Lexmark 13P0195 - C 750dn Color Laser Printer Service Manual
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Lexmark 13P0195 - C 750dn Color Laser Printer Service Manual

Lexmark 13P0195 - C 750dn Color Laser Printer Service Manual

Service manual
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Download this manual See also: Setup Manual
Revised: March 2005
Lexmark™ C750
5060-00x
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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Summary of Contents for Lexmark 13P0195 - C 750dn Color Laser Printer

  • Page 1 Revised: March 2005 Lexmark™ C750 5060-00x • 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 1-800-553-9727. In other countries, contact your point of purchase. Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    5060-00x Table of contents Notices and safety information ......... . . xi Laser notice .
  • Page 4 5060-00x Service checks ............. 2-42 100 ITU Error .
  • Page 5 5060-00x 930 Error code ..............2-92 940 Error code .
  • Page 6 5060-00x SIZE SENSING ..............3-8 TYPE SENSING .
  • Page 7 5060-00x DEVICE TESTS ..............3-29 Quick Disk Test .
  • Page 8 5060-00x Fuser fan removal ..............4-34 Fuser top duct removal .
  • Page 9 5060-00x High-capacity input tray (2000-sheet HCIT) board ........5-26 High-capacity output finisher (HCOF) .
  • Page 10 5060-00x Appendix A—Service tips..........A-1 Printhead diagnostics .

  • Page 11: Notices And Safety Information

    5060-00x Notices and safety information 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 5060-00x 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 5060-00x 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 5060-00x Service Manual...
  • Page 15 5060-00x Laser notice...
  • Page 16 5060-00x Service Manual...

  • Page 17: Safety Information

    5060-00x 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 18 5060-00x 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 19 5060-00x 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 20: Preface

    5060-00x 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 21: General Information

    You can add up to three optional drawers to the base printer, which can increase the printer paper capacity to 2000 sheets. The Lexmark C750 (5060-00x) laser printer is available in two models: 5060-001 5060-002...

  • Page 22: Options And Features

    5060-00x Options and features Lexmark C750 printers support only Lexmark C750 paper-handling options. These options are not compatible with any other Lexmark printer. • 500-Sheet Drawer - (includes 500-sheet tray and support unit) installs beneath the printer and holds approximately 500-sheets of 20 lb paper. Multiple optional drawers are supported simultaneously.

  • Page 23: Resolution

    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 C750 PostScript emulation driver. Printer specifications Dimensions...

  • Page 24: Electrical Specifications

    100 V web oiler upgrade kit 12G6502 The installation of the web oiler upgrade kit converts a standard Lexmark C750 printer to an oil web capable printer. The web oiler upgrade kit includes an oiler fuser and web oiler. Replacements...

  • Page 25: Acoustics

    5060-00x Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296. 1-Meter average sound Model Status pressure Lexmark C750(n) 2400 image quality printing 51 dBA Idle (standby) 42 dBA Lexmark C750dn 2400 image quality printing...

  • Page 26: Print Speed And Performance Print Speed

    5060-00x Print speed and performance print speed 2400 Image quality 1200 x 1200 dpi Simplex printing on letter-size media (pages per minute) Letter—8.5 in. x 11 in. A4—8.3 in. x 11.7 in. Legal—8.5 in. x 14 in. 16.2 Transparencies Envelopes Duplex printing on letter-size media (sides per minute) Letter—8.5 in.

  • Page 27: Media Specifications

    Maximum 512MB 512MB Available memory options Optional 64MB, 128MB and 256MB SDRAM DIMMs are available from Lexmark. The memory options are 168- pin synchronous DRAM DIMMs (dual in-line memory modules). Flash memory options • Memory slots for extra flash or DRAM: 2 •...

  • Page 28: Media Size

    5060-00x 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 8.27in. (148 mm x 210 mm) JIS-B5 7.17 in. x 10.23 in. (182 mm x 257 mm) Statement 5.5 in.
  • Page 29 5060-00x Media size supported Other envelope 3.87 x 6.38 in. to 6.93 x 9.84 in. (98.4 x 162 mm to 176 x 250 mm) When Universal is selected, the page is formatted for 8.5 x 14 in. (215.9 x 355.6 mm), unless the size is specified in the software application.

  • Page 30: Index

    5060-00x Input media types and weights Media Weight Integrated trays and optional 500-sheet drawer b, f Paper Xerographic or business paper 16 to 19.9 lb bond (60 to 74.9 g/m grain long) 20 to 47 lb bond (75 to 176 g/m grain long) Specialty papers Gloss book...

  • Page 31: Output Media Types And Weights

    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 32 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 33: Acronyms

    5060-00x 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 34 5060-00x 1-14 Service Manual...

  • Page 35: Diagnostic Information

    5060-00x 2. Diagnostic information Start 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.

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

    Busy is displayed Front panel LED blinks. Redrive exit roller turns. Any cartridge errors are posted such as a defective cartridge, Lexmark Return Program information, or missing cartridge. Any applicable maintenance messages display such as 80 Fuser Maintenance or 83 Maintenance.

  • Page 37: Symptom Tables

    5060-00x Symptom tables Symptom table—base printer Symptom Action Fuser fan fails to run or is noisy Go to “925 Error code” on page 2-90. RIP fan fails to run or is noisy Go to “927 Error code” on page 2-91. VTB fan fails to run or is noisy Go to “926 Error code”...

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

    5060-00x Symptom Action Print quality: toner on the back of the page Go to “Toner is on the back of the printed page” on page 2-146. Print quality: toner smears or rubs off the page Go to “Toner smears or rubs off the page with no error code displayed”...

  • Page 39: Symptom Table-Output Expander Option

    5060-00x Symptom table—output expander option Symptom Action Printer fails to recognize the option is installed. The Go to “Printer does not recognize that one or more paper feeds into the standard bin. output options as being installed.” on page 2-135 Printer does not display Output Bin Full Go to “No indication that Bin x is full or no...

  • Page 40: Error Code Table

    5060-00x Error code table Error code Action 9xx service errors 900 RIP Software Go to “900 RIP Software Error” on page 2-88. 902 Service Engine Error 0 General Engine Software Errors 902 through 908 indicate an unrecoverable engine software error. The engine board may cause this type of error.
  • Page 41 5060-00x Error code Action 917 Trans Sensor Tray 4 Transparency Sensor Error—replace Tray 4 transparency sensor assembly. If this does not fix the problem, replace the engine board. See “Engine board removal” on page 4-29. 920 Color Calibrate Unrecoverable TPS Gain Error—replace the ITU assembly. See “ITU assembly removal”...
  • Page 42 5060-00x Error code Action 960 RAM Memory Error RAM soldered on board is bad. Replace the RIP board. See “RIP board removal” on page 4-70. 961 RAM Memory Error Errors 961 through 963 indicate that a memory error has occurred on RAM x in slot x installed on the RIP card.

  • Page 43: 1Xx Service Errors

    5060-00x Error code Action 983 <device> comm Invalid command received by the specified device. • Engine • Duplex option • Tray x (where x=1,2,3,4, or 5) • Output bin (where x=1,2,3, or 6) Note: This message is used for single bin output devices. •...
  • Page 44 5060-00x Error code Action 103 ITU Error Memory load error—replace the ITU. See “ITU assembly removal” on page 4-37. 106 Printhead Error Cyan printhead lost Hsync Check for the correct installation of the all the cables to the RIP board assembly and to the printhead assembly;...
  • Page 45 5060-00x Error code Action 112 Printhead Error No first Hysnc (yellow) Check for the correct installation of the all the cables to the RIP board assembly and to the printhead assembly; J2, J3 and J4 on the RIP board. Go to “RIP board”...
  • Page 46 5060-00x Error code Action 116 Printhead Error A magenta printhead servo error has been detected. Verify all packing material has been removed from the printer. Check at the top of the printhead for the cardboard or plastic packaging. If error persists, see “Printhead diagnostics”...
  • Page 47 5060-00x Error code Action 128 Fuser Error Fuser under temperature in standby—hot roll. Go to “128 Error code” on page 2-48. 129 Fuser Error Fuser under temperature in standby—BUR. Go to “129 Error code” on page 2-49. 130 Fuser Error Fuser failed to reach standby temperature—hot roll.
  • Page 48 5060-00x Error code Action 147 Motor DC motor pick motor, no encoder feedback–autocompensator motor— replace the autocompensator assembly. See “Autocompensator pick assembly removal” on page 4-17. If this does not fix the problem, replace the engine board See “Engine board removal” on page 4-29.
  • Page 49 5060-00x Error code Action 170 Motor Mirror motor lost lock (black). Go to “Printhead diagnostics” on page 3-1. Note: Do not adjust or replace any printhead before performing checks in “Printhead diagnostics” on page 3-1. 171 Motor Mirror motor lock not achieved (cyan). Go to “Printhead diagnostics”...
  • Page 50 5060-00x Error code Action 186 PSD Error EOS sensor out of range scan direction (magenta). Update the machine code. Run a Line Length test page. See “Prt Line Len Pg” on page 3-19. If the problem persists, go to “Printhead diagnostics” on page 3-1.

  • Page 51: Sub Error Code Table

    5060-00x Sub error code table Use this table to troubleshoot the printer when 9xx and 1xx error codes are displayed. When a 9xx or 1xx error code is displayed, press and hold Return and press Select to view the Sub error code. Sub error code Explanation 2D 00...
  • Page 52 5060-00x 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 53 5060-00x 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 54: Programming Errors - P101 Through P116

    5060-00x 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 55 5060-00x Button Function Menu Press Menu to: • Take the printer offline (out of the Ready state) and enter the menus. When the printer is offline, press Menu to scroll through the menus and menu items. • List the menu items in the Job Menu (during Busy state). For menu items that have numerical values, such as Copies, press and hold Menu to scroll through the list of values.

  • Page 56: Color Menu

    Print Mode To determine whether images are Color* printed in a monochrome grayscale or in color. Black & White Note: Selections made in the Lexmark C750 PostScript emulation or PCL drivers for Windows will override other selections. 2-22 Service Manual...

  • Page 57: Utilities Menu

    5060-00x Menu Item Purpose Values Print Resolution To define the number of dots printed 2400 IQ* Provides the highest resolution for per inch (dpi). The higher the value, detailed line art or images. the sharper the clarity of printed characters and graphics. 1200 dpi Provides high quality output for text and business graphics, such as line art and...
  • Page 58 5060-00x 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 receive new Warning: Do not turn off the printer resources. while the hard disk is formatting. Cancels the request to format the hard disk and leaves current resources stored on the disk.

  • Page 59: 2Xx Paper Jam Message Table

    5060-00x 2xx Paper jam message table Note: A secondary message only displays if the finisher option is installed. Use the “Sub error code table” on page 2-17 to help diagnose paper jam problems. Primary message Secondary message Description code Paper Jam Leave sheets in Primary: Paper is jammed at the printer input Clear Paper Path...
  • Page 60 5060-00x Primary message Secondary message Description code Paper Jam Leave job in Finisher Primary: The media is jammed due to a Clear paper Path transparency sensor mismatch. Open the printer left door to access the jammed media. If sheets have been accumulated to be stapled or offset when the jam is detected, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be...
  • Page 61 5060-00x Primary message Secondary message Description code Paper Jam Leave Job in Finisher Primary: Media is jammed in the paper path near Clear Paper Path the MP Feeder due to an in-line transparency Go to sensor mismatch. If sheets have been “Autocompensator accumulated to be stapled or offset when the jam service check”...

  • Page 62: User Attendance Message Table

    5060-00x User attendance message table User primary User secondary Explanation message message 200 Paper Jam Clear Leave sheets in Primary: This message indicates that a paper jam has Paper Path Finisher occurred at or near the printer input sensor. Open the area 5 printers left door (paper jam removal door) to access the jammed media.
  • Page 63 5060-00x User primary User secondary Explanation message message 230 Paper Jam Clear Leave Job in Finisher Primary: Paper has most likely jammed in the duplex option. Paper Path 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 64 5060-00x User primary User secondary Explanation message message 272 Paper Jam Clear Leave Job in Finisher Primary: Media is jammed in the 5-bin mailbox option. Open Paper Path area 5 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 65 Change Cartridge This message is displayed when the printer has detected a <Color> Invalid Refill refilled Lexmark Return Program cartridge. <Color> can be black, cyan, magenta, or yellow. Remove the toner cartridge and install a new cartridge. Note: The user receives this message for every invalid cartridge installed.
  • Page 66 5060-00x User primary User secondary Explanation message message Reattach Output Bin x These messages are displayed anytime the printer loses Reattach Bins x-y communications with one of the following options: Check Tray x • Output Bin x (x=1, 2, or 3) Connection •...
  • Page 67 5060-00x User primary User secondary Explanation message message Priming Failed, Retry. This message is displayed when an error has occurred GO/Stop during the printer staple priming operation. The following actions can be taken: • Press Go to initiate the priming operation again or •...
  • Page 68 5060-00x User primary User secondary Explanation message message Install Tray x or This message is displayed when the printer requests the Cancel Job Install Bin user to insert tray x before it can continue printing the job. x or Cancel Job The printer needs to pick media from the missing tray or the Install Duplex or trays below it.
  • Page 69 5060-00x User primary User secondary Explanation message message 31 Defective Black This message is displayed when the top cover is closed and Cartridge a defective print cartridge is detected. It may take the printer 31 Defective Yellow 10 to 20 seconds to determine whether or not the print Cartridge cartridge is installed.
  • Page 70 5060-00x 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 71 5060-00x User primary User secondary Explanation message message 37 Insufficient Held Jobs May Not These messages are displayed when the printer has Memory Be Restored attempted to print and hold jobs from the disk and found that some or all of the jobs could not be restored. Each of the three 57 Configuration Held Jobs messages describe different conditions under which the restore failed.
  • Page 72 5060-00x User primary User secondary Explanation message message 51 Defective Flash This message is displayed when the printer detects a defective flash. Press Go to clear the message The flash is marked as bad and normal operation continues. No flash operation is allowed until the flash problem is resolved.
  • Page 73 5060-00x User primary User secondary Explanation message message 56 Standard Serial These messages may appear when data is sent to the Disabled printer across a serial port, but the port is disabled. 56 Serial 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 5060-00x User primary User secondary Explanation message message 58 Too Many Disks This message is displayed when too many disks are Installed installed. Note: Some configurations of different output options require the installation of one option before the other. 58 Too Many Flash This message is displayed when too many Flash Options Options are installed.
  • Page 75 5060-00x User primary User secondary Explanation message message 64 Unsupported Disk This message is displayed when the printer detects an Format unsupported disk format at POST. This message may appear if the disk was formatted on another system with a different format.

