34 for part number. Remove the rear cover. See “Rear cover” on page 4-16. Remove three transfer HVPS board screws (A). A(232) A(323) 4-73 Repair information...
Page 290 5060-4xx Remove all connectors (B). Remove the transfer HVPS board. 4-74 Service Manual...
Page 291 5060-4xx Installation notes • To identify the color coded cable bands to the connectors, see “Transfer high voltage power supply (HVPS)” on page 5-20. • When installing the transfer HVPS board, route the cable to the HVPS input connector at CN1 (C) over the cable to the yellow transfer contact (D), under the cable to the magenta transfer contact (E), and attached to the cable tie (F).
Page 292: Transfer Plate Assembly
5060-4xx Transfer plate assembly Go to “Transfer plate assembly” on page 7-12 for part number. Remove the S2/narrow media/transparency/multipurpose feeder cable. See “S2/narrow media/transparency/multipurpose feeder cable” on page 4-70. Remove the transfer plate. Lifting and rotating the right edge of the plate up to a 45° angle releases the transfer plate.
Page 293: Vacuum Transport Belt (Vtb)
5060-4xx Vacuum transport belt (VTB) Go to “Vacuum transport belt assembly” on page 7-11 for part number. Remove the transfer plate assembly. See “Transfer plate assembly” on page 4-76. Remove the fuser bottom duct. See “Fuser bottom duct” on page 4-36.
Page 294 5060-4xx Rotate release lever on gear until the gear can be removed. Remove screw from ground wire. Remove vacuum belt transfer belt unit far enough to release ground wire from restraint clips and remove completly. 4-78 Service Manual...
Page 295: Vacuum Transport Belt (Vtb) Fan
5060-4xx Vacuum transport belt (VTB) fan Go to “VTB fan, 60 mm” on page 7-35 for part number. Disconnect VTB fan from the system board. Remove VTB fan with a flatblade screwdriver. Waste container door Go to “Waste container door” on page 7-5 for part number.
Page 296: Waste Container Latch
5060-4xx Waste container latch Go to “Waste container latch” on page 7-26 for part number. Remove the paper size sensing assembly. See “Paper size sensing assembly” on page 4-55. Use a flatblade screwdriver to release the waste container latch from the paper size sensing assembly. Web oiler fuser kit installation Enter Diagnostic mode.
Page 297 5060-4xx Unlatch the two fuser latches (A). Remove the fuser assembly. Open the front cover. Remove the yellow print cartridge. Remove the front right light shield screws (B) and (C) and remove the light shield. B(323) C(324) 4-81 Repair information...
Page 298 5060-4xx Carefully remove the paper path access door cover right mounting screw (D). Tape front jam access door (E) if tape is available, to help hold the door in place. Remove the front right handle cover assembly screws (F) and remove the assembly. Open paper tray.
Page 299 5060-4xx Remove screw (G) from the top front support bracket. Swing bracket to the right. Use the alignment pins (H) on the web oiler fuser motor assembly to position the assembly in holes (J) and install the assembly. 4-83 Repair information...
Page 300 5060-4xx Secure the web oiler motor assembly with screws (K). Install the web oiler card using screws (L). 4-84 Service Manual...
Page 301 5060-4xx Plug web oiler cable into web oiler card connector (M). Plug web oiler drive assembly cable into cable connector (N). Note: Make sure the cables from the drive assembly are routed along the lower frame and are not in contact with the drive assembly gears.
Page 302 5060-4xx Move the front right light shield up until alignment stud (P) and the screw hole (Q) are aligned. Attach the new fuser web oiler fuser housing (R) to the new web oiler fuser. Insert the web oiler fuser assembly into the fuser assembly and install the fuser assembly into the printer. 4-86 Service Manual...
Page 303: Connector Locations
5060-4xx 5. Connector locations Locations Printer boards Connector locations...
Page 304: Printer Motors
5060-4xx Printer motors Web oiler drive motor (optional) Printheads BOR drive motor RIP fan Yellow carriage drive motor Fuser drive motor and card Pick asm motor Fuser fan VTB fan Registration drive motor Magenta carriage ITU drive motor drive motor Cyan carriage Black carriage drive motor...
Page 305: Printer Sensors
5060-4xx Printer sensors Connector locations...
Page 306: Cartridge Contact Assembly Pin Locations (Cyan, Magenta And Yellow)
5060-4xx Cartridge contact assembly pin locations (cyan, magenta and yellow) Service Manual...
Page 307: Cartridge Contact Assembly Pin Locations (Black)
5060-4xx Cartridge contact assembly pin locations (black) Connector locations...
Page 308: Connectors
5060-4xx Connectors System board - non-network Service Manual...
Page 309: System Board - Network
5060-4xx System board - network Connector locations...
Page 310 5060-4xx System board “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J1 USB Port Ground USB +5 V dc USB D- USB D+ Ground Ground J2 Top Options Connector Bin Full Printer TXD Ground Ground...
Page 311 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J7 Yellow Printhead Mirror Motor FUSE24V Ground Ground +5 V dc (through fuse F12) Y MMSTART Y HSYN-SOS Y MMLOCK Ground Y MMREF J8 Yellow and Cyan Video to C_DATA+...
Page 312 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J9 Printhead - Cyan Mirror Motor FUSE24V Ground Ground +5 V dc (through fuse F12) C_MMSTART C_HSYN_SOS C_MMLOCK Ground C_MMREF J10 Cover Open Switch +5 V dc (direct from low voltage power supply) Ground VDO_ERR (+5 V dc to J8 and J12)
