Lexmark 13P0150 - C 750dtn Color Laser Printer Service Manual
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Lexmark 13P0150 - C 750dtn Color Laser Printer Service Manual

Lexmark 13P0150 - C 750dtn Color Laser Printer Service Manual

Service guide
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TM
Lexmark
C750
5060-XXX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
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 13P0150 - C 750dtn Color Laser Printer

  • Page 1 C750 5060-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 6000-XXX...
  • Page 3 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PostScript is a registered trademark of Adobe Systems Incorporated.
  • Page 4 5060-XXX...

  • Page 5: Table Of Contents

    5060-XXX Table of Contents Notices and Safety Information ....... .vii Laser Notices .
  • Page 6 5060-XXX Diagnostic Aids ............. . Diagnostic Mode .
  • Page 7 5060-XXX Print Tests ............3-16 Print Tests (input source) .
  • Page 8 5060-XXX Multipurpose Feeder (MPF) ........4-31 Waste Container Access Door .
  • Page 9 5060-XXX Parts Catalog ..............How to Use This Parts Catalog .
  • Page 10 5060-XXX viii...

  • Page 11: Notices And Safety Information

    5060-XXX Notices and Safety Information Laser Notices 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.
  • Page 12 5060-XXX I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.
  • Page 13 5060-XXX Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.

  • Page 14: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts.
  • Page 15 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. • La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
  • Page 16 Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

  • Page 17: Preface

    5060-XXX Preface This manual describes the Lexmark C750 Color Printer (5060-XXX) and contains maintenance procedures for service personnel only. It is divided into the following chapters: General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
  • Page 18 5060-XXX Service Manual...

  • Page 19: General Information

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

  • Page 20: Acronyms

    5060-XXX 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 HVPS High Voltage Power Supply Intermediate Transfer Unit Black LASER...

  • Page 21: Diagnostic Information

    5060-XXX 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 22 5060-XXX Symptom Action Paper feed problems, base printer Go to the “Paper Path Service Check” on page 2-97. Paper feed problems, integrated tray Go to the “Tray 1 Service Check” on page 2-90. Paper fails to pick from Tray 1 Go to “Autocompensator Service Check”...

  • Page 23: Error Code Table

    5060-XXX Symptom Action Fuser Problem - Fuser running too hot Go to the “Hot Fuser Service Check” on page 2-83. Fuser Problem - Excessive Fuser Drive Motor Go to “Excessive Fuser Drive Motor Assembly Assembly Noise Noise” on page 2-85. Paper Jams in base printer Go to the “Paper Path Service Check”...
  • Page 24 5060-XXX Error code Action 911 Trans Sensor Tray 2 Transparency Sensor Error - Replace Tray 2 Transparency Sensor Assembly. If this does not fix the problem, replace the “Engine Board” on page 4-13. 912 Trans Sensor Tray 3 Transparency Sensor Error - Replace Tray 3 Transparency Sensor Assembly.
  • Page 25 5060-XXX Error code Action 941 TMC Error Magenta TMC switch failure - Go to the “Magenta Cartridge Drive Assembly” on page 2-44. 942 TMC Error Yellow TMC switch failure - Go to the “Yellow Cartridge Drive Assembly Service Check” on page 2-47.
  • Page 26 5060-XXX Error code Action 958 NAND Failure Replace the “RIP Board” on page 4-11. 960 RAM Memory Error RAM soldered on board is bad. Replace the “RIP Board” on page 4-11. 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 27 5060-XXX Error code Action 990 <device> This error message indicates that an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure. Note: <device> can be one of the following: * Duplex unit * Tray x (where x=1,2,3,4, or 5) * Output Bin x (where x=1,2,3, or 6)
  • Page 28 5060-XXX Error code Action 107 Printhead Error Magenta Printhead Lost Hsync Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J7, J8, and J9 on the RIP Board. Go to “RIP Board”...
  • Page 29 5060-XXX Error code Action 112 Printhead Error No first Hysnc - Yellow Replace the following FRU: Yellow Printhead Assembly - Go to “Printheads” on page 4-33. Note: Whenever a printhead assembly is replaced it is necessary to perform the “Printhead Adjustments” on page 4-1.
  • Page 30 5060-XXX Error code Action 121 Fuser Error Wrong Fuser Lamp - BUR - Replace with correct lamp. Go to “Error Code 120 Error Code 121” on page 2-80. 122 Fuser Error Fuser below temperature when printing - Hot Roll - Go to “Cold Fuser Service Check”...
  • Page 31 5060-XXX Error code Action 141 Motor DC Pick Motor Excessive PWM - Staging Motor - Replace the following FRU: “Engine Board” on page 4-13 If this does not fix the problem, replace: Replace the Staging Motor Assembly 142 Motor DC Pick Motor, over speed - Staging Motor - Replace the Staging Motor Assembly 143 Motor DC Pick Motor, No encoder Feedback - Staging Motor - Replace...
  • Page 32 5060-XXX Error code Action 156 Motor Black Cartridge Motor lost lock - Go to “Black Cartridge Drive Assembly Service Check” on page 2-44. 157 Motor Magenta Cartridge Motor lost lock - Go to “Magenta Cartridge Drive Assembly” on page 2-44. 158 Motor Cyan Cartridge Motor lost lock - Go to “Cyan Cartridge Drive...
  • Page 33 5060-XXX Error code Action 172 Motor Mirror motor lost lock - Cyan - Replace the Cyan Printhead Assembly - Go to “Printheads” on page 4-33. Note: Whenever the printhead assembly is replaced it is necessary to perform the “Printhead Adjustments” on page 4-1.
  • Page 34 5060-XXX Error code Action 184 PSD Error EOS sensor out of range scan direction (Black) - Replace the Black “PSD Sensor Assembly” on page 4-34. Note: It is necessary to remove the Black Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the “Printhead Adjustments”...