  • Page 76: Service Checks

    5060-00x 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 77 5060-00x Step Action and questions Remove the ITU assembly and check that the sensor Go to step 7 Reinstall the cables cables are seated in the handle of the ITU assembly correctly. Recheck correctly. for a 100 ITU error. If 100 ITU is Note: The sensor connectors are located on the side of displayed, go to the ITU handle assembly.

  • Page 78: 120 Error Code

    5060-00x Step Action and questions Check to see if the ITU drive motor is turning during Replace the ITU Go to step 11 POR. Observe the ITU motor during POR by removing assembly. See the rear cover. “ITU assembly removal” on Is the ITU drive motor turning? page 4-37 Make sure the ITU drive motor assembly cable is...

  • Page 79: Error Code

    5060-00x Step Action and questions Check for continuity between pins 1 and 2 on the AC Replace the LVPS Replace the fuser fuser connector located on the fuser assembly. assembly. See assembly. See “Low voltage “Fuser assembly power supply removal” on (LVPS) removal”...

  • Page 80: Error Code

    5060-00x 122 Error code The printer has detected a problem in the fuser hot roll lamp circuitry, backup roll fuser circuitry, fuser hot roll thermistor, backup roll thermistor, engine board, or LVPS fuser control circuits. Replace the FRUs in the order shown: Fuser assembly.
  • Page 81 5060-00x 125 Error code Hot fuser The printer detects a problem with the fuser running over temperature or the backup rolls have been on too long. A problem could exist in the fuser assembly with the backup roll bearings, backup roll thermistor, or other backup roll parts.

  • Page 82: Error Code

    5060-00x 127 Error code Backup roll thermistor or thermistor circuits are open The printer detects a problem in the fuser back up roll, circuits, fuser backup roll thermistor, engine board, or LVPS fuser control circuits. Step Action and questions Turn the printer on and allow it to reach Ready. Go to step 2 Replace the engine board.

  • Page 83: Error Code

    5060-00x 129 Error code The fuser backup roll is under temperature during standby. Replace the fuser top duct. See “Fuser top duct removal” on page 4-34. Step Action and questions Turn the printer on and allow it to reach Ready. Go to step 2 Replace the engine board assembly.

  • Page 84: Error Code

    5060-00x 130 Error code Hot roll did not reach the correct standby temperature Step Action and questions Measure the voltage on connector J10-11 on the Replace the fuser Go to step 2 engine board. The voltage should measure assembly. See approximately +0.13 V dc to +0.64 V dc as the hot roll “Fuser assembly lamp turn on and off.

  • Page 85: 131 Error Code

    5060-00x 131 Error code The fuser backup roll does not reach the correct standby temperature. Step Action and questions Measure the voltage on connector J10-12 on the Replace the fuser Go to step 2 engine board. See “Engine board” on page 5-7 assembly.

  • Page 86: Error Code

    5060-00x Step Action and questions Measure the voltage on pin 7 of the fuser DC control Replace the fuser Replace the LVPS connector The voltage should measure approximately assembly. See assembly. See +3.3 V dc. “Fuser assembly “Low voltage removal” on power supply Is the voltage correct? page...

  • Page 87: Error Code

    5060-00x Step Action and questions Turn the print on and allow it to reach Ready. Go to step 7 Replace the engine board assembly. Note: The printer may not complete POR and “Engine continues to display a 132 error. board removal” on page 4-29.

  • Page 88: 134 Error Code

    5060-00x Step Action and questions Reinstall the fuser assembly. Watch to see if the lamps Go to step 6 Replace the LVPS turn on and off as the lamps heat up. assembly. See “Low voltage Do the lamps turn on and off? power supply (LVPS) removal”...

  • Page 89: Error Code

    5060-00x 135 Error code Hot fuser The fuser assembly is running over temperature or the backup roll fuser lamp has been on too long. Error 135 may also indicate a problem in the fuser assembly with the backup roll fuser bearings, back up roll thermistor, LVPS, or engine board.

  • Page 90: 136 Error Code

    5060-00x 136 Error code Fuser assembly cam position is not found Step Action and questions Observe the fuser drive assembly gears rotate during Go to step 2 Go to step 6 POR. Do the gears rotate? Do the gears stop and the fuser drive assembly gears Replace the fuser Go to step 3 make a loud buzzing sound?

  • Page 91: Error Code

    5060-00x 148 Error code Step Action and questions Connector J64 on the engine 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 engine board connector J64. Is the cable connected correctly? ITU drive motor—check for continuity between pin 4 of Replace the drive...

  • Page 92: 149 Error Code

    5060-00x 149 Error code Step Action and questions Connector J8 on the engine board—make sure that the Go to step 2 Correctly install the fuser drive motor cable is correctly connected to J8 on cable the engine board. Go to “Engine board”...

  • Page 93: 151 Error Code

    5060-00x 151 Error code Magenta cartridge drive assembly The magenta cartridge drive motor has either failed to lock or has lost lock. Note: Any time any of the cartridge drive motor assemblies are replaced perform the “Motor Detect” on page 3-16.

  • Page 94: Error Code

    5060-00x Step Actions and questions Replace the engine board. Problem solved Call your next level support Does this fix the problem? 153 Error code Yellow cartridge drive assembly The yellow cartridge drive motor has either failed to lock or lost lock. Note: Any time any of the cartridge drive motor assemblies are replaced, perform the “Motor Detect”...
  • Page 95 5060-00x 154 Error code ITU belt motor Step Action and questions Connector J64 on the engine 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 engine board connector J64. Is the cable connected correctly? ITU drive motor—check for continuity between pin 4 of Replace the drive...
  • Page 96 5060-00x 155 Error code Hot fuser Step Action and questions Connector J8 on the engine board—make sure that the Go to step 2 Correctly install the fuser drive motor cable is correctly connected to J8 on cable the engine board. Go to “Engine board”...
  • Page 97 5060-00x 157 Error code Magenta cartridge drive assembly The magenta cartridge drive motor has either failed to lock or has lost lock. Note: Any time any of the cartridge drive motor assemblies are replaced, perform the “Motor Detect” on page 3-16.

  • Page 98: 158 Error Code

    5060-00x 158 Error code Cyan cartridge drive assembly The cyan cartridge drive motor has either failed to lock or has lost lock. Note: Any time any of the cartridge drive motor assemblies are replaced, perform the “Motor Detect” on page 3-16.

  • Page 99: 160 Error Code

    5060-00x Step Actions and questions Replace the engine board. Problem solved Call your next level support Does this fix the problem? 160 Error code Step Action and questions An incorrect motor has been detected. Replace the ITU Call your next level Problem solved drive motor.

  • Page 100: 163 Error Code

    5060-00x 163 Error code Magenta cartridge drive assembly Note: Any time any of the cartridge drive motor assemblies are replaced, perform the “Motor Detect” on page 3-16. If this procedure is not performed, error code 168 is displayed Step Actions and questions Magenta cartridge drive assembly—error code 163 Go to step 2 Problem solved...
  • Page 101 5060-00x 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 102 5060-00x 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 103: Paper Jam-Tray 1

    5060-00x 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 104: Multipurpose Feeder (Mpf)

    5060-00x Multipurpose feeder (MPF) 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 2-67. Verify that the media is loaded properly in the Replace the friction Properly load the multipurpose feeder.

  • Page 105: 201 Paper Jam

    5060-00x 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 fuser.

  • Page 106: Paper Jam

    5060-00x 201 Paper jam Unable to clear the message Step Action and questions Check the paper path near the fuser transfer plate, the Remove the Go to step 2 vacuum transport assembly or input to the fuser obstruction assembly for obstructions such as pieces of media that may be jammed.
  • Page 107 5060-00x 202 Paper jam Step Action and questions Remove the fuser from the printer. Remove the oiler Clear the jam from Go to step 2 housing from the fuser, and pivot the paper guide up. the fuser. Is media jammed inside the fuser? Check fuser exit sensor flag.
  • Page 108 5060-00x Step Action and questions Check for the proper operation of the redrive. Go to step 7 Install or replace the redrive Are both belts in good condition and properly installed? assembly. See “Redrive assembly removal” on page 4-68. If the duplex option is in use, check the lower right door Go to step 8 Replace the lower paper path.
  • Page 109 5060-00x Output expander A sheet of paper is jammed prior to the pass thru sensor flag or a sheet of paper feeds out to the standard bin even though bin x is selected. Paper exits half way out of the redrive. Note: For this type of problem check the “Sub error code table”...
  • Page 110 5060-00x 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 111: Printer Configuration And 24X Paper Jam Codes

    5060-00x Step Action and questions Make sure the sensors are correctly connected to the Repair or replace Correctly connect duplex system board. the duplex option. the cables. Are the cables correctly connected? 24x Paper jam Printer configuration and 24x paper jam codes Problem related to the following option or tray Paper jam code Tray identification...
  • Page 112 5060-00x Step Action and questions See if the paper is trying to feed from the tray. Go to step 9 Go to step 6 Note: You can observe the autocompensator feed rolls and the paper through the tray access door. Run the Tray x feed test from the Diagnostics Menu to help diagnose a feed problem.
  • Page 113 5060-00x 2000-Sheet high-capacity input tray (HCIT) (243, 244) Use the “HCIT Standalone Test Mode” on page 3-34 inside the HCIT to help isolate paper jams. Run the Standalone Feeding Operation to observe paper feeding from the tray and through the feed assembly. Use the “HCIT system board LED error code table”...
  • Page 114 5060-00x Step Action and questions Is the registration home sensor operating correctly? Replace the Replace the following FRUs in following FRUs in the order shown: the order shown: 1. HCIT system 1. Registration board sensor 2. Feed unit 2. HCIT system assembly board Use the...

  • Page 115: Printer Configuration Diagrams For 24X Paper Jams

    5060-00x Printer configuration diagrams for 24x paper jams 2-81 Diagnostic information...

  • Page 116: 250 Paper Jam

    5060-00x 250 Paper jam Unable to clear the message—multipurpose feeder loaded. Step Action and questions Make sure the media in the MPF meets specifications. Go to step 2 Inform user that the media in the MPF Does the media meet specifications? does not meet specifications.
  • Page 117 5060-00x Multipurpose feeder (MPF)—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 MFP sensor is malfunctioning.

  • Page 118: Paper Jam - Check Bin 1

    5060-00x 271 Paper jam - Check Bin 1 Output expander—POST incomplete. Step Actions and questions Pass thru sensor flag—check the sensor flag for Go to step 2 Repair or replace correct operation. as necessary Is the flag operating correctly? Pass thru sensor cable—make sure the pass thru Go to step 3 Reseat the cable sensor cable is correctly connected to J3 on the control...

  • Page 119: Paper Jam - Check Bin 4

    5060-00x Step Actions and questions Output expander board—disconnect the motor cable Replace the DC Replace the output from J4 and check the voltages at J4 on the board. motor mechanical expander control linkage assembly. board. Note: All voltages are approximate values: Connector pin Voltage, motor idle J4-1 +24 V dc...

  • Page 120: Paper Jam - Check Bin 4

    5060-00x Step Action and questions Voltage check—Disconnect the pass thru sensor cable Go to step 4 Replace the control from the control board and check the voltage on J3-3. board. The voltage measures approximately +5 V dc. Is the voltage correct? Voltage check—Measure the voltage at J3-2.

  • Page 121: 280 Paper Jam

    5060-00x 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 122: 900 Rip Software Error

    5060-00x 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 123 5060-00x Step Action and questions Restore factory defaults from the Configuration Menu. Record the Problem solved. secondary error Warning: When factory defaults are restored, all menu codes. With the items are returned to the factory default values except: 900 Service RIP Error displayed, •...

  • Page 124: 925 Error Code

    5060-00x 925 Error code Fuser fan Step Actions and questions Turn the power off and manually spin the fan and check Go to step 2 Replace the fuser that it rotates freely. fan. See “Fuser fan removal” on Does the fan rotate freely? page 4-34 Check the fuser fan cable connection to the engine Go to step 3...

  • Page 125: 927 Error Code

    5060-00x Step Actions and questions Disconnect the VTB fan from J4 on the engine board Replace the VTB Replace the engine and check the voltages on J4. fan. See “Vacuum board. See transport belt “Engine board Fan on Fan off (VTB) fan removal”...

  • Page 126: 930 Error Code

    5060-00x 930 Error code LVPS This problem with the fuser circuits is usually the zero crossover signal from the LVPS not working correctly. Step Action and questions LVPS cable—check the LVPS cable to J10 on the Go to step 2 Install the cable engine board to make sure it is seated correctly.
  • Page 127 5060-00x 940 Error code Cyan 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 128 5060-00x Step Actions and questions Press the TMC pin in the cyan cartridge contact Replace the Go to step 4 assembly make sure it actuates the TMC switch on the cartridge. developer HVPS. When the TMC pin is pressed you hear a click when the switch actuates.

  • Page 129: 941 Error Code

    5060-00x 941 Error code Magenta 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 5060-00x Step Actions and questions Press the TMC pin in the magenta cartridge contact Replace the Go to step 4 assembly to make sure it actuates the TMC switch on cartridge. the developer HVPS. When the TMC pin is pressed you hear a click when the switch actuates.

  • Page 131: 942 Error Code

    5060-00x 942 Error code Yellow 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 132 5060-00x Step Actions and questions Press the TMC pin in the yellow cartridge contact Replace the Go to step 4 assembly make sure it actuates the TMC switch on the cartridge. developer HVPS. When the TMC pin is pressed you hear a click when the switch actuates.

  • Page 133: 943 Error Code

    5060-00x 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 134 5060-00x Step Actions and questions Press the TMC pin in the black cartridge contact Replace the Go to step 4 assembly make sure it actuates the TMC switch on the cartridge. developer HVPS. When the TMC pin is pressed you hear a click when the switch actuates.