Page 313 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J12 Printhead - Black/Magenta Video K_DATA+ Ground K_DATA- M_THERMISTOR Ground M_LENA +5 V dc (through fuse F12 and safety switches at J10) Ground K_LPWM...
Page 314 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J14 Developer HVPS -CART_METER_K_IN K_AC_BIAS_ENABLE (active low) SC_K_CHIP K_DEV_PWM_OUT -CART_METER_M_IN K_CHARGE_PWM_OUT CMY_CHARGE_PWM_OUT SC_M_CHIP -CART_METER_C_IN CMY_AC_BIAS_ENABLE (active low) SC_C_CHIP M_DEV_PWM_OUT -CART_METER_Y_IN C_DEV_PWM_OUT Y_DEV_PWM_OUT SC_Y_CHIP Ground...
Page 315 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J15 Transfer HVPS ITU_TX_ENA_OUT (active low) ITU_TX_CUR_PWM_OUT ITU_SERVO_IN ITU_TX_PWM_OUT CMY_TX_ENA_OUT (active low) K_SERVO_IN K_TX_PWM_OUT C_SERVO_IN C_TX_PWM_OUT M_SERVO_IN Y_TX_PWM_OUT Y_SERVO_IN M_TX_PWM_OUT Ground +24V_SWITCHED J16 Option DRAM Socket J17 Not Used...
Page 316 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J21 S2/Narrow Media/Prism/ Ground MPF Sensor +5V dc S2 (switched) NARROW_MEDIA_IN PAPERPATH_S2_IN +5 V dc NM (switched) Ground Ground +5 V dc PRISM (switched) PRISM_SENSOR_IN PRISM_LED_VOLT Ground...
Page 317 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J29 Fuser Stepper Motor/ Y_ON_OUT Yellow BLDC Motor FUSER_ON_OUT (Fuser current I0) +5V dc (Through fuse F8) +5V dc (Through fuse F8) Y_DIR_OUT FUSER_DIR_OUT (Fuser phase B) +24V _Y_AND_FUSER (Through fuse F3)
Page 318 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J32 VTB Fan FAN2_STALL_IN Ground VTB_FAN_OUT (Fan 2 control) +24V_LEFTSIDE J33 Fuser Interface EXIT_SENSOR_IN FUSER_CAM_1_IN Ground OILER_ENC_A_IN OILER_ENC_B_IN HR_THERM_IN (hot roll thermistor) BR_THERM_IN (backup roll thermistor) Ground +5V_SWITCHED...
Page 319 5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal J35 Low Voltage Power Supply +3.3 V dc +3.3 V dc +5 V dc +5 V dc +24V dc +24V dc +24V dc +3.3 V dc Sense Ground...
Page 320: Autoconnect-Top
5060-4xx “System board - non-network” on page 5-6 “System board - network” on page 5-7. Connector Pin no. Signal JT25 - Diagnostic port Ground Printer RXD Printer TXD +5V dc (Through fuse F8) Autoconnect—top Connector Pin no Color Signal CN1 Autoconnect—top White +24 V dc Black...
Page 321: Autoconnect-Bottom
5060-4xx Autoconnect—bottom Connector Pin no Signal Signal CN1 Autoconnect—bottom White +24 V dc Black Ground Yellow Printer RXD Black Ground Brown STAGING_ENCODER +5 V dc Black Ground Blue Printer TXD 5-19 Connector locations...
Page 322: Transfer High Voltage Power Supply (Hvps)
5060-4xx Transfer high voltage power supply (HVPS) 5-20 Service Manual...
Page 323 5060-4xx Connector Pin no Signal CN1 HVPS Input Connector +24 V dc Switched +24 V dc Return M-Txpwm M-Srvo out Y-Txpwm Y-Srvo out C-Txpwm C-Srvo out K-Txpwm K-Srvo out KCYM-Txenable ITU-Txpwm ITU-Srvo out ITU-Txcurpwm TUI-Txenable T102 Transformer HV Terminal I (ITU) HV Transformer output to 2nd Transfer Roll Cable T201 Transformer HV Terminal K HV Transformer Output Terminal to Black Transfer...
Page 324: Developer High Voltage Power Supply (Hvps) Board
5060-4xx Developer high voltage power supply (HVPS) board Connector Pin no Signal CN1 Developer HVPS Input +24 V dc Return +24 V dc Y-Ctsense Y-Devpwm Y-TnrSense C-Devpwm C-CtSense M-Devpwm C-TnrSense CYM-Acenable M-CtSense CYM-Chgpwm M-TnrSense K-Chgpwm K-CtSense K-Devpwm K-TnrSense K-Acenable CN2 Cartridge Signature Button - K-CtSense (red wire) Black K-TnrSense (Gnd Return) (black wire)
Page 325: Low Voltage Power Supply (Lvps)
5060-4xx Connector Pin no Signal CN5 Cartridge Signature Button - Y-CtSense (red wire) Yellow Y-TnrSense (Gnd Return) (black wire) CB Terminal Cleaner Bias Terminal (not used) Low voltage power supply (LVPS) LVPS cable connectors to system board Connector Signal Main power to +3.3 V dc system board +3.3 V dc...
Page 326: Lvps Fuser Connectors
5060-4xx LVPS fuser connectors Connector Pin no. Signal LVPS AC Fuser Connector AC Load #1 AC Common Ground AC Load #2x LVPS DC Fuser Control Connector FusExitSen BURCam1 WebEncoderA WebEncoderB HRThermistor BURThermistor Return - Analog Ground +5 V dc switched 5-24 Service Manual...
Page 327: Paper Size Sensing Board
5060-4xx Paper size sensing board Connector Signal +3.3V dc EPROM Data Ground EPROM Clock J3-1 (Waste BTL Full) Ground Waste BTL PRESENT (SW4) Tray Size 1 (SW3) Ground Tray Size 2 (SW2) Tray Size 3 (SW1) J2-1 (Waste BTL Full) Ground 5-25 Connector locations...
Page 328: High-Capacity Input Tray (Hcit)
5060-4xx High-capacity input tray (HCIT) HCIT 2000-sheet board Connector Signal CN1 I/F Send PRI RXD PGND PERON SGND PRI TXD CN2 LVPS Poweron +5 V dc SGND PGND PGND PGND +24 V dc +24 V dc +24 V dc CN3 REG Motor +24 V dc +24 V dc REG A...
Page 329 5060-4xx Connector Signal CN6 Sensors +5 V dc Side Door/Level/ Empty/ Registration SIDE Home/Pick Home +5 V dc LEVEL +5 V dc EMPTY +5 V dc RHOME +5 V dc PHOME CN7 Size +5 V dc Sensors/Near Empty SIZE 0 +5 V dc SIZE 1 +5 V dc...
Page 330: High-Capacity Output Finisher (Hcof)
5060-4xx High-capacity output finisher (HCOF) HCOF system board For a more detailed diagram, see “Finisher cables” on page 7-68. 5-28 Service Manual...
Page 331 5060-4xx “HCOF system board” on page 5-28. Connector Pin no Signal CN1 Drop Solenoid SOL+ SOL- CN2 Stapler Assembly MTR- MTR- MTR+ MTR+ No Cartridge Low Staple Home Position Unit Check Ground +5 V dc CN3 Jogger Motor/ Jog A Accumulator Drive Motor Jog *A Jog B...