  • Page 35: Sub Error Code Table

    5060-XXX Error code Action 193 PSD Error No EOS reading (Cyan) - Go to “PSD Service Check” on page 2-88. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the “Printhead Adjustments”...
  • Page 36 5060-XXX Sub Error Code Explanation 2D 14 Prism Sensor detected different media from the tray sensor. 2D 15 Paper jam detected. A paper jam detected in Stacker 1. 2D 16 Paper jam detected. A paper jam detected in Stacker 2. 2D 17 Paper jam detected.
  • Page 37 5060-XXX Sub Error Code Explanation 2D 32 A Tray 2 pick motor stall error detected 2D 33 A Tray 2 pick motor PWM error detected 2D 34 A Tray 2 pick motor encoder error detected 2D 35 A Tray 2 feed motor stall error detected 2D 36 A Tray 2 feed motor PWM error detected 2D 37...

  • Page 38: Hcit System Board Led Error Code Table

    5060-XXX Sub Error Code Explanation 2D 51 The 5-Bin Mailbox pass thru sensor was not activated by the media. 2D 52 The 5-Bin Mailbox sensor was not deactivated by the previous page or not activated by the current page. 2D 53 The 5-Bin Mailbox sensor was not activated by the media.

  • Page 39: 2Xx Paper Jam Message Table

    5060-XXX 2XX Paper Jam Message Table Note: A secondary message only displays if the finisher option is installed. Primary Secondary Description code Message Message Paper Jam Leave Job in Finisher Primary: Paper is jammed at the printers input Clear Paper Path sensor.
  • Page 40 5060-XXX Primary Secondary Description code Message Message 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...
  • Page 41 5060-XXX Primary Secondary Description code Message Message Paper Jam Leave Job in Finisher Primary: Media is jammed in the MP Feeder. If Clear Paper Path sheets have been accumulated to be stapled or Go to the offset when the jam occurred, the printer “Multipurpose alternately flashes the primary and secondary Feeder (MPF)
  • Page 42 5060-XXX Primary Secondary Description code Message Message Paper Jam Leave Job in Finisher Primary: Media is jammed in output Bin x. Open Clear Paper Path the door of output Bin X to access the jam. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets...