  • Page 135: 990 Service Error

    5060-00x 990 Service error This error indicates which option is causing the error. 5-Bin mailbox Step Action and questions Mechanical linkage/DC motor assembly—make sure Go to step 2 Reseat the cable the DC motor cable connector is installed at J2 on the and recheck for control board.
  • Page 136 5060-00x 500-sheet drawer 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 137 5060-00x Step Actions and questions Output Expander control board check—disconnect the Replace the Output Replace the motor cable J4 and check the voltages at J4 on the Expander control mechanical board. Warning: Be careful not to short to adjacent board linkage/DC motor pins on the connector.

  • Page 138: 5-Bin Mailbox Option Service Check

    5060-00x 5-Bin mailbox option service check Note: Make sure the option(s) are installed correctly and the printer 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 139 5060-00x Step Symptoms 990 Service Error Go to “990 Call your next level Service error” on support page 2-101 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 140 5060-00x Paper does not feed into the 5-Bin mailbox bin selected. 271 Paper Jam - Check Bin 1 message Step Action and questions Bin parts—check all the bin parts, deflector, deflector Replace parts or Go to step 2 spring, deflector cover, deflector cover spring, and repairs necessary shaft assemblies for signs of missing or loose springs.
  • Page 141 5060-00x Bin x Full—no message that Bin x is full Step Action and questions Bin x sensor (Bin x=sensor 1 through 5)—make sure Go to step 2 Install the sensor the sensor is seated correctly in the side of tray x. correctly Is the sensor seated correctly? Bin x sensor cable—make sure that Bin x sensor cable...

  • Page 142: 500-Sheet Drawer Option Service Check

    5060-00x 500-Sheet drawer option service check If the paper does not feed from the 500-sheet option, see “Autocompensator service check” on page 2-114. 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 143 5060-00x 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 144 5060-00x The printer does not detect 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...
  • Page 145 5060-00x Step Action and questions Check the transparency sensing assembly cable for Replace the FRUs Install the cable correct installation to Tray x system board. in the following correctly order: Is the cable connected correctly? 1. Autocompensa- tor assembly “Auto- compensator pick assem- bly removal”...

  • Page 146: Ac And Dc Power Service Check

    5060-00x 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: Before proceeding with this service check turn the printer on and check to see if the Power on LED on the engine board is turned on.

  • Page 147: Dc Power Service Check

    5060-00x DC power service check The machine is partially operative, a motor turns, display is on or the power-on LED may be on or off. Step Actions and questions Does the printer beep 5 times and the operator panel Go to “Operator Go to step 2 display all diamonds?

  • Page 148: Autocompensator Service Check

    5060-00x Step Actions and questions Unplug all cables from the system board, except J6, Go to step 5 Replace the J35, J37. See “System board - non-network” on “System board” page 5-6 “System board - network” on page 5-7. on page 4-67.
  • Page 149 5060-00x 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 150 5060-00x Step D Step Action and questions Enter the Diagnostics Mode and select the Tray 1 Call your next level Go to step 2 Sensor Test from the Input Tray Tests menu. You can support. activate the paper level sensor inside the printer. The paper level sensor is a dual sensor and checks the following levels for tray 1.

  • Page 151: Black Only Retract (Bor) Service Check

    5060-00x Step Action and questions Check continuity of the paper level sensing cable. Replace the Replace the cable autocompensator Note: This cable is used for both the paper level assembly. If this sensing assembly and the transparency sensor does not correct assembly.

  • Page 152: Close Door/Hvps/Printhead Interlock Switch Service Check

    5060-00x Close door/HVPS/printhead interlock switch service check Note: There are two separate cables that contain two microswitches and a cable. These cable/switches provide separate interlocks for the printhead and HVPS. One switch in each cable is mounted in the front access door support and the other switch in each cable is mounted on the ITU light shield assembly.
  • Page 153 5060-00x POR complete, printer feeds blank page This symptom is usually associated with the Upper switch mounted on the Front Access Door Support and with the right switch mounted in the ITU Light Shield. Step Action and questions Make sure that the ITU light shield is not broken. Replace the ITU Go to step 2 light shield...

  • Page 154: Duplex Option Service Check

    5060-00x 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 155 5060-00x 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 J5-1 +24 V dc...

  • Page 156: Finisher Service Check

    5060-00x 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 157 5060-00x 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 on the printer? Is the pin on the magnetic bracket actuating the joint Go to step 3 Find out why the...
  • Page 158 5060-00x Step Action and questions Make sure the communications cable is connected Go to step 5 Install the cable properly to CN3 on the LVPS Relay board. correctly. Is the cable installed correctly? Note: The relay on the relay board is connected to +5 V dc from the printer through the communications cable.
  • Page 159 5060-00x Front door is open, no indication on display Step Action and questions Make sure the front door is activating the cover switch. Go to step 2 Repair or replace the door assembly. Is the door activating the cover switch? Check door—door switch activating tab (broken or Replace the front Go to step 3...
  • Page 160 5060-00x No indication that the chad box is full, no message Use the “HCOF error code table” on page 2-122 to help diagnose the problem. Step Action and questions Make sure the chad box is correctly installed in the Go to step 2 Install the chad box finisher.

  • Page 161: Fuser Service Check

    5060-00x Fuser service check Cold fuser service If error code 122, 123, 126, 127, 128, 129, 130, 131, 132, or 133 is displayed, the printer detects a problem in the fuser hot roll or back up roll fuser lamp circuits, fuser hot roll thermistor, back up roll thermistor, engine board or LVPS fuser control circuits.

  • Page 162: High-Capacity Input Tray (Hcit) 2000-Sheet Option Service Check

    5060-00x High-capacity input tray (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 163 5060-00x Step Action and questions Disconnect J5 from the engine board and check the Go to step 5 Replace the engine voltages on connector J5 on the engine board. board The voltages measure as follows: Note: All voltages are approximate values. Connector pin Voltage J5-1 +24 V dc...
  • Page 164 5060-00x 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 165 5060-00x 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 Check the paper tray guide for correct installation.

  • Page 166: Operator Panel Lcd/Status Led/Buttons Service Check

    5060-00x 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 167 5060-00x Step Action and questions RIP board—measure the voltage at connector J1-2 on Replace the Go to step 8 the RIP board. See “RIP board” on page 5-14. The operator panel. voltage measures approximately +5 V dc. “Operator panel removal” Is the voltage correct? on page 4-46 Operator panel cable (operator panel connection)—...

  • Page 168: Output Expander Option Service Check

    5060-00x 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 169 5060-00x 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 170: Print Quality Service Checks

    5060-00x Step Actions and questions Voltage check—output expander system board— Replace the Output Replace the Output Reinstall the output expander option and check the Expander option Expander option voltages at J1A and J1B on the connector. system board mechanical linkage assembly Are the voltages correct? Remove paper - Output Bin x displays, POST is incomplete, unable to clear the...

  • Page 171: Horizontal Line

    5060-00x Horizontal line • Go to step 1 if there is a horizontal black line only. • Go to step 2 if there is a cyan, magenta or yellow horizontal line. Step Action and questions Black print cartridge—the most likely cause of this Replace the Call your next level failure is a failing black print cartridge where the PC...

  • Page 172: Vertical Lines Or Streaks

    5060-00x Vertical lines or streaks Step Action and questions Are the vertical streaks visible outside the printed Go to step 2 Replace the image? cartridge. Are the vertical streaks in a single color? Go to step 3 Replace the ITU assembly.

  • Page 173: Blank Page (No Image)

    5060-00x Step Action and questions If another cartridge is not available, break the Replace the Go to step 5 corresponding tabs off the cartridge in question as well defective cartridge. as an adjacent color. The tabs are used to ensure that the cartridge is installed in the correct color station.

  • Page 174: Entire Page Is Mostly One Color-Full Bleed Planes In One Color

    5060-00x 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 175: Missing Colors-Complete Or Partially Missing Color Planes

    5060-00x Missing colors—Complete or partially missing color planes • If a color or colors are missing, or a color is partially missing, go to “Step A” on page 2-143. • If cyan, magenta, and yellow is missing, go to “Black and white only—cyan, magenta, and yellow are missing”...

  • Page 176: Black And White Only-Cyan, Magenta, And Yellow Are Missing

    5060-00x Step Action and questions Perform a continuity check on the developer HVPS Replace in order: Replace the cable. developer HVPS 1. Developer cable. Is there continuity? HVPS board. “Developer HVPS board removal” on page 4-28. 2. Engine board. “Engine board removal”...

  • Page 177: Low Image Density

    5060-00x 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 material the cartridge. and seat the cartridge.

  • Page 178: Poor Color Alignment

    5060-00x 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 179: Residual Image

    5060-00x Residual image • If only one color has a residual image repeated every 95mm, replace the print cartridge. • If all colors have a residual image 147 mm from the top of the page, replace the fuser assembly. Note: Do the following steps before you replace the fuser assembly: Check Media Type setting on the operator panel.

  • Page 180: Smudged Or Distorted Images On Fused Page

    5060-00x Smudged or distorted images on fused page Step Action and questions Remove the ITU assembly and check for any signs of Remove the debris Go to step 2 debris near the paper feed reference edge mechanism underneath the ITU assembly. Are there any signs of any debris in this location? Check for any signs of debris on the surface of the ITU Remove the debris...

  • Page 181: Transparency Print Quality Is Poor

    5060-00x Transparency print quality is poor Step Action and questions Transparencies - Check the media type and Go to step 2 Inform the transparency in use. customer Are the recommended transparencies and media type used? Is the quality of the transparency poor or do brown Go to step 3 Go to step 4 colors appear when projected?

  • Page 182: Second Transfer Roll Service Check

    5060-00x 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 183: Tray 1 Service Check

    5060-00x Step Actions and questions Transfer terminal contact assembly and ITU transfer Repair or replace Replace the FRUs bellcrank—check the transfer terminal contact, transfer as necessary. If in order: cable, and ITU transfer bellcrank assemblies to make this does not 1.

  • Page 184: Tray 1 Paper Size Sensing Service Check

    5060-00x Tray 1 paper size sensing service check The printer does not sense the size of the media installed in tray 1. Note: If there is a problem when installing tray 1, tray 1 is difficult to remove or does not stay locked in position, go to “Tray 1 service check”...

  • Page 185: Diagnostic Aids

    5060-00x 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 If you get a printhead error, follow this diagnostic to find the specific failure.
  • Page 186 5060-00x 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 RIP board in the printer and connect them to the printhead diagnostic tool.

  • Page 187: Print Quality Defect Locator Chart

    5060-00x Turn on the printer and note the new error codes. • If an automatic calibration begins, 36 Printer Service Required may appear. The printhead and RIP board are working correctly and the printhead cable connections should be checked. Press Go to clear the error.
  • Page 188 5060-00x Rollers Defect period Component Planes Component description affected inches Metering rolls Reference Edge 47.0 1.85 Color charge roll short C, M, or Y cart C, M and Y 101.0 3.98 NIP shock Defect period NIP distances Inches Y-C-M-K cartridge spacing 101.0 3.98 K to second transfer roll...

  • Page 189: Partial Print Test

    5060-00x Print quality For a transparency of the defect locator chart, go to the back of the hard copy service manual. Note: If you want to copy the chart, then the following should be observed. Since fax machines, digital scanners, and xerographic copiers can distort images, charts should be printed using the transparent copy provided in the service manual.
  • Page 190 5060-00x Remove all four toner cartridges and set them face down. Look at the surface of each toner cartridge and check for a developed image. Interpreting the results If the developed images are not visible on one of the PC drums, the following components should be checked: •...

  • Page 191: Configuration Menu

    5060-00x Configuration Menu The Configuration Menu (CONFIG 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. The following are available from the Configuration Menu: Black&White Lock Fuser Cnt Value Reset Fuser Cnt...

  • Page 192: Reset Fuser Cnt

    5060-00x Reset Fuser Cnt This only displays if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID. The fuser maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. The counter can be used to track printer usage. When the counter reaches 150,000, the printer posts a fuser maintenance message on the operator panel.

  • Page 193: Type Sensing

    5060-00x TYPE SENSING Only paper sources that support Auto Type Sensing are displayed. Select TYPE SENSING from the CONFIG MENU. Select a tray. Only those trays with type sensing display. These can include: Tray 1 Tray 2 Tray 3 Tray 4 Select Auto to turn type sensing on for that tray, or select Off to disable type sensing.

  • Page 194: Panel Menus

    5060-00x To calibrate the tray: Select CALIBRATE TRAYS from the CONFIG MENU. Select the tray you want from the menu. You are prompted to load paper into the selected tray (not transparencies). Load <input source> Plain Paper Press Go to initiate calibration. Press Return to stop the calibration and return to the previous menu.

  • Page 195: Factory Defaults

    5060-00x Factory Defaults The customer can restore either the network settings or the base printer settings to their factory default values. When Restore Base is selected, non-critical base printer NVRAM settings are restored. When Restore Network is selected, all network NVRAM settings are restored to their factory default settings. This option is only available on models with an integrated network adapter.

  • Page 196: Auto Color Adjust

    5060-00x Auto Color Adjust Automatic color adjustments periodically occur during printing, based on internal algorithms The following situations prompt the adjustment: • If the printer detects a new or different color cartridge is installed, usually at power on or when the cover is closed.

  • Page 197: Diagnostics Mode

    5060-00x 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 • TOP FINE MAR ADJ • MISC TESTS •...

  • Page 198: Registration

    5060-00x REGISTRATION The print registration range is: Bottom Margin: -25 to +25 Top Margin: -25 to +25 Left Margin: -12 to +12 Right Margin: -12 to +12 To set print registration: Select REGISTRATION from the Diagnostics Mode. T=sxx* B=sxx* L=sxx* R=sxx* B=Bottom margin T=Top margin...

  • Page 199: Alignment

    5060-00x ALIGNMENT Cyan, Yellow, Magenta Setting printer alignment Select ALIGNMENT from the Diagnostics Mode. Select one of the following: Cyan, Yellow, or Magenta. The following screen is displayed: T=sxx* R=sxx* L=sxx* Z=sxx* Value: Description: Range: Top Margin Offset -128 to +127 Left Margin Offset -300 to +300 Right Margin Offset...