Page 332 5060-4xx “HCOF system board” on page 5-28. Connector Pin no Signal CN6 Tray Sensors Tray Limit/ Tray Limit SW Near Full/Output Tray Offset Sensor Ground +5 V dc Tray Near Full Sensor Ground +5 V dc Tray Offset Posit Sensor Ground CN7 Output Tray Offset Motor MTR +...
Page 333 5060-4xx “HCOF system board” on page 5-28. Connector Pin no Signal CN14 Low Voltage Power Supply +24 V dc +24 V dc P-Ground P-Ground CN15 Enter Motor CN16 Punch Motor Homing Sensor/ +5 V dc Drop Timing Sensor/ Drop Timing Sensor Inverter Timing Sensor/ Punch timing Sensor Ground...
Page 334: Hcof Lvps Board
5060-4xx HCOF LVPS board Connector Pin No Signal CN2 LVPS Out +24 V dc +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground AC In from Relay Not used Not used Not used AC In from Relay HCOF sub LVPS relay board Connector Signal...
Page 335: Preventive Maintenance
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
Page 336: Lubrication For Replacement Motors
5060-4xx Lubrication for replacement motors The motor drive FRUs contain the proper lubricant in the FRU. Only use the lubricant included. Fuser drive assembly Before installing the new fuser drive assembly: Apply a thin coating of Nyogel type 774 grease to the points identified (A) from the supplied packet. Rotate the motor housing (B) to distribute evenly.
Page 337: Cartridge Drive Assembly
5060-4xx Cartridge drive assembly Apply a thin coating of Nyogel type 744 grease to the points identified (A) from the supplied packet. Rotate the motor housing (B) to distribute evenly. ITU drive assembly Apply a thin coating of Nyogel type 744 grease to the points identified (A) from the supplied packet. Note: Do not lubricate Gear 58 (C).
Page 338: Scheduled Maintenance
5060-4xx Scheduled maintenance The operator panel displays 80 Fuser Maintenance and 83 ITU Maintenance for scheduled maintenance. 80 Fuser Maintenance is displayed at each 200,000 copies when the fuser assembly needs to be replaced to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers: Standard fusers •...
Page 339: How To Use This Parts Catalog
• NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. The Lexmark C76x (506x-4xx) laser printer is available in four models: Lexmark C760 5060-401 Non-network...
Page 340: Assembly 1: Covers
5060-4xx Assembly 1: Covers Service Manual...
Page 341 5060-4xx Assembly 1: Covers Asm- Part Units Description index number 1–1 56P2821 Top cover assembly 56P3854 250 output flag and retainer 56P1539 Cable, options - stacker, including output bin sensor 56P2820 Redrive cap cover assembly 12G6380 Machine pad 12G6389 Top front support bracket 56P2813 Right rear cover Screw, parts packet 12G6530...
Page 342 5060-4xx Assembly 1.1: Covers Service Manual...
Page 343 5060-4xx Assembly 1.1: Covers Asm- Part Units Description index number 1.1–1 56P2819 Left upper cover assembly Screw type 323, parts packet 12G6309 56P2809 Left upper pivot cover 12G6491 Jam access spring 56P2835 Lower access jam door assembly 56P2814 Left lower pivot cover 56P2812 Cover, left lower 56P2815...
Page 344: Assembly 2: Cartridge Mounting
5060-4xx Assembly 2: Cartridge mounting Asm- Part Units Description index number 2–1 12G6535 Guide assembly, left side 12G6536 Guide assembly, right side Screws, parts packet 12G6532 Service Manual...
Page 345: Assembly 3: Fuser Assembly
5060-4xx Assembly 3: Fuser assembly Asm- Part Units Description index number 3–1 56P2852 Fuser assembly, 220 V 500W 56P2851 Fuser assembly, 115 V 500W 56P2853 Fuser assembly, 100 V 500W (Japan) Parts catalog...
Page 346 5060-4xx Assembly 3.1: Fuser (web oiler) Service Manual...
Page 347 5060-4xx Assembly 3.1: Fuser (web oiler) Asm- Part Units Description index number 3.1–1 12G6545 Web oiler assembly 56P2856 Fuser assembly, web oiler 220 V 500W 56P2855 Fuser assembly, web oiler 115 V 500W 56P2854 Fuser assembly, web oiler 100 V 500W (Japan) 56P1558 Web oiler driver board assembly 12G6543...
Page 348: Assembly 4: Fuser Drive
5060-4xx Assembly 4: Fuser drive Asm- Part Units Description index number 4–1 Screws type 323, parts packet 12G6309 56P2802 Fuser drive assembly 56P1563 Card assembly - fuser drive Screws, parts packet 12G6531 (card assembly mounting) 7-10 Service Manual...
Page 349: Assembly 5: Vacuum Transport Belt (Vtb) Assembly
5060-4xx Assembly 5: Vacuum transport belt (VTB) assembly Asm- Part Units Description index number 5–1 12G6491 Jam access spring 12G6489 Vacuum transport belt assembly 7-11 Parts catalog...
Page 350: Assembly 6: Transfer
5060-4xx Assembly 6: Transfer Asm- Part Units Description index number 6–1 12G6303 Second transfer roll 12G6488 Transfer plate assembly 7-12 Service Manual...
Page 351: Assembly 7: Printheads
5060-4xx Assembly 7: Printheads Asm- Part Units Description index number 7–1 56P2801 Printhead assembly (do not replace more than one printhead at a time) Screw, parts packet 12G6534 56P2292 Printhead spacer 56P1198 Thermistor card Screw, parts packet 12G6533 56P2296 Card assembly, printhead diagnostic aid 7-13 Parts catalog...
Page 352: Assembly 8: Paper Feed Output (Redrive)
5060-4xx Assembly 8: Paper feed output (redrive) Asm- Part Units Description index number 8–1 56P0167 Anchor, bracket mounting 12G6493 Upper door hinge Screw, parts packet 12G6533 56P2204 Redrive belt 300 T 12G6492 Redrive assembly 56P2836 Redrive door assembly 56P1532 Lower right door latch 56P1533 Lower left door latch Screw, parts packet 12G6530...
Page 353: Assembly 9: Paper Feed Input
5060-4xx Assembly 9: Paper feed input Asm- Part Units Description index number 9–1 56P2101 Sensor, S2/NMS 56P2175 Sensor, transparency reflective (XPAR) 56P2174 Cable, S2/XPAR/NMS/MPF (without sensors) 56P1524 Paper out sensor MPF 56P2100 Cable assembly, S2/XPAR/NMS/MPF (with sensors) 7-15 Parts catalog...