  • Page 43: User Attendance Message Table

    5060-XXX User Attendance Message Table User Primary User Secondary Message Explanation Message 200 Paper Jam Clear Leave Job in Finisher Primary: This message indicates that a paper Paper Path jam has occurred at or near the printer Input Sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.
  • Page 44 5060-XXX User Primary User Secondary Message Explanation Message 203 Paper Jam Clear Leave Job in Finisher Primary: Media has jammed due to a Paper Path transparency sensor mismatch. Open the printer left door 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 accumulated sheets...
  • Page 45 5060-XXX User Primary User Secondary Message Explanation Message 250 Paper Jam Clear Leave Job in Finisher Primary: Paper is jammed in the MPF. Paper Path 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 clearance.
  • Page 46 5060-XXX User Primary User Secondary Message Explanation Message 280 Paper Jam Clear Leave Job in Finisher Primary: Media has jammed in the Finisher Paper Path Option, open the Finisher Option Side door to top cover to access the jammed pages. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary...
  • Page 47 5060-XXX User Primary User Secondary Message Explanation Message Calibrate <Tray x> This message will be displayed when the user Load Paper has initiated a tray calibration procedure. <Tray x> = Tray 1 thru 4, MPF, Envelope Feeder, Manual Paper and Manual Envelope. The following actions can be taken while this message is displayed: * Load paper into Tray x and press Go to initiate...
  • Page 48 5060-XXX User Primary User Secondary Message Explanation Message Reattach Output Bin x These messages will be displayed anytime the Reattach Bins x-y printer loses communications with one of the Check Tray x following options: Connection * Output Bin x(x=1,2 or 3) * Bins (x-y=1 thru 5) * Tray x (x=2,3,4 or 5) * Duplex...
  • Page 49 5060-XXX User Primary User Secondary Message Explanation Message Hole Punch Waste Full This message will be displayed when the Hole Punch Alarm is ON and any of the following is true: * The code has determined that the Hole Punch Waste Box is completely full.
  • Page 50 5060-XXX User Primary User Secondary Message Explanation Message Load Staples This message will be displayed when the Staples Empty Alarm is activated and one of the following has occurred: * There are no staples in the staple unit or the staple unit is not installed.
  • Page 51 5060-XXX User Primary User Secondary Message Explanation Message Install Tray x or Cancel This message will be displayed when the printer Job Install Bin x or requests the user to insert tray x before it can Cancel Job Install continue printing the job. This message is Duplex or Cancel Job displayed because the printer needs to pick media from the missing tray or the trays below it.
  • Page 52 5060-XXX User Primary User Secondary Message Explanation Message 30 ITU Missing This message will be displayed when the ITU is missing. The following action can be taken while this message is displayed: * Turn the printer off, insert the ITU and turn the printer back on.
  • Page 53 5060-XXX User Primary User Secondary Message Explanation Message 34 Incorrect Media This message will be displayed when the printer <type> <size> Change has detected a media mismatch feeding from the MP Feeder MPF. Primary Message: Incorrect Media detected Secondary Message: <type>= Bond, Cardstock, Colored, Labels, Envelopes, Letterhead, Plain, Preprint, Transparency or Glossy.
  • Page 54 5060-XXX User Primary User Secondary Message Explanation Message 36 Printer Service This message will be displayed when background Required toner has prevented a completion of a TPS calibration cycle. Service will be required to fix the problem. The following action can be taken while this message is displayed: * Press Go to clear the error.
  • Page 55 5060-XXX User Primary User Secondary Message Explanation Message 37 Insufficient Defrag This message will be displayed when insufficient Memory printer memory is available to perform Flash Memory Defragment operation. Note: This message sill be posted prior to the actual start of the defragment operation. The following actions can be taken while this message is displayed: * Press Go to clear the message.
  • Page 56 5060-XXX User Primary User Secondary Message Explanation Message 38 Memory Full This message will be displayed when the printer is processing an incoming job and there is not enough memory available to continue processing the job. The following actions can be taken while this message is displayed: You may want to determine how to make more memory available to your print job by:...
  • Page 57 5060-XXX User Primary User Secondary Message Explanation Message 52 Flash Full This message will be displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. Note: The following action will delete all downloaded Fonts and Macros written to disk: *Press Go to clear the message and continue...
  • Page 58 5060-XXX User Primary User Secondary Message Explanation Message 54 Serial Option x This message will be displayed when a serial Error error either framing, parity or overrun, has been detected on the specified (option x) serial port. This usually means the serial port has not been set up correctly.
  • Page 59 5060-XXX User Primary User Secondary Message Explanation Message 56 Std Parallel Port These messages may be displayed when data is Disabled sent to the printer across a parallel port, but the 56 Parallel Port x port has been disabled. Disabled Note: Once the error has been displayed for the first time, reporting of further errors will be suppressed until the printer is reset or menus are...
  • Page 60 5060-XXX User Primary User Secondary Message Explanation Message 58 Too Many Disks This message will be displayed when too many Installed disks have been installed. Note: Some configurations of different output options require the installation of one option before the other. 58 Too Many Flash This message will be displayed when too many Options...
  • Page 61 5060-XXX User Primary User Secondary Message Explanation Message 62 Disk Full This message will be displayed when there is not enough free space on the disk to hold the data that have been requested to be written to the disk. This message will be displayed for both resource collection and PostScript when the disk is full.
  • Page 62 5060-XXX User Primary User Secondary Message Explanation Message 81 Engine Code CRC This message will be displayed when microcode Failure is programmed into the engine flash code has failed a CRC check. The following action can be taken while this message is displayed: * Press Go to clear the message.