  • Page 200: Drift Sensors

    5060-00x 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 C=cc Y=dd K=ee Values: Value: Description: Com= RIP to A/D communication error Good Communication is good...

  • Page 201: Belt Tracking (Itu 4Th Point Adjustment)

    5060-00x 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 202: Print Tests

    5060-00x 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 Env Feeder (if installed) The following test pages are available Print Quality Pages Print Line Len Pages Print Tests (input source)

  • Page 203: Prt Quality Pgs

    5060-00x Prt Quality Pgs The print quality test has five pages of settings, various color blocks, color array scales, and color gradients. This test may be printed from either CONFIG MENU or the Diagnostics Menu. • When printed from the Configuration Menu, the toner cartridge lockout function is enabled, which means these pages cannot be printed unless a cartridge is installed with a Machine Class ID which matches the Machine Class ID stored in the printer NVRAM.

  • Page 204: Dram Test

    5060-00x DRAM Test This test checks the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: Select DRAM Test from the menu.

  • Page 205: Rom Test

    5060-00x ROM Test The ROM Test is used to check the validity of the controller board code and fonts. To run the ROM Test: Select ROM Test from the menu. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in progress. The test runs continuously. Press Return or Stop to exit the test.

  • Page 206: Serial Wrap Test

    5060-00x Serial Wrap Test Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. Only displayed if the printer is configured with a standard serial port. If a serial port is available in the PCI slot 1, the Serial 1 Wrap appears.

  • Page 207: Duplex Tests

    5060-00x DUPLEX TESTS These tests display if a duplex option is installed. 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 backside of the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages (Continuous) until Return or Stop is pressed.

  • Page 208: Input Tray Tests

    5060-00x 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 envelope feeder or MPF.

  • Page 209: Output Bin Tests

    5060-00x 2000-sheet trays Use this test to determine if the 2000-Sheet Tray sensors are working correctly. Select Sensor Test from the menu for the tray you want to test. The following is displayed: <input tray> EM=OP NE=OP LE=OP SC=OP The selected tray is displayed on line 1 <input tray> either Tray 1, 2, 3, or 4. =trays empty sensor =trays near empty sensor =trays paper level sensor...

  • Page 210: Sensor Test

    5060-00x Sensor Test This test verifies if the output bin sensors are working correctly. The following Output options, if installed, are supported by this test. Standard Bin Output Expander 5-Bin Mailbox To run the Output Bin Sensor Test: Select Sensor Test from the menu. Select the bin you want to test.

  • Page 211: Finisher Tests

    5060-00x FINISHER TESTS Staple Test This test verifies the operation of the staple mechanism in the finisher. To run the Staple Test: Select Staple Test from the Finisher Tests menu. Select a destination bin. The printer feeds eight pieces of media to the finisher and accumulates all eight pieces in the accumulator. After the last sheet is accumulated, the pack is stapled.

  • Page 212: Hole Punch

    5060-00x • 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=CL S4=CL =Inverter Jam Sensor =Drop Timing Sensor...

  • Page 213: Base Sensor Test

    5060-00x 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 Sensor •...

  • Page 214: Flash Test

    5060-00x The power indicator blinks during the test. The test can be canceled anytime during the test by pressing Return or Stop. • Once the test is complete, the power indicator turns on solid and a message displays. xxxx Bad Blocks/yyyyyy Usable is displayed if fewer than 2000 bad blocks are detected. xxxx •...

  • Page 215: Reset Calibrat

    5060-00x Reset Calibrat. The Reset Calibration resets the TPS NVRAM values when initiated. Select Reset Calibration from the Printer Setup Menu 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 Count The printer’s page count can be changed by the Diagnostics Mode.

  • Page 216: Model Name

    5060-00x Model Name You can view the model name. Configuration ID Warning: Should not be changed without specific instructions from the next level support. The configuration ID is used to communicate characteristics of certain areas of the printer that cannot be determined by hardware sensors.

  • Page 217: Dev Bias Adj

    5060-00x Dev Bias Adj Warning: Should not be changed without specific instructions from the next level support. Transfer Adjust Warning: Should not be changed without specific instructions from the next level support. ERROR LOG View 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).

  • Page 218: High-Capacity Input Tray Tests

    5060-00x High-capacity input tray tests HCIT Standalone Test Mode This test lets you check out and test the HCIT (2000-Sheet High Capacity Input Tray) without removing any option or the base printer mounted above the optional HCIT. Note: During normal operation, the red LED on the HCIT system board blinks or flashes on for one second and off for one second.

  • Page 219: Repair Information

    5060-00x 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 220: Screw Identification Table

    5060-00x 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 221 5060-00x Reference Screw type Location Purpose number M2.9x6mm Front access door assembly Mounting Plastite Door handle to cover Mounting Detent housing to cover Mounting ITU switch housing to light shield Attach Duplex baffle to lower right door Attach Front and rear latches to lower right door Mounting Bias latch cover to door Attach...
  • Page 222 5060-00x Reference Screw type Location Purpose number M3.5 x 1.35mm ITU drive asm to lower frame Mounting (continued) Plastite 8 long Fuser drive asm to lower frame Mounting (continued) Vacuum top duct to lower frame Mounting Toner shield to lower frame Attach Upper deflector to lower frame (PF XPORT) Mounting...

  • Page 223: Removal Procedures

    5060-00x 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 printer weighs 47.7 kg (105 lb) and requires at least two people to lift it safely.
  • Page 224 5060-00x Remove the operator panel bezel. Remove the top cover mounting screws (D) from the front of the printer. Remove the three top cover screws (E) type “323” on page 4-3 from the rear and the screw (F) from the left side of the printer.
  • Page 225 5060-00x Remove the flag retainer (G) from the top cover. Under the top cover, unclip the bin full sensor (H). Tilt the sensor and lower it through the top cover. Remove the upper option autoconnect (I). Remove the top cover. Repair information...

  • Page 226: Rear Fan Cover Removal

    5060-00x Rear fan cover removal “Rear fan cover” on page 7-5 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-8. Remove the rear fan cover screw type “323” (A) and remove the rear fan cover. Rear cover removal “Rear cover”...

  • Page 227: Front Right Handle Cover Assembly Removal

    5060-00x Front right handle cover assembly removal “Front right handle cover assembly” on page 7-3 for the part number. Open the front cover. Remove the light shield screw type “324” (A) and screw type “323” (B) and release tab (C) from the frame slot.

  • Page 228: Front Left Handle Cover Assembly Removal

    5060-00x Front left handle cover assembly removal “Front left handle cover assembly” on page 7-3 for the part number. Open the front cover. Remove the front left handle cover assembly screw type “323” (A) and remove the assembly. A A (323) Front cover assembly removal “Front cover assembly”...
  • Page 229 5060-00x Remove the bezel (B). Hold the front cover and remove the two screws type “102” (C) from the upper front pivot cover. C(102) Remove the front cover assembly. 4-11 Repair information...

  • Page 230: Lower Right Door Assembly Removal

    5060-00x Lower right door assembly removal “Lower right door assembly” on page 7-3 for the part number. Open the lower right door assembly. Remove the front right handle cover assembly. See “Front right handle cover assembly removal” on page 4-9. Remove the screw (A) on the lower right front cover.

  • Page 231: Left Lower Cover Removal

    5060-00x Loosen the two screws (C). Remove the lower right door assembly. Left lower cover removal Remove the lower jam access door assembly. See “Lower jam access door assembly removal” on page 4-14. Remove the left lower cover screw type “323”...

  • Page 232: Lower Jam Access Door Assembly Removal

    5060-00x Lower jam access door assembly removal “Cover, left lower” on page 7-5 for the part number. Remove the front left handle cover assembly. See “Front left handle cover assembly removal” on page 4-10. Remove the lower jam access door assembly screw type “323”...

  • Page 233: Paper Path Access Door Cover Removal

    5060-00x Paper path access door cover removal “Paper path access door” on page 7-3 for part number. Remove the paper tray. Remove the front left handle cover assembly. See “Front left handle cover assembly removal” on page 4-10. Open the paper path access door, carefully remove screw (A) type “323”...

  • Page 234: Front Lower Left Cover Removal

    5060-00x Front lower left cover removal “Front lower left cover” on page 7-3 for part number. Remove the paper tray. Remove the front left handle cover assembly. See “Front left handle cover assembly removal” on page 4-10. Open the paper path access door, carefully remove screw (A) type “323”...

  • Page 235: Autocompensator Pick Assembly Removal

    5060-00x Autocompensator pick assembly removal Remove all cartridges. Remove the ITU. See “ITU assembly removal” on page 4-37. Remove tray 1. Remove the second transfer roll. See “Second transfer roll removal” on page 4-79. Remove the transfer plate. Lifting and rotating the right edge of the plate up to a 45° angle will release the transfer plate.
  • Page 236 5060-00x Remove the five screws “323” (C) and remove the lower left cover and the jam access door. Warning: Be careful not to lose the access door spring. C(323) Remove the pin (D) that holds in the MPF swing arm assembly. 4-18 Service Manual...
  • Page 237 5060-00x Remove the MPF swing arm assembly (E). 4-19 Repair information...

  • Page 238: Left Side View

    5060-00x Remove 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 5060-00x Disconnect the pick motor and the transparency sensor connectors (G). Remove four screws (H) holding the pick assembly in place. DO NOT REMOVE THIS SCREW 4-21 Repair information...
  • Page 240 5060-00x Push the bellcrank (I) in to allow the pick arm to fall to the bottom of the tray. Disconnect the spring clip (J) from the pick arm. Be sure not to let the spring come off of the lower frame. Also identify which pegs the spring clip is sitting on.

  • Page 241: Bor Drive Assembly Removal

    5060-00x BOR drive assembly removal “BOR housing assembly with motor” on page 7-30 for the part number. Open the front cover. Remove the yellow toner cartridge. Remove the front right light shield cover. Remove the BOR housing assembly screw type “323”...
  • Page 242 5060-00x Disconnect the signature button cable (A) from the developer HVPS board for the cartridge contact assembly you are removing. Remove the three mounting screws from the cartridge rail screws in the front (B) and one from the rear (C) and remove the rail of the selected cartridge assembly (yellow shown).
  • Page 243 5060-00x Remove the two upper screws (D) that mount each cartridge drive motor and the cartridge contact assembly to the upper frame for the cartridge contact assembly you want to remove. D (Yellow) D (Cyan) D (Magenta) D (Black) Press the three cartridge contact assembly retaining tabs (E) and remove the assembly. 4-25 Repair information...

  • Page 244: Cartridge Drive Assembly Removal

    5060-00x Cartridge drive assembly removal “Cartridge drive assembly, cyan/magenta/black” for the part number. Remove the RIP board shield assembly. See “RIP board shield assembly removal” on page 4-71. Remove the engine board. See “Engine board removal” on page 4-29. Remove the three cartridge drive assembly mounting screws (A) for the cartridge drive assembly you want to remove.

  • Page 245: Cartridge Rail Assembly

    5060-00x Cartridge rail assembly Open the front cover. Remove the toner cartridges. Remove the ITU assembly. See “ITU assembly removal” on page 4-37. Set aside the top cover assembly. It is not necessary to totally remove it. See “Top cover assembly removal”...

  • Page 246: Developer Hvps Board Removal

    5060-00x Developer HVPS board removal “Developer HVPS board” on page 7-38 for the part number. Remove the RIP board shield assembly. See “RIP board shield assembly removal” on page 4-71. Remove the four screws type “323” (A) and four screws type “121”...

  • Page 247: Engine Board Removal

    5060-00x Engine board removal “Engine board” on page 7-39 for the part number. Remove the rear fan cover. See “Rear fan cover removal” on page 4-8. Remove the rear cover. See “Rear cover removal” on page 4-8. Disconnect all cables from the engine board. Remove the screw “323”...

  • Page 248: Engine Board Shield Removal

    5060-00x Engine board shield removal “Engine board shield” on page 7-39 for the part number. Remove the RIP board shield assembly. See “RIP board shield assembly removal” on page 4-71. Remove the engine board. See “Engine board removal” on page 4-29.

  • Page 249: Fuser Assembly Removal

    5060-00x Fuser assembly removal CAUTION: Be sure the fuser assembly has cooled before you remove it. “Fuser assembly 115V 500W” on page 7-9 “Fuser assembly 220V 500W” on page 7-9 for the part numbers. Open the lower right door assembly. Unlatch the two fuser latches (A).

  • Page 250: Fuser Bottom Duct Removal

    5060-00x Fuser bottom duct removal “Fuser bottom duct” on page 7-5 for the part number. Remove “Fuser assembly removal” on page 4-31. Remove “Fuser top duct removal” on page 4-34. Remove the redrive belt cover duct (A). Remove fuser left duct (B). Remove fuser bottom duct.

  • Page 251: Fuser Drive Assembly Removal

    5060-00x Fuser drive assembly removal “Fuser drive assembly w/motor” on page 7-12 for the part number. Remove “Fuser bottom duct removal” on page 4-32. Swing lever (A) and disengage VTB shaft. Remove the fuser drive assembly screws (A) type “323” on page 4-3 and remove the assembly.

  • Page 252: Fuser Fan Removal

    5060-00x Fuser fan removal “Fuser fan” on page 7-41 for the part number. Remove the rear fan cover. See “Rear fan cover removal” on page 4-8. Disconnect the fuser fan cable from connector J2 (B) on the engine board. Remove the fuser fan screws (A), part number 12G6529 and remove the fan. Fuser top duct removal “Fuser top duct”...

  • Page 253: Fuser Web Oiler Motor Assembly Removal

    5060-00x Fuser web oiler motor assembly removal “Fuser assembly, web oiler 115V 500W” on page 7-11 “Fuser assembly, web oiler 220V 500W” on page 7-11 for the part number. Remove the fuser top duct. See “Fuser top duct removal” on page 4-34.

  • Page 254: Installation Notes

    5060-00x Installation notes Note: When you reinstall the web oiler motor assembly, pull the excess cable, twist, install a cable tie, and route the cable down into the printer. Note: Make sure the motor cable (A) is routed away from gears (B). 4-36 Service Manual...