Page 354: Assembly 10: Paper Size Sensing
5060-4xx Assembly 10: Paper size sensing Asm- Part Units Description index number 10–1 56P1564 System board shield support with clips 12G6468 Paper size sensing bracket 12G6467 Paper size sensing spring Screw, paper size sensing assembly mounting, parts packet 12G6531 Screw, paper size sensing card mounting, parts packet 12G6531 56P2845 US media size sensing card assembly, 421/422 only 56P2895...
Page 355: Assembly 11: Paper Feed Transport
5060-4xx Assembly 11: Paper feed transport Asm- Part Units Description index number 11–1 56P2194 Nip relief handle 56P2857 Kit, registration motor assembly, including - Staging motor assembly - Gear, reference plate - Gear, staging idler - Gear, staging reduction - Motor screws Screw type 323, parts packet 12G6309 7-17 Parts catalog...
Page 356: Assembly 12: Multipurpose Feeder (Mpf)
5060-4xx Assembly 12: Multipurpose feeder (MPF) 7-18 Service Manual...
Page 357 5060-4xx Assembly 12: Multipurpose feeder (MPF) Asm- Part Units Description index number 12–1 56P2825 MP feeder door cover 12G6460 Door hinge restraint Screw, parts packet 12G6533 56P2826 Frame bias latch 56P2827 Frame bias latch cover Screw, parts packet 12G6533 12G6454 Frame bias spring 56P2831 MPF support bracket cover...
Page 358: Assembly 13: 500-Sheet Integrated Tray
5060-4xx Assembly 13: 500-Sheet integrated tray Asm- Part Units Description index number 13–1 56P2834 500-Sheet tray assembly 12G6419 Back restraint latch 12G6418 Back restraint 12G6425 Tray bias bellcrank assembly Screw, parts packet 12G6533 12G6426 Tray bias spring 12G6568 Reflector label 12G6421 Wear strip 12G6420...
Page 359: Assembly 14: Autocompensator Assembly
5060-4xx Assembly 14: Autocompensator assembly Asm- Part Units Description index number 14–1 12G6471 Tray interlock bellcrank 12G6558 Pick arm lift bellcrank 56P1526 Pick assembly 500-tray 12G6557 Bellcrank lift spring 12G6476 Paper level sensing assembly 12G6472 Tray interlock bracket 12G6461 Sensor, paper out/low Screw, pick roll mounting, parts packet 12G6533 99A0070 Pick roll tires (2 per pack)
Page 360: Assembly 15: Itu Assembly
5060-4xx Assembly 15: ITU assembly Asm- Part Units Description index number 15-1 56P1513 ITU light shield assembly (autoconnect) 56P1540 Printhead interlock cable assembly 56P2847 ITU assembly 56P1572 ITU coupler retract lever 7-22 Service Manual...
Page 361: Assembly 16: Itu Drive Assembly
5060-4xx Assembly 16: ITU drive assembly Asm- Part Units Description index number 16–1 56P2806 ITU drive motor assembly 12G6385 #58 gear 56P2805 ITU motor drive Screw type 323, parts packet 12G6309 (ITU drive motor to ITU drive assembly) Screw type 323, parts packet 12G6309 (ITU drive assembly lower frame) 7-23 Parts catalog...
Page 362: Assembly 17: Itu Loading
5060-4xx Assembly 17: ITU loading 7-24 Service Manual...
Page 363 5060-4xx Assembly 17: ITU loading Asm- Part Units Description index number 17–1 56P1568 Yellow terminal contact assembly 12G6442 Terminal, contact spring Screw, parts packet 12G6533 12G6353 Cartridge support roller 56P1495 Parts packet, ITU loading - yellow, including - Yellow BOR spring - Rear block guide - Rear transfer bellcrank - Front V block guide...
Page 364: Assembly 18: Waste Toner
5060-4xx Assembly 18: Waste toner Asm- Part Units Description index number 18–1 12G6494 Waste toner container 12G6470 Waste container latch spring 12G6469 Waste container latch 7-26 Service Manual...
Page 365: Assembly 19: Bor Drive Assembly
5060-4xx Assembly 19: BOR drive assembly Asm- Part Units Description index number 19–1 56P1536 Motor assembly, Lift/BOR 7-27 Parts catalog...
Page 366: Assembly 20: Cartridge Contact Assembly
5060-4xx Assembly 20: Cartridge contact assembly Asm- Part Units Description index number 20–1 56P0310 Cartridge contact assembly, complete, cyan/magenta/yellow 12G6376 Spring, rear hold down 12G6377 Rear hold down bellcrank 56P1561 Cartridge contact assembly, complete black 7-28 Service Manual...
Page 367: Assembly 21: Cartridge Drive Assembly
5060-4xx Assembly 21: Cartridge drive assembly Asm- Part Units Description index number 21–1 56P2803 Cartridge drive assembly, cyan/magenta/black (one drive assembly per package) Screw, parts packet 12G6530 56P2804 Cartridge drive assembly, yellow 7-29 Parts catalog...
Page 368: Assembly 22: Electronics
5060-4xx Assembly 22: Electronics 7-30 Service Manual...
Page 369 5060-4xx Assembly 22: Electronics Asm- Part Units Description index number 22–1 11A9095 Power cord set (LV)—U.S., Asia Pacific (English), Canada, Colombia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Taiwan, Venezuela, Virgin Islands 1339553 Power cord set (LV)—Japan 43H5544...
Page 370 5060-4xx Assembly 22.1: Electronics 7-32 Service Manual...
Page 371 5060-4xx Assembly 22.1: Electronics Asm- Part Units Description index number 22.1–1 56P1517 System board outer shield 56P1547 Cable clip 56P1518 System board shield assembly with clips 56P1545 Cable, ground 56P1564 System board shield support with clips Screw, parts packet 12G6531 56P2841 System board, network, 402/422 only 56P2840...
Page 372 5060-4xx Assembly 22.2: Electronics Asm- Part Units Description index number 22.2–1 12G6327 Transfer HVPS board Screw type 323, parts packet 12G6309 (TFR HVPS board to frame) Screw, parts packet 12G6530 (TFR HVPS board to frame) 12G6541 Standoff, high voltage power supply - developer board Screw, parts packet 12G6540 56P2897 Developer HVPS board...