  • Page 63: Service Checks

    5060-XXX User Primary User Secondary Message Explanation Message 88 Yellow Toner Low These messages will be displayed when either 88 Magenta Toner Low the Yellow, Magenta, Cyan or Black toner 88 Cyan Toner Low cartridge is low on toner. 88 Black Toner Low The following actions can be taken while this message is displayed: * Open the front door, remove the old toner...

  • Page 64: Black Cartridge Drive Assembly Service Check

    5060-XXX Black Cartridge Drive Assembly Service Check Error Code 162 Step Actions and Questions Error Code 162 - Manufacturer of Drive Motor unknown. Go to Step 2 Problem Does the printer display Error Code 162? Solved Reflash the NVRAM on the Engine Board. Call your next Problem level support...
  • Page 65 5060-XXX Step Actions and Questions Reflash the NVRAM on the Engine Board. Call your next Problem level support Solved Is Error Code 163 still being displayed? Error Code 151 Error Code 157 Step Actions and Questions Error Codes 151 and 157. These error codes indicate that Go to step 2 Install the the Magenta Cartridge Drive Motor has either failed to lock...

  • Page 66: Cyan Cartridge Drive Assembly Service Check

    5060-XXX Cyan Cartridge Drive Assembly Service Check Error Code 164 Step Actions and Questions Cyan Cartridge Drive Motor Assembly - Error Code 164 Go to step 2 Problem Solved indicates that an incorrect motor is detected. Replace the Cyan Cartridge Drive Assembly. Go to “Cartridge Drive Motor Assembly (Cyan, Magenta, Black)”...

  • Page 67: Yellow Cartridge Drive Assembly Service Check

    5060-XXX Yellow Cartridge Drive Assembly Service Check Error Code 165 Step Actions and Questions Yellow Cartridge Drive Motor Assembly - Error Code 165 Go to step 2 Problem Solved indicates that an incorrect motor is detected. Replace the Yellow Cartridge Drive Assembly. Go to “Cartridge Drive Motor Assembly (Cyan, Magenta, Black)”...

  • Page 68: Fan Service Checks

    5060-XXX Fan Service Checks Error Code 925 Main Fan Service Check Step Actions and Questions Turn the power off and manually spin the fan and check that Go to Step 2 Replace the it rotates freely. “Main Fan” on page 4-13 Does the fan rotate freely? Check the Main Fan Cable connection to the Engine Board, Go to Step 3...
  • Page 69 5060-XXX Step Actions and Questions Disconnect the VTB fan from J4 on the Engine Board and Replace the Replace the check the voltages on J4 (refer to Table 2). “VTB Fan” on “Engine page 4-37 Board” on Are the voltages correct? page 4-13 Table 2 Connector...

  • Page 70: Ac And Dc Power Service Check

    5060-XXX 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 71: Dc Power Service Check

    5060-XXX 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 the Go to Step 2 display all diamonds?

  • Page 72: Second Transfer Roll Service Check

    5060-XXX 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. Note: The second transfer roll is also part of the maintenance kit and should be replaced when a “83 ITU Maintenance”...