  • Page 255: Itu Assembly Removal

    5060-00x ITU assembly removal “ITU assembly” on page 7-25 for the part number. Open the front cover. Remove the toner cartridges. Open the MPF. Raise the ITU release lever (A) and slide the ITU from the printer. ITU drive assembly removal “ITU motor drive assembly with SKC motor”...

  • Page 256: Itu Drive Motor Removal

    5060-00x ITU drive motor removal “ITU drive motor, SKC” on page 7-27 for the part number. Remove the RIP board shield assembly. See “RIP board shield assembly removal” on page 4-71. Remove the engine board shield. See “Engine board shield removal” on page 4-30.
  • Page 257 5060-00x Remove the right rear cover screw type “121” (A). Open the redrive cover and remove the screw type “121” (A) from the top of the LVPS and remove the LVPS from the printer. Note: Be sure to reinstall the ground strap when you replace the LVPS. 4-39 Repair information...

  • Page 258: Multipurpose Feeder (Mpf) Removal

    5060-00x Multipurpose feeder (MPF) removal “Multipurpose Feeder (MPF)” on page 7-21 for the part number. 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. 4-40 Service Manual...
  • Page 259 5060-00x 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 4-4. 4-41 Repair information...

  • Page 260: Nip Relief Handle Removal

    5060-00x Release the MPF latch (F) and remove the MPF. Nip relief handle removal “Nip relief handle” on page 7-19 for the part number. Remove lower left side covers to gain access to the nip relief handle. Remove waste toner container. Reinsert paper tray into printer.
  • Page 261 5060-00x Some scarring of the post is expected, but be careful not to damage the post. Remove any remnants of the handle. Check the paper tray to check for debris. For example, see the fragment (B) in the following picture. 4-43 Repair information...
  • Page 262 5060-00x 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) towards the rear of the machine and insert lower portion of handle so that it is trapped between the lever and the reference edge plate (C). Holding the nip relief handle in place, use a flathead screwdriver to gently pry up on the top portion of the lever allowing the handle to press into place onto the post using moderate force.
  • Page 263 5060-00x 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. This seats the nip relief lever into the correct position. Check for proper operation. Install the waste toner container.

  • Page 264: Operator Panel Removal

    5060-00x Operator panel removal “Operator panel assembly, low volt” on page 7-3 “Operator panel assembly, high volt” on page 7-3 for the part number. Remove the operator panel bezel. Unlatch the operator panel latches (A). 4-46 Service Manual...

  • Page 265: Outer Emc Shield Removal

    5060-00x Disconnect the operator panel cable from the operator panel and remove the operator panel. Outer EMC shield removal Loosen screw type “232” (A) and lift the outer EMC shield from the printer. 4-47 Repair information...

  • Page 266: Paper Size Sensing Assembly Removal

    5060-00x Paper size sensing assembly removal “Paper size sensing assembly” on page 7-57 for the part number. Note: The paper size sensing assembly contains components that easily fall apart as you remove the assembly. Be careful not to lose any of the components. Remove the rear cover.
  • Page 267 5060-00x Rear roll Reach around and depress the latch (A) on the side of the shaft and remove the tire. Installation notes: • Replace both rollers at the same time. • When you replace the front roller, make sure the roller is pressed against the shaft and the screw is fastened all the way down.

  • Page 268: Printhead Removal And Adjustment

    5060-00x Printhead removal and adjustment See “Printhead assembly” on page 15 for the part numbers. Warnings: • Do not loosen or replace more than one printhead at a time to retain factory settings. • Whenever a printhead is replaced, you must to perform the “Printhead mechanical alignment”...

  • Page 269: Printhead Mechanical Alignment

    5060-00x Printhead mechanical alignment Identify the configuration of your printer. The following steps are similar for both versions, except you need to remove two extra screws when you have the PSD bracket. You may have a PSD bracket (A), whether or not the PSD or thermistor is connected. You may not have a bracket.
  • Page 270 5060-00x Insert the first printhead alignment tool. If you have a PSD bracket, remove the two screws (A and B). Note: Use a small diameter Phillips screwdriver to remove screw (A). Insert the printhead alignment tool, placing the locating pin (C) in the middle hole (A). Secure the alignment tool bracket (D) with screw provided or a screw removed from the previous step.
  • Page 271 5060-00x Install the second printhead alignment tool in the front of the printhead and secure alignment tool bracket (D) with screw provided. Align the locating pin (C) in the hole in printer frame. Turn the thumbwheel (E) until the end of the thumbwheel just touches the printhead mounting arm for both the front and rear alignment assemblies.
  • Page 272 5060-00x 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. Bias the new printhead assembly against the front and rear stops. Tighten the right rear printhead mounting screw.
  • Page 273 5060-00x Securely close the front cover or reattach if previously removed. If replacing the black printhead, go to step 12. Otherwise, enter Diagnostics Mode: Turn the printer off. Press and hold Go and Return. Turn the printer on. Release the buttons when Performing Self Test displays. Select Alignment Menu, select the color of the printhead that was replaced, and set the Z value to zero.

  • Page 274: Printer Registration (Only For Black Printhead Replacement)

    5060-00x 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. For example, if the test page indicates a +10 as the misalignment, turn the thumbwheel 10 clicks in the positive direction indicated on the test page.
  • Page 275 5060-00x Examine the registration marks on the top, bottom, left, and right sides on the page. Adjust the margin settings so that the Registration lines are on the edge of the page. Repeat for each margin. • Adjust the top margin before bottom margin, and the right margin before the left. Value Description Value change effect:...

  • Page 276: Electronic Color Alignment

    5060-00x Electronic color alignment Note: Use of a loupe or magnifying glass (4x or higher) may make observation of the alignment targets easier. Press Menu until Alignment displays and press Select. Select Alignment Test from the Alignment menu. Three sheets print for cyan, magenta, and yellow. Each is compared to black alignment. For example, one of the sheets shows cyan printed over a black target.
  • Page 277 5060-00x Press Go to print the Cyan Alignment Page. Use the top row to determine adjustments. “Printhead alignment test page—cyan (three of three)” on appendix page B-11 for a color sample of the entire page. Use the leftmost target in the first row to adjust the cyan and black horizontal lines in the target (T value or Top).
  • Page 278 5060-00x To adjust R or Right value press Go to print the Cyan Alignment Page. Use the rightmost target in the first row to adjust the cyan and black vertical lines. Adjust the setting and press Go to print the page and verify the setting, until the lines are even. Press Select to save the value.

  • Page 279: Print Line Length Calibration

    5060-00x Print line length calibration Press Return until you reach the main Diagnostic Menu (the top line is blank and bottom line displays Alignment). Press Menu until Print Tests is displayed and press Select. Select Print Line Length Calibration. There are six alignment groups, A through F. “Print Line Len page”...

  • Page 280: Printhead Thermistor Card Removal

    5060-00x Select the appropriate color. Change value of the respective setting by the calculated value. For example, if T= -5 and dT= 2, the new T value is (T+dT= -5 + 2) -3. Once all values are changed, return to the Print Tests menu and select Print Line Length Calibration. Verify that the adjusted values and the color bands for cyan, magenta, and yellow on all six groups, A through F, are centered between -2 and +2.

  • Page 281: Psd Sensor Assembly Removal

    5060-00x Installation notes • If a PSD exists, install the new printhead thermistor card. Leave the old PSD sensor assembly in place. • Disconnect the cable from the PSD card and connect it to the printhead thermistor card. Note: Whether replacing a printhead thermistor or an existing PSD sensor assembly, check the Registration and Color Alignment.

  • Page 282: Rear Bellcrank Removal (Cyan, Magenta, Yellow)

    5060-00x Rear bellcrank removal (cyan, magenta, yellow) See the assembly, “ITU loading” on page 7-29, for the part number. Power off the printer. Remove the four toner cartridges and leave the front door open. Remove the ITU assembly. See “ITU assembly removal” on page 4-37.
  • Page 283 5060-00x 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 284: Rear Bellcrank Removal (Black)

    5060-00x Rear bellcrank removal (black) See the assembly, “ITU loading” on page 7-29, for the part number. Power off the printer. Remove the four toner cartridges and leave the front door open. Remove “ITU assembly removal” on page 4-37. Check each of the rear bellcranks for cracks or breakage. Remove the spring.
  • Page 285 5060-00x 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 286: Redrive Assembly Removal

    5060-00x Redrive assembly removal “Redrive assembly” on page 7-16 for the part number. Open the redrive door. Remove the redrive assembly screw type “323” (A). Remove the drive belt (B) from the lower redrive pulley. Remove the redrive assembly. Note: When you reinstall the redrive assembly be sure to align the notch in the redrive assembly with tab (A). 4-68 Service Manual...

  • Page 287: Registration Motor Removal

    5060-00x Registration motor removal “Registration motor” on page 7-19 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-8. Remove the transfer HVPS. See “Transfer HVPS board removal” on page 4-80. Remove the registration motor mounting screws (B), cut the cable tie (A), and remove the assembly. 4-69 Repair information...

  • Page 288: Rip Board Removal

    5060-00x RIP board removal “RIP board assembly - network, model 5060-002” on page 7-37 “RIP board assembly, non- network, Model 5060-001” on page 7-37 for the part number. Warning: Improper RIP board replacement can result in incorrect printer function and significant additional service time due to loss of data.

  • Page 289: Rip Fan Removal

    5060-00x RIP fan removal “RIP fan” on page 7-41 for the part number. Remove the top cover assembly. See “Top cover assembly removal” on page 4-5. Remove the rip fan screw type “324” (A). Disconnect the rip fan cable from the engine board at connector J53. Remove the rip fan.

  • Page 290: S2/Nms/Transparency Sensor Assembly Removal

    5060-00x S2/NMS/transparency sensor assembly removal The S2, narrow media sensor (NMS), and transparency sensor are bundled into a sensor cable assembly. See “S2/transparency/narrow media sensor assembly” on page 7-17 for the part number. Removing the old assembly Note: Disconnect all power from the printer before proceeding with the steps below. Open the front cover and remove the print cartridges.
  • Page 291 5060-00x Disconnect the MPF assembly door hinge restraint by removing screw (E) and remove the MPF assembly. Gently pull the sensor assembly cable (B) through the opening between the upper and lower frame and remove the sensor assembly through the rectangular opening. Clip and remove the cable tie (C).
  • Page 292 5060-00x Disconnect the three sensors (A) from the frame. Service tip: A light aimed toward the grounding clip (B) makes the removal easier. Service tip: Leave the old sensor cable assembly (C) in place temporarily after disconnecting the sensors as a guide to placement of the sensors for the new assembly. Lay the new sensor cable assembly beside the old one and connect the new sensors as you remove the old assembly.
  • Page 293 5060-00x Installing the new assembly Remove the J70 connector cable to allow space. Note the route it shares with sensor cable assembly through the frame (see openings D and E below). Place a new cable sensor assembly in the printer next to the sensor connectors (A). Route the J68 connector around the ground clip (B) and cable channel between the upper and lower frame.
  • Page 294 5060-00x Insert the cable connector into the rectangular opening and twist left and push up gently, the connector tends to follow the pathway through and out. Insert the J68 connector of the sensor cable assembly into the rectangular opening and push up. With your other hand, twist the sensor cable assembly toward the left and continue guiding the cable 4-76 Service Manual...
  • Page 295 5060-00x Continue to push until the J68 connector (A) appears in the opening. Route the MPF tray assembly sensor cable through the same openings. Connect J68 to the engine board. Connect the MPF tray assembly sensor cable to the engine board at J70. Install the new cable tie (B) on the cable bundle and trim the excess cable tie flush.
  • Page 296 5060-00x Ensure the sensor cable assembly is on the side of the grounding clip (A) closest to the fuser end of the printer. Install the new sensor assembly (B) in the lower frame. Verify the sensors flags are not sticking and are moving freely. Service tip: Use a sheet of paper between the upper and lower guides to activate the sensors.

  • Page 297: Second Transfer Roll Removal

    5060-00x Install a new cable tie in the same location as the one that was previously removed (B), if necessary. Install the MPF tray assembly and replace the screw to reconnect the MPF assembly door hinge restraint. Install the ITU and print cartridges. Reconnect power to the printer.

  • Page 298: Transfer Hvps Board Removal

    5060-00x Transfer HVPS board removal “Transfer HVPS board” on page 7-38 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-8. Remove the transfer HVPS board screw type “324” “312” (A). Disconnect the five spade terminals (B) from the transformers. Disconnect the control cable (C).

  • Page 299: Transfer Plate Assembly

    5060-00x Transfer plate assembly “Transfer plate assembly” on page 7-14 for part number. Remove the “S2/NMS/transparency sensor assembly removal” on page 4-72. Remove the transfer plate. Lifting and rotating the right edge of the plate up to a 45° angle releases the transfer plate.

  • Page 300: Vacuum Transport Belt (Vtb) Removal

    5060-00x Vacuum transport belt (VTB) removal “Vacuum transport belt assembly” on page 7-13 for part number. Remove the transfer plate assembly. See “Transfer plate assembly” on page 4-81. Remove the fuser bottom duct. See “Fuser bottom duct removal” on page 4-32.
  • Page 301 5060-00x 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. 4-83 Repair information...

  • Page 302: Vacuum Transport Belt (Vtb) Fan Removal

    5060-00x Vacuum transport belt (VTB) fan removal “VTB fan” on page 7-41 for the part number. Remove the RIP board shield assembly. See “RIP board shield assembly removal” on page 4-71. Remove the VTB fan with a flatblade screwdriver. Waste container door removal “Waste container door”...