Page 373 5060-4xx Assembly 22.3: Electronics Asm- Part Units Description index number 22.3–1 56P1551 VTB fan, 60 mm 12G6490 VTB fan gap cover 56P1509 Fuser fan assembly with cable 12G6529 Screws, fuser fan mounting 56P1538 RIP fan, 92 mm 56P1500 RIP fan duct Screws, parts packet 12G6530 7-35 Parts catalog...
Page 374: Assembly 23: Electronics-Cabling Interconnections 1
5060-4xx Assembly 23: Electronics—cabling interconnections 1 7-36 Service Manual...
Page 375 5060-4xx Assembly 23: Electronics—cabling interconnections 1 Asm- Part Units Description index number 23–1 56P1539 Cable, options - stacker with output bin sensor 56P1538 RIP fan, 92 mm 56P1536 Motor assembly, Lift/BOR 56P1550 Cable, oiler motor driver 12G6321 Cable, operator panel 56P2801 Printhead assembly - yellow mirror motor (attached to yellow printhead) 56P1549...
Page 376 5060-4xx Assembly 24: Electronics—cabling interconnections 2 7-38 Service Manual...
Page 377 5060-4xx Assembly 24: Electronics—cabling interconnections 2 Asm- Part Units Description index number 24–1 56P1565 Black terminal contact assembly 56P1567 Cyan terminal contact assembly 56P1568 Yellow terminal contact assembly 56P1566 Magenta terminal contact assembly 56P0174 Cable assembly, second transfer voltage 56P1502 Cable, HVPS control - transfer 7-39 Parts catalog...
Page 378 5060-4xx Assembly 25: Electronics—cabling interconnections 3 Asm- Part Units Description index number 25–1 56P1501 Cable assembly, HVPS control - developer 56P0310 Cartridge contact assembly, complete, cyan/magenta/yellow 56P1561 Cartridge contact assembly, complete, black 7-40 Service Manual...
Page 379 5060-4xx Assembly 26: Electronics—cabling interconnections 4 Asm- Part Units Description index number 26–1 56P1503 Cable assembly - options bottom/paper size sensing 56P2806 ITU drive assembly with motor and waste toner full switch 7-41 Parts catalog...
Page 380: Assembly 27: Output Expander
5060-4xx Assembly 27: Output expander 7-42 Service Manual...
Page 381 5060-4xx Assembly 27: Output expander Asm- Part Units Description index number 27–1 56P2870 Output expander, complete 56P2918 Right cover 56P2919 ESD brush cover 56P2875 Deflector, upper redrive, also order 99A0104 99A0104 Spring, upper diverter 99A0369 Shaft assembly, exit, also order parts packet 99A0572 99A0052 Shaft assembly, lower exit, also order parts packet 99A0572...
Page 382 5060-4xx Assembly 27.1: Output expander 7-44 Service Manual...
Page 383 5060-4xx Assembly 27.1: Output expander Asm- Part Units Description index number 27.1–1 56P2916 Door assembly, right jam access 99A0368 Shaft assembly, lower, also order parts packet 99A0572 99A0363 Pulley, drive 56P0410 Bracket, rear attach Screw, parts packet 56P0169 56P2872 Cover, front 99A0361 Belt, 160 gear 99A0362...
Page 384: Assembly 28: 5-Bin Mailbox
5060-4xx Assembly 28: 5-Bin mailbox 7-46 Service Manual...
Page 385 5060-4xx Assembly 28: 5-Bin mailbox Asm- Part Units Description index number 28–1 56P2880 5-Bin mailbox, complete 56P2820 Redrive cap cover assembly 56P2937 Cover, wire 56P2882 Cover, top bin 56P2931 Latch, access door rear 99A0104 Spring, upper diverter 56P2889 Door, front 56P2881 Latch, access door front 56P2930...
Page 386 5060-4xx Assembly 28.1: 5-Bin mailbox 7-48 Service Manual...
Page 387 5060-4xx Assembly 28.1: 5-Bin mailbox Asm- Part Units Description index number 28.1–1 99A1741 Spring, diverter 56P2936 Frame asm, right side Screw type 323, parts packet 12G6309 99A1728 Cam, diverter actuator 99A1731 Spring, diverter actuator 99A1729 Latch, diverter actuator 99A1730 Arbor, diverter actuator 99A1789 Retainer, C-clip 56P0418...
Page 388: Assembly 29: 500-Sheet Drawer Option
5060-4xx Assembly 29: 500-Sheet drawer option 7-50 Service Manual...
Page 389 5060-4xx Assembly 29: 500-Sheet drawer option Asm- Part Units Description index number 29–1 56P2850 500-Sheet drawer option, complete 56P2834 500-Sheet tray assembly 12G6419 Back restraint latch 12G6418 Back restraint 12G6425 Tray bias bellcrank assembly Screw, parts packet 12G6533 12G6426 Tray bias spring 12G6568 Reflector label 12G6421...
Page 390 5060-4xx Assembly 29.1: 500-Sheet drawer option 7-52 Service Manual...
Page 391 5060-4xx Assembly 29.1: 500-Sheet drawer option Asm- Part Units Description index number 29.1–1 56P0168 Drive assembly, 500 option 2 Screw type 323, parts packet 12G6309 56P2868 500-Sheet option tray pick assembly 12G6565 Paper level sensing assembly 12G6471 Tray interlock bellcrank 56P2859 Cover, frame 12G6553...
Page 392: Assembly 30: Duplex Option
5060-4xx Assembly 30: Duplex option 7-54 Service Manual...
Page 393 5060-4xx Assembly 30: Duplex option Asm- Part Units Description index number 30–1 56P2860 Duplex option, complete 56P2863 Back cover 56P2898 Redrive bearing 56P0447 Duplex entry shaft assembly Screw, parts packet 12G6533 56P0434 Right side front tray guide 56P0483 Deflector actuator assembly 56P1570 Deflector follower assembly 56P2861...
Page 394 5060-4xx Assembly 30.1: Duplex option 7-56 Service Manual...
Page 395 5060-4xx Assembly 30.1: Duplex option Asm- Part Units Description index number 30.1–1 56P0456 Duplex support plate 56P0462 Autoconnect cable assembly 56P0463 DC forward/reverse motor assembly 56P0464 DC duplex feed motor Screw type 323, parts packet 12G6309 12G6510 Cable tie (6 in pack) Screw type 323, parts packet 88A0235 56P0459 Back support...
Page 396 5060-4xx Assembly 31: High-capacity input tray (HCIT) 7-58 Service Manual...