  • Page 73: Output Expander Service Check

    5060-XXX Step Actions and Questions Check the Transfer HVPS to ITU HV Transfer Terminal for Reinstall or Go to step 8 the color(s) that is having transfer problems. replace the cable Is the cable disconnected or broken? Transfer Terminal Contact assembly and ITU Transfer Repair or Replace the Bellcrank - Check the Transfer terminal contact, transfer...
  • Page 74 5060-XXX Step Symptoms Remove paper - Output Bin X is displayed, POST is Go to Go to Step 4 incomplete unable to clear the message. “Remove paper - Output Bin X is displayed, POST is incomplete unable to clear the message.”...
  • Page 75 5060-XXX Printer does not recognize that one or more output options as being installed. Step Actions and Questions Excessive static electricity buildup - Check the output Go to Step 2 1. Attach the expander Control Board cover to make sure the ESD brush ground cable ground lead is firmly attached to the output expander frame.
  • Page 76 5060-XXX 202 Paper Jam, Open Rear Door Message Displays. 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.
  • Page 77 5060-XXX Remove paper - Output Bin X is displayed, POST is incomplete unable to clear the message. Step Actions and Questions Output Sensor Flag check - Check the flag for correct Replace the Go to Step 2 operation, binds, broken parts or interference from the flag or repair sensor cable.
  • Page 78 5060-XXX 271 Paper Jam - Check Bin X, Post Complete, first sheet of paper feeds into Output Bin X. Note: Before proceeding with this service check run the Output Bin X Sensor Test and check for the failing sensor. Sensor Tests: XNF=Near Full (Upper Part of sensor assembly) F=Full (Lower part of sensor assembly) P=Pass Thru Sensor...
  • Page 79 5060-XXX 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 of Go to step 2 Install the the sensor cable at J5 on the Control Board. cable correctly Is the cable installed correctly? Dual Output Bin X Sensor Assembly...

  • Page 80: 5-Bin Mailbox Service Check

    5060-XXX 5-Bin Mailbox Service Check Note: Before proceeding with this service check make sure the option(s) are installed correctly before attempting to service the unit. Be sure the option is correctly installed and the machine is configured correctly. The majority of the mechanical components can be observed during operation by removing the left and right side covers.
  • Page 81 5060-XXX Step Symptoms Ready - Bin X Full displays and paper feeds into Bin X Go to “Ready - Go to Step 8 Bin X Full displays and paper feeds into Bin X.” on page 2-65 Paper does not feed into the bin selected. 271 Paper Jam - Go to “Paper Go to Step 9...
  • Page 82 5060-XXX Step Action and Questions Options - Check to make sure that the output expander Go to Step 2 Check the option is the only output option that is not recognized by the autoconnect base printer. system in base printer Is this the only output option not recognized by the base printer? Mechanical Linkage (Cables) - Check the 5-Bin Mailbox...
  • Page 83 5060-XXX 271 Paper Jam - Check Bin 1 displays. Step Action and Questions Bottom Pass Thru Sensor Flag - Check to make sure the Fix or replace Go to Step 2 Bottom Pass Thru Sensor Flag is operating correctly and is the flag not binding, broken or any interference from the sensor cable.
  • Page 84 5060-XXX Ready Bin X Full Message Displays - May be able to clear message and will feed paper into Bin selected. Note: This sensor is in a normally open position with the flag out of the sensor slot. Step Action and Questions Bin X Sensor (Bin X=Sensor 1 thru 5) - Check to make sure Go to Step 2 Install the...
  • Page 85 5060-XXX Ready - Bin X Full displays and paper feeds into Bin X. Step Action and Questions Bin X Sensor Flag - Check the Bin X sensor flag to make it Replace the Repair or is not in the up position and is operating correctly. Bin X Sensor.

  • Page 86: Print Quality Service Checks

    5060-XXX Step Action and Questions Resistance Check - Disconnect J4 from the option board Go to Step 3 Replace the and check the resistance of the motor on the cable Mechanical connector between J2-1 and J2-2. The resistance Linkage/DC measures between 115 and 135 ohms. Motor Assembly Is the resistance correct?

  • Page 87: Horizontal Line

    5060-XXX 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 Replace the Call your next Note: The most likely cause of this failure is a failing black Cartridge level support...

  • Page 88: Missing Colors

    5060-XXX The entire page is mostly all one color. Some printing may appear in other colors. This applies to Black, Cyan, Magenta and Yellow. Step Action and Questions Print Cartridge Check - Generally this problem is caused by Problem Go to Step 2 a bad charge roll contact in the cartridge.Try a new print Solved cartridge for the color that is covering most of the page.

  • Page 89: Light Print Over The Entire Page

    5060-XXX Step Action and Questions High Voltage Contact Block Assembly Check, PC Drum Repair the HV Go to Step 4 Contact Pin - Check for a stuck PC Drum Contact in the HV Contact Block contact block assembly. Refer to figure 1 for the location of Assembly.
  • Page 90 5060-XXX Step Action and Questions Toner Cartridge Check - Try a new toner cartridge for the Problem Go to Step 3 missing color. Solved Does a new toner cartridge fix the problem? High Voltage Contact Block Assembly Check, PC Drum Repair the HV Go to Step 4 Contact Pin - Check for a stuck PC Drum Contact in the HV...