  • Page 303: Waste Container Latch Removal

    5060-00x Waste container latch removal “Waste container latch” on page 7-18 for the part number. Remove the paper size sensing assembly. See “Paper size sensing assembly removal” on page 4-48. Use a flatblade screwdriver to release the waste container latch from the paper size sensing assembly. Web oiler fuser kit installation “Fuser web oiler upgrade kit and replacements”...
  • Page 304 5060-00x 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) 4-86 Service Manual...
  • Page 305 5060-00x Carefully remove the paper path access door cover right mounting screw (D). Tape front jam access door (E) if tape is available, to help hold the door in place. 4-87 Repair information...
  • Page 306 5060-00x Remove the front right handle cover assembly screws (F) and remove the assembly. F(323) Open paper tray (G). 4-88 Service Manual...
  • Page 307 5060-00x Remove screw (H) from the top front support bracket. Swing bracket to the right. Use the alignment pins (I) on the web oiler fuser motor assembly to position the assembly in holes (J) and install the assembly. 4-89 Repair information...
  • Page 308 5060-00x Secure the web oiler motor assembly with screws (K). Install the web oiler card using screws (L). 4-90 Service Manual...
  • Page 309 5060-00x 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 310 5060-00x Align tabs on the front right light shield with the slots (O) on the frame. Move the front right light shield up until alignment stud (P) and the screw hole (Q) are aligned. 4-92 Service Manual...
  • Page 311 5060-00x 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. 4-93 Repair information...
  • Page 312 5060-00x 4-94 Service Manual...

  • Page 313: Connector Locations

    5060-00x 5. Connector locations Locations Printer boards Connector locations...

  • Page 314: Printer Motors

    5060-00x Printer motors Web oiler drive motor (optional) Printheads BOR drive motor RIP fan Yellow carriage drive motor Fuser drive Pick assy. motor motor Fuser fan VTB fan Registration drive motor Magenta carriage ITU drive motor drive motor Cyan carriage Black carriage drive motor drive motor...

  • Page 315: Printer Sensors

    5060-00x Printer sensors Connector locations...

  • Page 316: Cartridge Contact Assembly Pin Locations

    5060-00x Cartridge contact assembly pin locations Service Manual...

  • Page 317: Engine Board Cabling

    5060-00x Engine board cabling Connector locations...

  • Page 318: Rip Board Cabling

    5060-00x RIP board cabling Service Manual...

  • Page 319: Connectors

    5060-00x Connectors Engine board “Engine board” on page 5-7 Connector Pin no. Signal J2 Main Fan FAN1 Stall IN Ground FAN1 PWM Out +24 V dc Left Side J3 Oiler Stepper Motor Oiler PHA OUT - Oiler PHA OUT + Oiler PHB OUT + Oiler PHB OUT - Connector locations...
  • Page 320 5060-00x “Engine board” on page 5-7 Connector Pin no. Signal J4 VTB Fan FAN2 Stall IN Ground FAN2 PWM Out +24 V dc Left Side J5 Options Conn. Trays +24 V dc (options) Ground RXD1_OPTS_IN Ground STAG_ENC +5 V dc (options) Ground -TXD1_OUT J7 Options Conn.
  • Page 321 5060-00x “Engine board” on page 5-7 Connector Pin no. Signal J9 LVPS +3.3 V dc +5 V dc +5 V dc +24 V dc +24 V dc Ground Ground Ground Ground Ground J10 Fuser EXIT SENSOR IN FUSER CAM1 IN FUSER CAM2 IN OILER ENC A IN OILER ENC B IN...
  • Page 322 5060-00x “Engine board” on page 5-7 Connector Pin no. Signal J20 HVPS - Developer (-CART METER K IN) K AC B EN OUT SC K CHIP KDEV PWM OUT (-CART METER M IN) K CHG PWM OUT SC M CHIP CMY CHG PWM OUT (-CART METER C IN) CMY AC B EN OUT...
  • Page 323 5060-00x “Engine board” on page 5-7 Connector Pin no. Signal J47 Cyan Cartridge Motor M ON OUT Magenta Cartridge Motor C ON OUT +5 V dc +5 V dc M DIR OUT C DIR OUT +24 V dc M and C +24 V dc M and C Ground Ground...
  • Page 324 5060-00x “Engine board” on page 5-7 Connector Pin no. Signal J67 Registration Motor +5 V dc switched STAGING ENC OUT Ground Ground STAGING OUT 2 STAGING OUT 1 J68 S2/NM/Prism Media 1 Narrow Media IN +5 V dc switched Ground PPS2 IN +5 V dc switched Ground...
  • Page 325 5060-00x “Engine board” on page 5-7 Connector Pin no. Signal J71 HVPS- Transfer ITU TX ENA OUT ITU TX CUR PWM 0 ITU SERVO INTO ITU TX PWM OUT CMY TX ENA OUT K SERVO INTO K TX PWM OUT C SERVO INTO C TX PWM OUT Y SERVO INTO...

  • Page 326: Rip Board

    5060-00x RIP board Connector Signal J1 Operator Panel OP I2CDATA Connector +5 V dc OP I2CClk Ground OP I2R- J2 Printhead Ground Yellow Connector HSYNC-/SOS (Mirror Motor) Ground +5 V dc Hsync Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr J3 Printhead...
  • Page 327 5060-00x Connector Signal J5 Printhead Cyan Ground Connector HSYNC-/SOS (Mirror Motor) Ground +5 V dc Hsync Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr J6 Printhead Cyan Connector (Video) laser en Ground laser PWR ADJ Ground laser PWM +5 V dc head...
  • Page 328 5060-00x Connector Signal J8 Printhead Magenta Connector (Video) laser en Ground laser adj Ground laser PWM +5 V dc head Ground video data - video data +x J9 Printhead Ground Magenta/Black lexhsync/eos Connector (EOS) thermistor +5 V dc EOS card Ground lexhsync/eos thermistor...
  • Page 329 5060-00x Connector Signal J11 Printhead Black Connector (Video) laser en Ground laser adj Ground laser PWM +5 V dc head Ground video data - video data + J12 Cover Open +5 V dc Switch Connector Ground V Cor J13 Parallel Port Connector J18 USB Port USB +5 V dc...
  • Page 330 5060-00x Connector Signal J23 Power Ground Connector Ground Ground Ground Ground Ground Ground Ground +3 V dc Sense +3.3 V dc +3.3 V dc +3.3 V dc +5 V dc +5 V dc +5 V dc +24 V dc (Fuser) J24 Engine to RIP ITU Zone CLk Connector...

  • Page 331: Transfer High Voltage Power Supply (Hvps)

    5060-00x Transfer high voltage power supply (HVPS) Connector Pin no Signal CN1 HVPS Input Connector +24 V dc +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 5-19 Connector locations...

  • Page 332: Developer High Voltage Power Supply (Hvps) Board

    5060-00x Connector Pin no Signal CN1 HVPS Input Connector I-Txpwm (continued) I-Srvo out I-Txcurpwm I-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 Black Cable T301 Transformer HV Terminal C...
  • Page 333 5060-00x Connector Pin no Signal CN1 Developer HVPS Input M-TnrSense (continued) K-Chgpwm K-CtSense K-Devpwm K-TnrSense K-Acenable CN2 Cartridge Signature Button - K-CtSense Black K-TnrSense (Gnd Return) CN3 Cartridge Signature Button - M-CtSense Magenta M-TnrSense (Gnd Return) CN4 Cartridge Signature Button - C-CtSense Cyan C-TnrSense (Gnd Return)

  • Page 334: Low Voltage Power Supply (Lvps)

    5060-00x Low voltage power supply (LVPS) Engine and RIP board cable connectors Connector Signal RIP Board Power Ground Return +3.3 V dc rtn Ground Return +3.3 V dc rtn Ground Return +3.3 V dc rtn Ground Return +3.3 V dc rtn Ground Return +5 V dc rtn Ground Return +5...
  • Page 335 5060-00x Connector Signal Engine board EXITSENSORIN cable (LVPS to BURCam1 J10 fuser connector) WebEncoderA WebEncoderB HRThermistor BURThermistor Ground +5 V dc switched ZEROXINGIN Heat On #1 (HR) Heat On #2x (BUR) 5-23 Connector locations...

  • Page 336: Low Voltage Power Supply (Lvps)

    5060-00x Low voltage power supply (LVPS) LVPS to fuser connectors (on LVPS) Fuser to LVPS connectors (on fuser) 5-24 Service Manual...
  • Page 337 5060-00x 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 5-25 Connector locations...

  • Page 338: High-Capacity Input Tray (2000-Sheet Hcit) Board

    5060-00x High-capacity input tray (2000-sheet HCIT) 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 339 5060-00x 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 340: High-Capacity Output Finisher (Hcof)

    5060-00x High-capacity output finisher (HCOF) 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...

  • Page 341: Hcof System Board

    5060-00x HCOF system board “HCOF system board” on page 5-32 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 Bundle Motor Jog *A...
  • Page 342 5060-00x “HCOF system board” on page 5-32 Connector Pin no Signal CN6 Tray Sensors Tray Limit/Near Tray Limit SW Full/Offset Position Ground +5 V dc Tray Near Full Sensor Ground +5 V dc Tray Offset Posit Sensor Ground CN7 Tray Motor MTR + MTR - CN8 Tray Sensors Exit Timing/Paper...
  • Page 343 5060-00x “HCOF system board” on page 5-32 Connector Pin no Signal CN14 Power +24 V dc +24 V dc P-Ground P-Ground CN15 Feed Motor CN16 Punch +5 V dc Drop Timing Sensor Ground +5 V dc Punch Home Sensor Ground +5 V dc Punch Timing A Sensor Ground...
  • Page 344 5060-00x HCOF system board 5-32 Service Manual...

  • Page 345: 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 346: Lubrication For Replacement Motors

    5060-00x 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 347: Cartridge Drive Assembly

    5060-00x 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 348: Scheduled Maintenance

    5060-00x Scheduled maintenance The operator panel displays 80 Fuser Maintenance and 83 ITU Maintenance for scheduled maintenance. 80 Fuser Maintenance is displayed at each 150K 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 349: Parts Catalog

    • PP: (Parts Packet) in the Description column indicates the part is contained in a parts packet. The Lexmark C750 (5060-00x) laser printer is available in two models: 5060-001 5060-002 The parts catalog uses these designations to identify model specific FRUs.

  • Page 350: Assembly 1: Covers

    5060-00x Assembly 1: Covers Service Manual...
  • Page 351 5060-00x Assembly 1: Covers Asm– Part Units Description Index number 1–1 12G6410 Top cover assembly 12G6507 250 output flag, includes flag retainer 12G6506 Bin full sensor 12G6319 Cable, options - stacker 12G6409 Redrive cap cover assembly 12G6380 Machine pad 12G6389 Top front support bracket 12G6396 Right rear cover...
  • Page 352 5060-00x Assembly 1.1: Covers Service Manual...
  • Page 353 5060-00x Assembly 1.1: Covers Asm– Part Units Description Index number 1.1–1 12G6408 Left upper cover assembly Screw, PP 12G6309 12G6392 Left upper pivot cover 12G6485 Lower access jam door assembly 12G6398 Left lower pivot cover 12G6395 Cover, left lower 12G6400 Waste container door 12G6339 Blank, TLI/SN label...

  • Page 354: Assembly 2: Cartridge Mounting

    5060-00x Assembly 2: Cartridge mounting Service Manual...
  • Page 355 5060-00x Assembly 2: Cartridge mounting Asm– Part Units Description Index number 2–1 Screw, PP 12G6532 12G6535 Guide assembly, left side 12G6536 Guide assembly, right side Parts catalog...

  • Page 356: Assembly 3: Fuser

    5060-00x Assembly 3: Fuser Service Manual...
  • Page 357 5060-00x Assembly 3: Fuser Asm– Part Units Description Index Number 3–1 12G6495 Fuser assembly 100V 500W 12G6301 Fuser assembly 115V 500W 12G6302 Fuser assembly 220V 500W 12G6516 Fuser lamp, 100V 500W hot roll 12G6337 Fuser lamp, 115V 500W hot roll 12G6341 Fuser lamp, 220V 500W hot roll 12G6517...
  • Page 358 5060-00x Assembly 3.1: Fuser (web oiler) 7-10 Service Manual...
  • Page 359 5060-00x Assembly 3.1: Fuser Asm– Part Units Description Index Number 3.1–1 12G6545 Web oiler assembly 12G6495 Fuser assembly, web oiler 100V 500W 12G6514 Fuser assembly, web oiler 115V 500W 12G6515 Fuser assembly, web oiler 220V 500W 12G6543 Web oiler index drive assembly 7-11 Parts catalog...

  • Page 360: Assembly 4: Fuser Drive

    5060-00x Assembly 4: Fuser drive Asm– Part Units Description Index Number 4–1 56P1213 Fuser drive assembly w/motor Screws PP 12G6309 56P1238 Fuser drive motor Screws, motor mounting 7-12 Service Manual...

  • Page 361: Assembly 5: Vacuum Transport Belt Assembly

    5060-00x Assembly 5: Vacuum transport belt assembly Asm– Part Units Description Index Number 12G6491 Jam access spring 12G6489 Vacuum transport belt assembly 7-13 Parts catalog...

  • Page 362: Assembly 6: Transfer

    5060-00x Assembly 6: Transfer Asm– Part Units Description Index Number 6–1 12G6303 Second transfer roll 12G6488 Transfer plate assembly 7-14 Service Manual...

  • Page 363: Assembly 7: Printheads

    5060-00x Assembly 7: Printheads Asm– Part Units Description Index Number 7–1 12G6322 Printhead assembly (Do not replace more than one printhead at a time.) Screw, PP 12G6534 Screw, PP 12G6539 PSD assembly (order 7-5, thermistor card, when replacing this assembly) 56P1198 Thermistor card Screw, PP 12G6533...

  • Page 364: Assembly 8: Paper Feed Output (Redrive)

    5060-00x Assembly 8: Paper feed output (redrive) Asm– Part Units Description Index number 8–1 56P0167 Anchor, bracket mounting 12G6493 Upper door hinge Screw, PP 12G6533 56P2204 Redrive belt 300 T 12G6492 Redrive assembly 12G6355 Redrive door 12G6513 Lower rear door latch 12G6512 Lower front door latch Screw, PP 12G6530...

  • Page 365: Assembly 9: Paper Feed Input

    5060-00x Assembly 9: Paper feed input Asm– Part Units Description Index number 9–1 12G6486 S2/transparency/narrow media sensor assembly 7-17 Parts catalog...

  • Page 366: Assembly 10: Paper Size Sensing

    5060-00x Assembly 10: Paper size sensing Asm– Part Units Description Index Number 10–1 12G6470 Waste container latch spring 12G6469 Waste container latch 12G6467 Paper size sensing spring 12G6468 Paper size sensing bracket Screw, paper size sensing assembly mounting PP 12G6531 12G6466 Paper size sensing link 7-18...