Page 397 5060-4xx Assembly 31: HCIT Asm- Part Units Description index number 31–1 56P0561 Paper size sensor box assembly 56P0519 Flag, paper size F 56P0520 Flag, paper size C 56P0518 Flag, paper size R 56P0522 Spring, paper size flag 56P0516 Sensor, photo interrupter 56P0511 Paper size sensors cable 56P0494...
Page 398: Assembly 31: High-Capacity Input Tray (Hcit)
5060-4xx Assembly 31.1: High-capacity input tray (HCIT) 7-60 Service Manual...
Page 399 5060-4xx Assembly 31.1: HCIT Asm- Part Units Description index number 31.1–1 56P2905 Rear cover 56P2903 Right side cover 56P0491 Caster, movable Screws, parts packet 12G6533 56P0493 F adjuster 56P2901 Front cover 56P2902 Cover, main CA 56P0492 Caster, fixed 56P2904 Left side cover 56P2906 Upper left side jam cover 56P0507...
Page 400: Assembly 32: Finisher
5060-4xx Assembly 32: Finisher 7-62 Service Manual...
Page 401 5060-4xx Assembly 32: Finisher Asm- Part Units Description Index number 32–1 56P0321 Top cover (tall finisher) 56P1287 Scanner plate (short finisher) 56P0569 Rear cover (tall finisher) 56P1285 Rear cover (short finisher) 56P0573 Upper right side cover (tall finisher) 56P1286 Upper right side cover (short finisher) 56P0574 Lower tray cover 56P0576...
Page 402 5060-4xx Assembly 32.1: Finisher 7-64 Service Manual...
Page 403 5060-4xx Assembly 32.1: Finisher Asm- Part Units Description index number 32.1–1 56P0324 Motor assembly elevator tray 56P0357 Actuation assembly 56P1471 HCOF control board assembly 56P0325 Motor assembly paper feed 56P0332 Accumulator paper feed belt (40S3M900) 56P2294 Accumulator drive belt (B30S2M334) 56P0315 Punch assembly 56P0345...
Page 404 5060-4xx Assembly 32.2: Finisher 7-66 Service Manual...
Page 405 5060-4xx Assembly 32.2: Finisher Asm- Part Units Description index number 32.2–1 56P0355 Guide vertical paper 56P0385 Solenoid drop assembly 56P0347 Jogger fence homing sensor (EE-SX1235A-P2) 56P0384 Accumulator belt (hook) 56P2294 Accumulator drive belt (B30S2M334) 56P0319 Accumulator w/o stapler 56P0348 Drop timing sensor (OS-535223-602) 56P0349 Accumulator homing sensor (OS-311D-A5) 56P0316...
Page 406 5060-4xx Assembly 33: Finisher cables Service Manual...
Page 407: Assembly 33: Finisher Cables
5060-4xx Assembly 33: Finisher cables Asm- Part Units Description index number 33–1 56P0340 Communications cable 56P0341 Power cord 56P0359 Harness cable assembly H2 - system board to drop solenoid 56P0360 Harness cable assembly H3 - system board to harness cable assembly H4/drop timing sensor/punch motor homing sensor/inverter timing sensor 56P0361 Harness cable assembly H4 - harness cable H3 to punch timing sensor...
Page 408: Assembly 34: Envelope Option
5060-4xx Assembly 34: Envelope option 7-70 Service Manual...
Page 409 5060-4xx Assembly 34: Envelope option Asm- Part Units Description index number 34–1 56P2890 Envelope option (complete) 56P2891 Envelope tray assembly 7-71 Parts catalog...
Page 410: Assembly 35: Outdoor Media Tray Option
5060-4xx Assembly 35: Outdoor media tray option Asm- Part Units Description index number 35–1 56P2892 Outdoor media drawer assembly 56P2893 Outdoor media tray assembly 7-72 Service Manual...
Page 411: Assembly 36: Banner Option
5060-4xx Assembly 36: Banner option Asm- Part Units Description index number 36–1 56P2894 Banner input assembly 7-73 Parts catalog...
Page 412: Assembly 37: Options
5060-4xx Assembly 37: Options 7-74 Service Manual...
Page 413 ImageQuick™ card assembly 56P3303 PRESCRIBE card assembly 56P1433 MarkNet X2031e Ethernet 10/100BaseTX - 3 Port External Server 56P1434 MarkNet X2030t Token-Ring External Server 56P1742 MarkNet N2101e Ethernet 10/100BaseTX Internal Server 56P9932 Lexmark Forms hard disk, 5GB or larger w/adapter 7-75 Parts catalog...
Page 414: Assembly 38: Miscellaneous
5060-4xx Assembly 38: Miscellaneous Asm- Part Units Description index number Screw type 323, parts packet 12G6309 Screw type 324, parts packet 12G6530 Screw type 232, parts packet 12G6531 Screw type 102, parts packet 12G6532 Screw type 312/322/412/423, parts packet 12G6533 Screw type 484, parts packet 12G6534 Screw, 500-sheet tray, parts packet 12G6538 Screw type 124, parts packet 12G6539...
Page 415: Appendix A-Service Tips
5060-4xx Appendix A—Service tips Printhead diagnostics If you get a printhead error, follow this diagnostic to find the specific failure. Verify all the printhead cables are properly seated. If the printhead cables are properly seated and the error remains, record the error code. Continue to the next step.
Page 416 5060-4xx Install the printhead diagnostic tool and determine the problem. The following procedure shows the yellow and cyan switch as an example. Turn off the printer. Unplug the printhead cables from the system board and connect them to the printhead diagnostic tool.
Page 417 5060-4xx Turn on the printer and note the new error codes. • If an automatic calibration begins, 36 Printer Service Required may appear. The printhead and system board are working correctly and the printhead cable connections should be checked. Press Go to clear the error. •...
Page 418: Identifying The Printheads
5060-4xx Identifying the printheads Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost. Notes: • Whenever a printhead is removed, it is necessary to perform the “Printhead mechanical alignment”...
Page 419: System Board Cabling Reference
5060-4xx System board cabling reference “System board - non-network” on page 5-6 “System board - network” on page 5-7 for connections. Refer to the System board wiring diagram for additional details. Appendix A—Service tips...