  • Page 91: Low Image Density

    5060-XXX Step A Step Action and Questions Print Cartridge Check Replace the Go to step 2 print cartridge. Are lines spaced at 46 mm or 95 mm intervals? Cartridge Drive Motor Assembly Check Replace the No problem “Cartridge found Are the lines spaced at a 4mm interval? Drive Assembly”...

  • Page 92: Poor Color Registration

    5060-XXX Step B Step Action and Questions Check to make sure that Color Calibration has not been Set Color Go to step 2 disabled in the CE menus, especially if the printer has been Calibration on previously serviced. Was Color Calibration disabled? Toner Density Calibration - Run Toner Density Calibration Problem Replace the...

  • Page 93: Residual Image

    5060-XXX Step Action and Questions Is the quality of the transparency poor or do brown colors Go to Step 3 Go to Step 4 appear when projected? Fuser Settings - From the CE menu select fuser settings Problem Replace the and set to "High".
  • Page 94 5060-XXX Step A Step Action and Questions Print Cartridge - This is most likely caused by a failure of the Problem Go to Step 2 cleaner in the print cartridge. Try a new print cartridge for Solved the faulty color. Does this fix the problem? HV Contact Block Assembly, Doctor Blade or TAR Contact Go to Step 3...

  • Page 95: Uneven Printing

    5060-XXX Step Action and Questions HV Contact Block Assembly Check, Doctor Blade or TAR Go to Step 3 Repair the HV Contact - Check for a stuck TAR contact pin in the HV Block Contact Contact Block Assembly of the colors with the problem. for the faulty Look at figure 1 for pin locations.

  • Page 96: Toner Smears Or Rubs Off The Page With No Error Code Displayed

    5060-XXX Step Action and Questions Cartridge Check - The cartridge may be out of toner or have Problem Call your next another toner problem. Try a new toner cartridge. Solved level support Does a new toner cartridge fix the problem? Toner smears or rubs off the page with no error code displayed Note: This type of problem is associated with improper fusing or incorrect settings for media type being used.

  • Page 97: Operator Panel Lcd/Status Led/Buttons Service Check

    5060-XXX Step Action and Questions Does resetting the media type fix the problem? Problem Go to Step 3 Solved Fuser Settings - Set the fuser to "High" in the CE menu. Problem Replace the Solved “Fuser” on Does setting the fuser to "High" fix the problem? page 4-15 Light lines or streaks appear on the page Single color streaks in non-print areas are most likely caused by a cleaner problem in the...
  • Page 98 5060-XXX Step A Step Action and Questions Buttons Test - Perform the “Button Test” on page 3-5. Replace the Test Passes “Operator No problem Do any or all of the Buttons fail to operate correctly? Panel” on found Note: If all the buttons fail to operate correctly, the LCD page 4-25 display is blank, Power On Status LED is on, and the Machine beeps 5 Times, go Step B.
  • Page 99 5060-XXX Step Action and Questions RIP Board - A poor ground connection between pin 4 on the Go to step 11 Replace the Operator Panel board connector can cause this symptom. “RIP Board” Check for continuity between Pin J1-4 and ground on the on page 4-11 board.

  • Page 100: Fuser Service Check

    5060-XXX Fuser Service Check Error Code 120 Error Code 121 Incorrect Lamp Installed - The Hot Roll and Backup Roll may have the wrong voltage lamp installed. Step Action and Questions Is Error Code 120 displayed? Install the Go to step 2 correct voltage hot roll lamp Is Error Code 121 displayed?

  • Page 101: Error Code

    5060-XXX Error Code 130 Hot Roll did not reach the correct standby temperature. Step Action and Questions Voltage Check - Go to “Engine Board” on page 5-1. Replace the Go to step 2 Measure the voltage on connector J10-11. “Fuser” on page 4-15 The voltage measures approximately .13 V dc to .64 V dc as the hot roll lamp turns off and on.
  • Page 102 5060-XXX Error Code 132 - Cold Hot Roll Error Code 133 - Cold Backup Roll Step Action and Questions Lamp continuity Check, Hot Roll - Check continuity of the Replace the Go to step 2 hot roll lamp. The continuity can be checked by measuring “Fuser”...