  • Page 367: Assembly 11: Paper Feed Transport

    5060-00x Assembly 11: Paper feed transport Asm– Part Units Description Index Number 11–1 56P2199 Nip relief handle 12G6483 Gear, staging idler 12G6482 Gear, staging reduction #1 12G6481 Registration plate assembly 12G6484 Gear, reference plate drive 12G6480 Registration motor Registration motor assembly screw, PP 12G6309 7-19 Parts catalog...

  • Page 368: Assembly 12: Multipurpose Feeder (Mpf)

    5060-00x Assembly 12: Multipurpose feeder (MPF) 7-20 Service Manual...
  • Page 369 5060-00x Assembly 12: Multipurpose Feeder (MPF) Asm– Part Units Description Index number 12–1 12G6452 MP feeder door cover 12G6460 Door hinge restraint Screw, PP 12G6533 12G6453 Frame bias latch 12G6455 Frame bias latch cover Screw, PP 12G6533 12G6454 Frame bias spring 12G6457 MPF support bracket cover 12G6456...

  • Page 370: Assembly 13: 500-Sheet Integrated Tray

    5060-00x Assembly 13: 500-sheet integrated tray 7-22 Service Manual...
  • Page 371 5060-00x Assembly 13: 500-sheet integrated tray Asm– Part Units Description Index number 13–1 12G6416 500-Sheet tray assembly 12G6419 Back restraint latch 12G6418 Back restraint 12G6425 Tray bias bellcrank assembly Screw, PP 12G6533 12G6426 Tray bias spring 12G6568 Reflector label 12G6421 Wear strip 12G6420 Tray wear clip...

  • Page 372: Assembly 14: Autocompensator Assembly

    5060-00x Assembly 14: Autocompensator assembly Asm– Part Units Description Index Number 14–1 56P0551 Cable, paper media low/out 12G6471 Tray interlock bellcrank 12G6558 Pick arm lift bellcrank 12G6427 Pick assembly 500-tray 12G6557 Bellcrank lift spring 12G6476 Paper level sensing assembly 12G6472 Tray interlock bracket 12G6461 Sensor, paper out/low...

  • Page 373: Assembly 15: Itu Assembly

    5060-00x Assembly 15: ITU assembly Asm– Part Units Description Index Number 15–1 12G6413 ITU light shield assembly Cable, printhead interlock/cover open (3-wire) 12G6503 12G6504 Cable, HVPS interlock/cover open (2-wire) 56P1295 ITU assembly 7-25 Parts catalog...

  • Page 374: Assembly 16: Itu Drive Assembly

    5060-00x Assembly 16: ITU drive assembly 7-26 Service Manual...
  • Page 375 5060-00x Assembly 16: ITU drive assembly Asm- Part Units Description index number 16–1 56P1216 ITU motor drive assembly with SKC motor 12G6385 #58 Gear 56P0568 ITU drive motor, SKC Screw, PP 12G6309 (ITU drive motor to ITU drive assembly) Screw, PP 12G6309 (ITU drive assembly lower frame) 7-27 Parts catalog...

  • Page 376: Assembly 17: Itu Loading

    5060-00x Assembly 17: ITU loading 7-28 Service Manual...
  • Page 377 5060-00x Assembly 17: ITU loading Asm– Part Units Description Index number 17–1 12G6546 Yellow terminal contact assembly 12G6442 Terminal, contact spring Screw PP 12G6533 12G6353 Cartridge support roller 56P1495 Parts packet, ITU loading - yellow, including - Yellow BOR spring - Rear block guide - Rear transfer bellcrank - Front V block guide...

  • Page 378: Assembly 18: Bor Drive Assembly

    5060-00x Assembly 18: BOR drive assembly Asm– Part Units Description Index number 18–1 12G6446 BOR housing assembly with motor 7-30 Service Manual...

  • Page 379: Assembly 19: Cartridge Contact Assembly

    5060-00x Assembly 19: Cartridge contact assembly Asm– Part Units Description Index number 19–1 56P0310 Cartridge contact assembly, complete 12G6377 Rear hold down bellcrank 12G6376 Rear hold down spring 7-31 Parts catalog...

  • Page 380: Assembly 20: Cartridge Drive Assembly

    5060-00x Assembly 20: Cartridge drive assembly 7-32 Service Manual...
  • Page 381 5060-00x Assembly 20: Cartridge drive assembly Asm– Part Units Description Index Number 20–1 Screw, PP 12G6530 56P1214 Cartridge drive assembly, cyan/magenta/black 56P1215 Cartridge drive assembly, yellow 7-33 Parts catalog...

  • Page 382: Assembly 21: Electronics

    5060-00x Assembly 21: Electronics 7-34 Service Manual...
  • Page 383 5060-00x Assembly 21: Electronics Asm– Part Units Description Index number 21–1 11A9095 Power cord set U.S., Canada (LV), Brazil (LV), Colombia (LV), Costa Rica (LV), Dominican Republic (LV), Ecuador (LV), El Salvador (LV), Guatemala (LV), Honduras (LV), Nicaragua (LV), Panama (LV), Venezuela (LV), Puerto Rico (LV), Virgin Islands (LV) Mexico (LV), Asia Pacific (English) LV, Japan (LV), Taiwan (LV), Saudi Arabia (LV), 43H5544 Power cord set PRC (HV)
  • Page 384 5060-00x Assembly 21.1: Electronics 7-36 Service Manual...
  • Page 385 5060-00x Assembly 21.1: Electronics Asm– Part Units Description Index number 21.1–1 Screw, PP 12G6309 12G6331 RIP board ground shield 12G6511 Cable mount 56P1188 RIP board assembly - network, model 5060-002 12G6334 INA riser support bracket 12G6326 Riser card assembly w/o support brackets 12G6335 Standoff, INA RIP spacer 56P9910...
  • Page 386 5060-00x Assembly 21.2: Electronics Asm– Part Units Description Index number 21.2–1 12G6327 Transfer HVPS board Screw, PP 12G6309 Screw, PP 12G6533 Screw, PP 12G6530 12G6541 Standoff, high voltage power supply - developer Screw, PP 12G6540 12G6328 Developer HVPS board 7-38 Service Manual...
  • Page 387 5060-00x Assembly 21.3: Electronics Asm– Part Units Description Index Number 21.3–1 12G6336 Engine board shield Screw, PP 12G6531 12G6323 Engine board 12G6387 Ground strap Screw, PP 12G6309 7-39 Parts catalog...
  • Page 388 5060-00x Assembly 21.4: Electronics 7-40 Service Manual...
  • Page 389 5060-00x Assembly 21.4: Electronics Asm– Part Units Description Index Number 21.4–1 12G6343 RIP fan duct Screws, PP 12G6530 12G6361 RIP fan 12G6479 VTB fan 12G6490 VTB fan gap cover 12G6382 Fuser fan 12G6529 Screws, fuser fan mounting 7-41 Parts catalog...

  • Page 390: Assembly 22: Electronic Cabling-Engine Board

    5060-00x Assembly 22: Electronic cabling—engine board 7-42 Service Manual...
  • Page 391 5060-00x Assembly 22: Electronic cabling—engine board Asm– Part Units Description Index Number 22—1 Cable, waste toner full, attached to ITU drive assembly (P/N 56P1216) 12G6317 Cable, HVPS control - transfer 12G6448 Cable, MPF paper level 56P0552 Cable, autocompensator motor 12G6486 Cable assembly (includes S2/NMS/transparency sensors) 56P0551 Cable, paper out/low and transparency media 2 sensors...

  • Page 392: Assembly 23: Electronic Cabling-Rip Board

    5060-00x Assembly 23: Electronic cabling—RIP board 7-44 Service Manual...
  • Page 393 5060-00x Assembly 23: Electronic cabling—RIP board Asm– Part Units Description Index Number 23—1 12G6503 Cable, printhead interlock/cover open 56P0310 Cable, signature button, attached to yellow HV contact assembly 56P0310 Cable, signature button, attached to cyan HV contact assembly 56P0310 Cable, signature button, attached to magenta HV contact assembly 56P0310 Cable, signature button, attached to black HV contact assembly 12G6387...

  • Page 394: Assembly 24: Electronic Cabling-Transfer Hvps

    5060-00x Assembly 24: Electronic cabling—transfer HVPS Asm– Part Units Description Index Number 24–1 56P1565 Cable assembly, black terminal contact 56P1567 Cable assembly, cyan terminal contact 56P1568 Cable assembly, yellow terminal contact 56P1566 Cable assembly, magenta terminal contact 56P0174 Cable assembly, second transfer voltage 56P1502 Cable, HVPS control - transfer 7-46...

  • Page 395: Assembly 25: Electronic Cabling-Developer Hvps

    5060-00x Assembly 25: Electronic cabling—developer HVPS Asm– Part Units Description Index Number 25–1 56P1502 Cable assembly, HVPS control - developer 56P0310 Cartridge contact assembly, complete, cyan/magenta/yellow 56P1561 Cartridge contact assembly, complete, black 56P0311 Cable, ITU Autocomp out with CB lead 7-47 Parts catalog...

  • Page 396: Assembly 26: Output Expander

    5060-00x Assembly 26: Output expander 7-48 Service Manual...
  • Page 397 5060-00x Assembly 26: Output expander Asm– Part Units Description Index number 26–1 99A0107 Deflector, upper redrive, also order 99A0104 99A0104 Spring, upper diverter 99A0369 shaft assembly, exit, also order PP 99A0572 99A0052 Shaft assembly, lower exit, also order PP 99A0572 56P0407 Shield, output option card 99A0915...
  • Page 398 5060-00x Assembly 26.1: Output expander 7-50 Service Manual...
  • Page 399 5060-00x Assembly 26.1: Output expander Asm– Part Units Description Index number 26.1–1 56P0405 Door assembly, right jam access 99A0368 Shaft assembly, lower, also order PP 99A0572 99A0363 Pulley, drive 56P0410 Bracket, attach Screw, PP 56P0169 56P0400 Cover, front 99A0361 Belt, 160 gear 99A0362 Arm assembly, belt idler 99A0364...

  • Page 400: Assembly 27: 5-Bin Mailbox

    5060-00x Assembly 27: 5-bin mailbox 7-52 Service Manual...
  • Page 401 5060-00x Assembly 27: 5-bin mailbox Asm– Part Units Description Index number 27–1 12G6409 Cover, redrive cap 99A1710 Cover, wire 56P0416 Cover, top bin 56P0423 Latch, rear access door 99A0104 Spring, upper diverter 56P0411 Door, front 56P0422 Latch, access door front 56P0415 Cover, right 99A1723...
  • Page 402 5060-00x Assembly 27.1: 5-bin mailbox 7-54 Service Manual...
  • Page 403 5060-00x Assembly 27.1: 5-Bin Mailbox Asm– Part Units Description Index number 27.1–1 99A1741 Spring, diverter 99A1727 Frame asm, right side Screw, board mounting PP 12G6309 99A1728 Cam, diverter actuator 99A1731 Spring, diverter actuator 99A1729 Latch, diverter actuator 99A1730 Arbor, diverter actuator 99A1789 C-clip 56P0418...

  • Page 404: Assembly 28: 500-Sheet Drawer Option

    5060-00x Assembly 28: 500-sheet drawer option 7-56 Service Manual...
  • Page 405 5060-00x Assembly 28: 500-sheet tray option Asm– Part Units Description Index number 28–1 56P0168 Drive assembly, 500 option 2 Screw, PP 12G6309 12G6550 500-Sheet Option tray pick assembly 12G6565 Paper level sensing assembly 12G6471 Tray interlock bellcrank 12G6556 Cover, frame 12G6553 Pass thru sensor 12G6562...
  • Page 406 5060-00x Assembly 28.1: 500-sheet tray option 7-58 Service Manual...
  • Page 407 5060-00x Assembly 28.1: 500-sheet tray option Asm– Part Units Description Index number 28.1–1 12G6416 500-Sheet tray assembly 12G6419 Back restraint latch 12G6418 Back restraint 12G6425 Tray bias bellcrank assembly Screw, PP 12G6533 12G6426 Tray bias spring 12G6568 Reflector label 12G6421 Wear strip 12G6420 Tray wear clip...

  • Page 408: Assembly 29: Duplex Option

    5060-00x Assembly 29: Duplex option 7-60 Service Manual...
  • Page 409 5060-00x Assembly 29: Duplex option Asm– Part Units Description Index number 29–1 56P0480 Back cover 99A2540 Redrive bearing 56P0447 Duplex entry shaft assembly Screw PP 12G6533 56P0434 Right side front tray guide 56P0483 Deflector actuator assembly 56P0432 Duplex front jam tray assembly 56P0457 Duplex support bracket 56P0455...
  • Page 410 5060-00x Assembly 29.1: Duplex option 7-62 Service Manual...
  • Page 411 5060-00x Assembly 29.1: Duplex option Asm– Part Units Description Index number 29.1–1 56P0456 Duplex support plate 56P0462 Autoconnect cable assembly 56P0463 DC forward/reverse motor assembly 56P0464 DC duplex feed motor Screw PP 12G6309 12G6510 Cable Tie (6 in pack) 56P0459 Back support 56P0430 Duplex card assembly...

  • Page 412: Assembly 30: High-Capacity Input Tray (Hcit)

    5060-00x Assembly 30: High-capacity input tray (HCIT) 7-64 Service Manual...
  • Page 413 5060-00x Assembly 30: High-capacity input tray (HCIT) Asm– Part Units Description Index number 30–1 56P0561 Paper size sensor box assembly 56P0519 Flag, paper size R 56P0520 Flag, paper size F 56P0518 Flag, paper size C 56P0522 Spring, paper size flag 56P0516 Sensor, photo interrupter 56P0511...
  • Page 414 5060-00x Assembly 30.1: High-capacity input tray (HCIT) 7-66 Service Manual...
  • Page 415 5060-00x Assembly 30.1: High-capacity input tray (HCIT) Asm– Part Units Description Index number 30.1–1 56P0505 Rear cover 56P0503 Right side cover 56P0491 Caster, movable Screws PP 12G6533 56P0493 F adjuster 56P0500 Front cover 56P0501 Cover, main CA 56P0492 Caster, fixed 56P0504 Left side cover 56P0508...