Page 420: Redrive Belt Routing
5060-4xx Redrive belt routing If the redrive belt has been removed, use the diagram and information to properly route the belt. The idler gear roller in these photos is only visible because the printer has been disassembled to the frame. The gear will have to be located by feel to ensure proper installation.
Page 421: Finisher Alignment
5060-4xx Finisher alignment This tip provides detailed instructions for aligning the finisher to the printer. The sides of the finisher must be parallel with the printer and at the same height, or you may have paper feeding problems. There are four locations where adjustments can be made to correctly align the finisher with the printer. There are two adjustment casters on the left (the side closest to the printer) and two on the right, underneath the platform cover.
Page 422 5060-4xx • Tall finisher – Printer – Optional duplex unit – One additional 500-sheet drawer – Optional 2000-sheet drawer – Finisher Finisher Printer Duplex unit 500-sheet drawer 2000-sheet drawer Service Manual...
Page 423 5060-4xx Step 1: Secure the printer Completely stabilize the printer before the finisher alignment process is started. How this is done depends on whether you have a short or tall finisher. Short finisher Attach caster brakes (A) to the two back legs of the printer caster base. Screw the caster brakes onto the legs of the caster base.
Page 424 5060-4xx Step 2: Align the pin Adjust the two casters on the left side (closest to the printer) to raise or lower the finisher as needed, so the pin (D) on the printer properly aligns with the hole in the finisher (the pin should freely slide into the hole). Short finisher Insert the Allen wrench (E) into either caster bolt (F).
Page 425 5060-4xx Tall finisher Loosen or tighten the wingnuts (G) to adjust the height of the finisher (clockwise raises the finisher). Step 3: Align the bumper pads Adjust the two casters on the right side (under the platform cover) to raise or lower the finisher as needed so the two bumper pads on the finisher lightly touch the printer.
Page 426 5060-4xx Short and tall finisher Lift the platform cover. Insert the Allen wrench (E) into either caster bolt (J). Rotate the wrench in the appropriate direction to adjust the height of the finisher (clockwise raises the finisher). Repeat with the other caster bolt. Step 4: Adjust the tilt If necessary, adjust the tilt of the finisher so that the front is flush with the front of the printer.
Page 427 5060-4xx Step 5: Connect the finisher and printer Push the finisher against the printer, making sure the gap in the front is the same as the gap in the back. When adjoining the finisher and the printer, make sure that the finisher cable is out of the way of the paper path. If the cable folds itself between the finisher and the printer, disconnect the cable, twist it one time, and then reconnect it.
Page 428: Duplex Option Deflector Button Replacement
5060-4xx Duplex option deflector button replacement 230 Paper Jam - duplex deflector fails During a duplex job, the duplex option fails to actuate the deflector in the fuser and the paper is diverted away from the duplex. The duplex option does not receive the sheet and prompts a 230 Paper Jam message. Replace the rubber deflector button with the enclosed compression spring deflector button.
Page 429 5060-4xx Place the new button into the cam. Verify the new button moves freely by pressing the button firmly down and watching it snap back. Note: Leave the button in the up position. A-15 Appendix A—Service tips...
Page 430 5060-4xx A-16 Service Manual...
Page 431: Appendix B-Print Quality Samples
5060-4xx Appendix B—Print quality samples The following pages represent some of the pages available in various menus. While they are as close as possible to what you will see, variations in printing may result from individual user printer settings, media, and printer alignment.
Page 432: Print Menus-Page Two Of Two
5060-4xx Print Menus—Page two of two Service Manual...
Page 433: Print Tests
5060-4xx Print tests Print Quality Pages—Title page (total of five) Appendix B—Print quality samples...
Page 434: Print Quality Pages-Page 1 (Total Of Five
5060-4xx Print Quality Pages—Page 1 (total of five) Service Manual...
Page 435: Print Quality Pages-Page 2 (Total Of Five
5060-4xx Print Quality Pages—Page 2 (total of five) Appendix B—Print quality samples...
Page 436: Print Quality Pages-Page 3 (Total Of Five
5060-4xx Print Quality Pages—Page 3 (total of five) Service Manual...
Page 437: Print Quality Pages-Page 4 (Total Of Five
5060-4xx Print Quality Pages—Page 4 (total of five) Appendix B—Print quality samples...
Page 438: Registration And Alignment
5060-4xx Registration and alignment Quick Test Page Service Manual...
Page 439: Printhead Mechanical Alignment Test Page
5060-4xx Printhead mechanical alignment test page Appendix B—Print quality samples...
Page 440: Printhead Electronic Alignment Test Page-Magenta (One Of Two
5060-4xx Printhead electronic alignment test page—Magenta (one of two) B-10 Service Manual...
Page 441: Printhead Electronic Alignment Test Page-Magenta (Two Of Two
5060-4xx Printhead electronic alignment test page—Magenta (two of two) B-11 Appendix B—Print quality samples...
Page 442 5060-4xx B-12 Service Manual...
Page 443: Index
5060-4xx Index Numerics BOR drive motor, location 3-20 Button Test 2-40 1565 Emul Error Load 1xx service errors 2-13 error code table – cabling 2-41 2-65 error-specific service checks – 7-36 system board 2000-sheet input tray option system board in color diagnostics 7-38 transfer HVPS...