  • Page 103: Hot Fuser Service Check

    5060-XXX Step Action and Questions Voltage Check - Measure the voltage on J10-6. Go to Find the Replace the “Engine Board” on page 5-1. The voltage will vary as the correct system following lamp turns off and on between approximately +1.5 V dc to problem or FRU's in 1.8 V dc.
  • Page 104 5060-XXX Replace the FRU's in the following order: “Fuser” on page 4-15 “LVPS” on page 4-14 “Engine Board” on page 4-13 Error Code 125 Error Code 135 Error codes 125 and 135 indicate that a problem exists in the fuser assembly with the back up roll bearings, back up roll thermistor, LVPS or engine board.
  • Page 105 5060-XXX Excessive Fuser Drive Motor Assembly Noise Step Action and Questions Excessive Noise from the Fuser Drive Motor Assembly - Go to step 2 Correctly Check for correct installation of the fuser drive motor install the assembly. “Fuser Drive Assembly” Is the fuser drive motor installed correctly? on page 4-16.

  • Page 106: Paper Jam

    5060-XXX Paper Jam 202 Paper jam is detected at the fuser assembly. Step Action and Questions Paper Jam at the Exit of the Fuser Assembly - Check to see Go to step 2 Go to the if the paper is jammed after the Fuser Exit Sensor. “2XX Paper Did the paper jam at the exit of the Fuser Assembly? Message...

  • Page 107: Cover Open/Hv Interlock Switch Service Check

    5060-XXX Cover Open/HV Interlock Switch Service Check "Close Door" is displayed constantly, unable to clear the message from the display, POR incomplete. Step Action and Questions Front Cover and HV Interlock Switches - Check to make Go to step 2 Check the sure both switches are mounted correctly.

  • Page 108: Psd Service Check

    5060-XXX PSD Service Check Error Code 192 Error Code 193 Error Code 194 Error Code 195 Go to step 1 for Error Codes 192 and 194. Go to step 5 for Error Codes 193 and 195 Step Action and Questions Check to make sure that the PSD Cable is installed Go to step 2 Install the...

  • Page 109: Tray 1 Paper Size Sensing Service Check

    5060-XXX Step Action and Questions Check continuity of the PSD cable. Replace the Replace the “PSD Sensor PSD cable for Note: The PSD cable has one connector on one end, RIP Assembly” on the Cyan and Board, and two connectors on the other end, Cyan PSD page 4-34.

  • Page 110: Tray 1 Service Check

    5060-XXX Step Action and Questions Check the following parts to make sure they are installed Go to step 6 Repair or correctly and they replace parts as necessary are not damaged or broken. * Size Sensing Gear Cover * Size Sensing Gear * Size Sensing Barrel Cam Note: Make sure the Size Sensing Barrel Cam is correctly installed.

  • Page 111: Autocompensator Service Check

    5060-XXX Step Action and Questions Check to make sure the autocompensator has fully Go to step 3 Go to the retracted to its upper position. “Autocompe nsator Does the Autocompensator retract correctly? Service Check” on page 2-91 Check for any signs of damage to the Paper Tray Guide. Replace the Go to the Paper Tray...
  • Page 112 5060-XXX Step A Step Action and Questions Use the Tray 1 feed test to feed paper from Tray 1. Check to Go to step 2 Go to step 3 see if the Pick Rolls are turning? Note: You can observe the pick rolls by opening the Lower Jam access door assembly.
  • Page 113 5060-XXX Step Action and Questions Check Tray 1 for any signs of damage to the Pick Arm Lift Replace Tray 1 Go to step 4 Bellcrank activation tabs on the rear of the tray. Is there any damage to the tray? Check for any loose or broken parts on the Replace the Go to step 5...

  • Page 114: Multipurpose Feeder (Mpf) Service Check

    5060-XXX Step Action and Questions Check continuity of the Paper Level Sensing cable. Go to step 6 Replace the Level Sensing Is there continuity? Cable Check the voltage at J69-1. The voltage measures Replace the Replace the approximately +5V dc. Level Sensing “Engine Assembly...
  • Page 115 5060-XXX Step Action and Questions Access the CE Diagnostic Test Menu. Select Input Tray Go to step 5 Go to step 3 Tests, Select MPF Feed Test, Select MP Feeder, Select Single. Note: The MPF Drive parts can be observed by opening the Lower Left Jam Cover.
  • Page 116 5060-XXX Step Action and Questions Check to make sure that the MP sensor cable from the Go to step 3 Install the Engine Board is correctly installed at J70 on the Engine cable correctly Board. Is the cable correctly installed? Check the cable connection between the MP Sensor Cable Go to step 4 Install the...