  • Page 416: Assembly 31: High-Capacity Output Finisher (Hcof)

    5060-00x Assembly 31: High-capacity output finisher (HCOF) 7-68 Service Manual...
  • Page 417 5060-00x Assembly 31: High-capacity output finisher (HCOF) Asm– Part Units Description Index number 31–1 56P0321 Top cover (tall finisher) 56P1287 Scanner plate (short finisher) 56P0569 Rear cover 56P0573 Upper right side cover (tall finisher) 56P1286 Upper right side cover (short finisher) 56P0574 Lower tray cover 56P0576...
  • Page 418 5060-00x Assembly 31.1: High-capacity output finisher 7-70 Service Manual...
  • Page 419 5060-00x Assembly 31.1: High-capacity output finisher Asm– Part Units Description Index number 31.1–1 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 420 5060-00x Assembly 31.2: High-capacity output finisher 7-72 Service Manual...
  • Page 421 5060-00x Assembly 31.2: High-capacity output finisher Asm– Part Units Description Index number 31.2–1 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...
  • Page 422 5060-0xx Assembly 32: High-capacity output finisher cables Service Manual...

  • Page 423: Assembly 32: High-Capacity Output Finisher Cables

    5060-00x Assembly 32: High-capacity output finisher cables Asm– Part Units Description Index number 32–1 56P0340 Cable, communications 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 424: Assembly 33: Options

    56P9982 Hard disk, 20GB with/adapter (formatted) 56P9926 Lexmark Optra Forms™ software 56P9927 Lexmark Forms Director software 56P9928 Lexmark Forms 4MB flash DIMM 56P9929 Lexmark Forms 8MB flash DIMM 56P9930 Lexmark Forms 16MBMB flash DIMM 56P9932 Hard disk, Lexmark Forms 56P9942...

  • Page 425: Assembly 34: Miscellaneous

    5060-00x Assembly 34: Miscellaneous Asm– Part Units Description Index number Screw type 323, PP 12G6309 Screw type 324, PP 12G6530 Screw type 232, PP 12G6531 Screw type 102, PP 12G6532 Screw type 312/322/412/423, PP 12G6533 Screw type 484, PP 12G6534 Screw, 500-sheet tray, PP 12G6538 Screw type 124, PP 12G6539 Screw type 121, PP 12G6540...
  • Page 426 5060-00x 7-78 Service Manual...

  • Page 427: Appendix A-Service Tips

    5060-00x Appendix A—Service tips Printhead diagnostics If you get a printhead error, follow this diagnostic to find the specific failure. Verify that 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 428 5060-00x 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 RIP board in the printer and connect them to the printhead diagnostic tool.
  • Page 429 5060-00x Turn on the printer and note the new error codes. • If an automatic calibration begins, 36 Printer Service Required may appear. The printhead and RIP board are working correctly and the printhead cable connections should be checked. Press Go to clear the error.

  • Page 430: Printhead Alignment

    5060-00x Printhead alignment Identifying the printheads Warnings: • Do not loosen or replace more than one printhead at a time to retain factory settings. • Whenever a printhead is replaced, you must to perform the “Printhead mechanical alignment” on appendix page A-5 “Electronic color alignment”...

  • Page 431: Printhead Mechanical Alignment

    5060-00x Printhead mechanical alignment Identify the configuration of your printer. The following steps are similar for both versions, except you need to remove two extra screws when you have the PSD bracket. You may have a PSD bracket (A), whether or not the PSD or thermistor is connected. You may not have a bracket.
  • Page 432 5060-00x Insert the first printhead alignment tool. If you have a PSD bracket, remove the two screws (A and B). Note: Use a small diameter Phillips screwdriver to remove screw (A). Insert the printhead alignment tool, placing the locating pin (C) in the middle hole (A). Secure the alignment tool bracket (D) with screw provided or a screw removed from the previous step.
  • Page 433 5060-00x Install the second printhead alignment tool in the front of the printhead and secure alignment tool bracket (D) with screw provided. Note: Align the locating pin (C) in the hole in printer frame. Turn the thumbwheel (E) until the end of the thumbwheel just touches the printhead mounting arm for both the front and rear alignment assemblies.
  • Page 434 5060-00x 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. Bias the new printhead assembly against the front and rear stops. Tighten the right rear printhead mounting screw.
  • Page 435 5060-00x Securely close the front cover or reattach if previously removed. If replacing the black printhead, go to step 12. Otherwise, enter Diagnostics Mode: Turn the printer off. Press and hold Go and Return. Turn the printer on. Release the buttons when Performing Self Test displays. Select Alignment Menu, select the color of the printhead that was replaced, and set the Z value to zero.

  • Page 436: Printer Registration (Only For Black Printhead Replacement

    5060-00x Turn each thumbwheel the appropriate number of clicks as indicated by the test page. For example, if the test page indicates a +10 as the misalignment, turn the thumbwheel 10 clicks in the positive direction indicated on the test page. Do this for both the front and rear. •...
  • Page 437 5060-00x Examine the registration marks on the top, bottom, left, and right sides on the page. Adjust the margin settings so that the Registration lines are on the edge of the page. Repeat for each margin. • Adjust the top margin before bottom margin, and the right margin before the left. Value Description Value change effect:...

  • Page 438: Electronic Color Alignment

    5060-00x Electronic color alignment Note: Use of a loupe or magnifying glass (4x or higher) may make observation of the alignment targets easier. Press Menu until Alignment displays and press Select. Select Alignment Test from the Alignment menu. Three sheets print for Cyan, Magenta, and Yellow. Each is compared to Black alignment. For example, one of the sheets shows Cyan printed over a Black target.
  • Page 439 5060-00x Press Go to print the Cyan Alignment Page. Use the top row to determine adjustments. Use the leftmost target in the first row to adjust the Cyan and Black horizontal lines in the target (T value or Top). Adjust the setting and press Go to print the page and verify the setting, until the lines are even. Press Select to save the value.

  • Page 440: Print Line Length Calibration

    5060-00x To adjust L or Left value, press Go to print the Cyan Alignment Page. Use the leftmost target in the first row to adjust the Cyan and Black vertical lines until the targets overlap. Adjust the setting and press Go to print the page and verify the setting, until the lines are even. Press Select to save the value.
  • Page 441 5060-00x A color band is visible through the black bars. Locate the center of the color band and determine the value. • If all the color bands for Cyan, Magenta, and Yellow on all six groups A through F are centered between -2 and +2, you are done.

  • Page 442: Partial Print Test

    5060-00x 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 “Entering CONFIG MENU” on page 3-7. 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 443 5060-00x Look at the surface of each toner cartridge and check for a developed image. 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 444: Nip Relief Handle Replacement

    5060-00x Nip relief handle replacement Removing the old nip relief handle Remove lower left side covers to gain access to the nip relief handle. Remove waste toner container. Reinsert paper tray into printer. If any fragments fall into the printer they should land in the paper tray and be easy to remove. Remove the broken pieces of old nip relief handle.
  • Page 445 5060-00x Remove any remnants of the handle. Check the paper tray to check for debris. For example, see the fragment (B) in the following picture. A-19 Appendix A—Service tips...
  • Page 446 5060-00x Installing the new nip relief handle 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) towards the rear of the machine and insert lower portion of handle so that it is trapped between the lever and the reference edge plate (C).
  • Page 447 5060-00x Holding the nip relief handle in place, use a flathead screwdriver to gently pry up on the top portion of the lever allowing the handle to press 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 448: Finisher Alignment

    5060-00x 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 449 5060-00x • Tall finisher – Printer – Optional duplex unit – One additional 500-sheet drawer – Optional 2000-sheet drawer – Finisher A-23 Appendix A—Service tips...
  • Page 450 5060-00x 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 451 5060-00x 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 452 5060-00x 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 453 5060-00x Short and tall finisher Lift the platform cover. Insert the Allen wrench (D) into either caster bolt (J). Rotate the wrench in the appropriate direction to adjust the height of the finisher (clockwise raises the finisher). Repeat with the other caster bolt. Step 4: Adjust the tilt If necessary, adjust the tilt of the finisher so that the front is flush with the front of the printer.
  • Page 454 5060-00x 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 455: Duplex Option Deflector Button Replacement

    5060-00x Duplex option deflector button replacement 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 compression spring deflector button.
  • Page 456 5060-00x A-30 Service Manual...

  • Page 457: Appendix B-Print Quality Samples

    5060-00x 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 458: Print Menus-Page Two Of Two

    5060-00x Print Menus—Page two of two Service Manual...

  • Page 459: Print Tests

    5060-00x Print tests Print Quality Pages—Title page (total of five) Appendix B—Print quality samples...

  • Page 460: Print Quality Pages-Page 1 (Total Of Five

    5060-00x Print Quality Pages—Page 1 (total of five) Service Manual...

  • Page 461: Print Quality Pages-Page 2 (Total Of Five

    5060-00x Print Quality Pages—Page 2 (total of five) Appendix B—Print quality samples...

  • Page 462: Print Quality Pages-Page 3 (Total Of Five

    5060-00x Print Quality Pages—Page 3 (total of five) Service Manual...

  • Page 463: Print Quality Pages-Page 4 (Total Of Five

    5060-00x Print Quality Pages—Page 4 (total of five) Appendix B—Print quality samples...

  • Page 464: Registration

    5060-00x Registration Quick Test Service Manual...

  • Page 465: Alignment Test Pages

    5060-00x Alignment test pages Printhead alignment test pages—magenta (one of three) Appendix B—Print quality samples...

  • Page 466: Printhead Alignment Test Page-Yellow (Two Of Three

    5060-00x Printhead alignment test page—yellow (two of three) B-10 Service Manual...

  • Page 467: Printhead Alignment Test Page-Cyan (Three Of Three

    5060-00x Printhead alignment test page—cyan (three of three) B-11 Appendix B—Print quality samples...

  • Page 468: Print Line Len Page

    5060-00x Print Line Len page B-12 Service Manual...

  • Page 469: Index

    5060-00x Index Numerics 2-41 3-29 1565 Emul Error Load Base Sensor Test 3-17 1xx service errors Belt Tracking 2-16 error table – black only retract (BOR) motor 2-42 2-67 service checks – location 4-23 2000-sheet option tray removal 5-26 2-117 board connectors service checks 7-64...
  • Page 470 5060-00x 5-22 5-24 LVPS duplex option 5-14 8-29 RIP board deflector button replacement covers error codes 7-60 7-62 parts catalog parts catalog 7-77 removals relocation packaging 2-120 service check 2-17 sub error codes 3-10 Demo Mode 3-23 tests developer HVPS board 3-23 duplex sensor test 5-20...
  • Page 471 5060-00x fuser drive assembly ITU drive assembly lubricating replacement motors lubrication 4-37 lubrication removals 7-12 7-28 parts catalog ITU loading, parts catalog 4-33 removal fuser web oiler 3-19 LCD Test 7-10 parts catalog 3-19 LCD test replacements locations upgrade kit developer HVPS board fuser web oiler motor assembly engine board...
  • Page 472 5060-00x 2-144 poor color alignment 2-145 residual image 7-77 packaging 2-136 service check 3-10 Panel Menus 2-146 smudged or distorted images 7-16 paper feed output (redrive) 2-146 toner is on the back of the printed page paper size sensing 2-145 toner smears or rubs off the page 7-18 parts catalog...
  • Page 473 5060-00x 4-14 redrive door top cover assembly 4-72 S2/NMS/transparency sensor assembly 4-28 developer HVPS board v-xvii safety information 4-29 engine board safety inspection guide 4-30 engine board shield scheduled maintenance 4-30 friction buckler screw identification table 4-31 fuser assembly second transfer roll 4-32 fuser bottom duct 7-14...
  • Page 474 5060-00x reliability resolution 4-84 waste container door 3-27 staple test 4-85 waste container latch start here web oiler drive motor 2-17 sub error code tables locations symptom tables web oiler fuser symptoms 7-10 parts catalog 500-sheet drawer option 4-85 removal 5-bin mailbox option replacements base printer...

  • Page 475: Part Number Index

    5060-00x Part number index Description Page 11A9095 Power cord set, U.S., Canada, Brazil, Colombia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Nicaragua, Panama, Venezuela, Puerto Rico, Virgin Islands, Mexico, Asia Pacific (English), Japan, Taiwan, Saudi Arabia - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 12G1695 MarkNet N2001e Ethernet 10/100BaseTX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-76 12G1696 MarkNet N2002e Ethernet 10BaseT/2...
  • Page 476 5060-00x 12G6340 Fuser top duct - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5 12G6341 Fuser lamp, 220V 500W hot roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 12G6342 Fuser lamp, 220V 400W backup roll...
  • Page 477 5060-00x 12G6413 ITU light shield assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 12G6416 500-Sheet tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-23 7-59...
  • Page 478 5060-00x 12G6490 VTB fan gap cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 12G6491 Jam access spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 12G6492 Redrive assembly...
  • Page 479 5060-00x 12G6543 Web oiler index drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 12G6545 Web oiler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 12G6545 Web oiler replacement...
  • Page 480 5060-00x 56P0325 Motor assembly paper feed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 56P0326 Flag paper full - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 56P0327 Paper feed belt (40S3M888)
  • Page 481 5060-00x 56P0386 Fan assembly DC motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 56P0387 Bar tip unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-69 56P0388 Tray limit switch...
  • Page 482 5060-00x 56P0476 5 mm bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 56P0477 Reduction gear shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63 56P0478 Aligner spring...
  • Page 483 5060-00x 56P0548 Elevator lift gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-65 56P0549 Elevator lift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-65 56P0550 Cable, tray media level sensor...
  • Page 484 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-76 56P9928 Lexmark Forms 4MB flash DIMM...
  • Page 485 5060-00x 99A0368 Shaft assembly, lower, also order PP 99A0572 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-51 99A0369 shaft assembly, exit, also order PP 99A0572 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49 99A0408 INA blank flat shield, use when options are not installed...
  • Page 486 5060-00x 99A1786 Gear, drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-53 99A1787 Deflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55 99A1788 Retainer, R-ring...

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