Page 444 5060-4xx 5-20 3-20 HVPS board HARDWARE TESTS 5-23 3-20 LVPS Button Test 5-25 3-21 paper size sensing board CACHE Test 3-21 system board DRAM Test 3-20 LCD Test 3-22 Parallel Wrap Test 3-34 DC Charge Adjustment 3-22 ROM Test 2-105 DC power, service checks 3-23 Serial Wrap Test...
Page 445 5060-4xx error codes fuser web oiler motor assembly 2-40 4-42 1565 service error installation 4-40 1xx service errors removal 2-15 2xx paper jams 2-31 3x-8x attendance errors 3-36 HCIT standalone test mode 9xx service errors high-capacity input tray (HCIT) 2-18 sub error code tables, 9xx and 2xx 5-26 connections...
Page 446 5060-4xx 3-32 7-38 Mono Page Count electronics—cabling interconnections 2 3-17 7-40 Motor Detect electronics—cabling interconnections 3 7-41 multipurpose feeder (MPF) electronics—cabling interconnections 4 7-18 7-19 7-70 parts catalog envelope option 4-48 7-62 7-64 7-66 removal finisher 7-68 finisher cables fuser assembly 4-70 narrow media sensor (NMS) cable, removal 7-10...
Page 447 5060-4xx 4-37 PRINT TESTS fuser drive card assembly 3-19 4-38 Print Quality Pgs fuser fan 3-19 4-39 Quick Test Page fuser top duct 4-61 4-63 4-40 printer alignment procedures fuser web oiler motor assembly and card 4-43 printhead diagnostics inner system board shield 4-63 4-44 printhead electronic alignment...
Page 448 5060-4xx 4-70 4-71 7-15 S2/narrow media (NMS) excessive fuser drive motor assembly noise 7-15 transparency fuser fan fails to run or is noisy 3-33 Serial Number machine inoperative 3-23 Serial Wrap Test one or more op panel buttons do not work 2-41 service checks operator panel - one pel or random pels are missing...
Page 449 5060-4xx vacuum transport belt (VTB) 7-11 parts catalog 4-77 removal vacuum transport belt (VTB) fan 4-79 removal 2-85 service check 4-79 waste container door, removal 7-26 waste container latch 7-26 waste toner container, parts catalog web oiler fuser location 4-80 removal replacement web oiler fusers replacements...
Page 450 5060-4xx Service Manual...
Page 451: Part Number Index
5060-4xx Part number index Description Page 11A9095 Power cord set (LV)—U.S., Asia Pacific (English), Canada, Colombia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Japan, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Taiwan, Venezuela, Virgin Islands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 12G6303 Second transfer roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12...
Page 452 5060-4xx 12G6471 Tray interlock bellcrank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 7-53 12G6472 Tray interlock bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 453 5060-4xx 56P0174 Cable assembly, 2nd transfer voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 56P0310 Cartridge contact assembly, complete, cyan/magenta/yellow - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28...
Page 454 5060-4xx 56P0375 Harness cable assembly E9 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-69 56P0376 Harness cable assembly E10 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-69...
Page 455 5060-4xx 56P0493 F adjuster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 56P0494 System control board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59...
Page 456 56P1427 Lexmark Forms 32MB Flash DIMM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 457 5060-4xx 56P1555 110 V web oiler upgrade kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17 56P1556 220 V web oiler upgrade kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17...
Page 458 5060-4xx 56P2813 Right rear cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56P2814 Left lower pivot cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56P2815 Waste container door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56P2816 Handle, front access door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 459 5060-4xx 56P2873 Rear cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43 56P2874 Cover, rear support - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43...
Page 460 56P9932 Lexmark Forms hard drive, 5GB or larger w/adapter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 461 5060-4xx 99A1741 Spring, diverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49 99A1742 Sensor, 5-bin mailbox pass thru - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47...
Page 462 5060-4xx I-20 Service Manual...
Page 466: Nip Shock
2.02 Transfer to Fuser 319.4 12.57 Fuser Nip to First Redrive 50.0 1.97 Fuser Nip to Exit Sensor 58.2 2.29 Fuser Nip to Exit Tray Nip 420.3 16.55 M to 2 Xfer Lexmark International, Inc. Revision 3.1 July 13, 2004...

This manual is also suitable for:

C 762

Lexmark C760 Service Manual

Notices and Safety Information

Laser Notice

Safety Information

Preface

Definitions

General Information

Tools Required for Service

Options and Features

Printer Specifications

Print Speed and Performance Print Speed

Media Specifications

Web Oiler Upgrade Kit and Replacements

Acronyms

Diagnostic Information

Start

POR (Power-On Reset) Sequence

Symptom Tables

Error Code Table

Service Checks

Diagnostic Aids

Configuration Menu

Diagnostics Mode

HCIT Standalone Test Mode

Repair Information

Handling ESD-Sensitive Parts

Screw Identification Table

Removal Procedures

Connector Locations

Locations

Connectors

Quick Links

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Summary of Contents for Lexmark C760