  • Page 117: Paper Path Service Check

    5060-XXX Paper Path Service Check Note: A 200 Paper Jam only displays when using a Multpurpose Feeder. Go to the “Multipurpose Feeder (MPF) Service Check” on page 2-94. 200 Paper Jam Displayed - Unable to clear the message from the display Step Action and Questions...
  • Page 118 5060-XXX Step Action and Questions Check the Vacuum Transport assembly to make sure the Go to Step 3 Go to Step 5 belts are moving. Are the Vacuum Transport belts moving during printing? Note: You can observe the belts through the front paper jam door.
  • Page 119 5060-XXX 202 Paper Jam Displayed - Unable to clear the message from the display Step Action and Questions Check the Vacuum Transport for correct operation. Go to step 2 Replace the Vacuum Is the Vacuum Transport operating correctly? Transport Assembly Does the media jam at the entry to the fuser assembly.
  • Page 120 5060-XXX 2-100 Service Manual...

  • Page 121: Diagnostic Aids

    5060-XXX 3. Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostic Mode To enter the Diagnostic Mode: Turn the printer off.

  • Page 122: Device Tests

    5060-XXX Device Tests Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk.

  • Page 123: Flash Test

    5060-XXX Flash Test This test causes the file system to write and read data on the flash to test the flash. WARNING: This test destroys all data on the flash because the flash is reformatted at the end of the test. To run the Flash Test: Select Flash Test from the Device Tests menu.

  • Page 124: Duplex Sensor Test

    5060-XXX Duplex Sensor Test This test determines whether or not the Duplex sensors and switches are working correctly. Select Sensor Test from the Duplex Tests menu. Manually actuate each of the duplex sensors. When the sensor/switch is closed, CL (closed) displays, when the sensor/switch is open, OP (Open) displays. Duplex input sensor Duplex exit sensor Press Return/Stop to exit the test.

  • Page 125: Hardware Tests

    5060-XXX Hardware Tests The following Hardware Tests can be selected from this menu: LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 2 Wrap (if available) Serial 3 Wrap (if available) LCD Test To run the LCD Test:...

  • Page 126: Rom Memory Test

    5060-XXX Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display. If the test fails, the message SDRAM Error displays for approximately three seconds and the failure count increases by 1.

  • Page 127: Serial Wrap Test

    5060-XXX Each time the test finishes, the screen updates. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately three seconds: Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error...

  • Page 128: Input Tray Tests

    5060-XXX Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error...

  • Page 129: Input Tray Sensor Test (500-Sheet Trays)

    5060-XXX To run the Input Tray Feed Test: Select Input Tray Feed Test from the menu. Select the input source from the sources displayed on the Feed Test Menu. All installed sources are displayed. Select either Single (feeds one sheet of media from the selected source) or Continuous (continues to feed from the selected source until Return/Stop is pressed).

  • Page 130: Output Bin Test - Standard Bin

    5060-XXX The selected tray is displayed on line 1 <input tray> either Tray 1, 2, 3, or 4. EM=trays empty sensor NE=trays near empty sensor LE=trays paper level sensor SC=input trays side cover sensor Manually actuate the bin sensor by moving the flag in and out of the sensor. The display indicates OP (Open) when the flag is out of the sensor or CL (Closed) when the flag is in the sensor.

  • Page 131: Output Bin Sensor Test

    5060-XXX Output Bin Sensor Test This test verifies if the any of the output bin sensors are working correctly. The following Output options, if installed, are supported by this test. Standard Bin Output Expander High Capacity Output Stacker 5-Bin Mailbox To run the Output Bin Sensor Test: Select Output Bin Sensor Test from the menu.

  • Page 132: Output Bin X Sensor Test

    5060-XXX Output Bin X Sensor Test Output Expander or High Capacity Output Stacker To run the Output Bin x Sensor tests: Select Output Bin Tests from the menu. Select Output Bin Tests - Sensor Tests. Select Sensor Tests - Output Bin x. Press Return/Stop to exit the test.

  • Page 133: Base Sensor Test

    5060-XXX Base Sensor Test The Base Sensor Test is used to determine that the sensors located inside the printer are operating correctly. The following sensors can be checked using this test: * Input Sensor S1 * Input Sensor S2 * Inline Media Sensor * Fuser Exit Sensor To run the Base Printer Sensor Test.

  • Page 134: Finisher Feed Test

    5060-XXX Finisher Feed Test This test verifies that media can be fed to a Finisher output bin and then stapled. To run the Finisher Feed Test: Select Finisher Feed Test from the menu. Select a destination bin. The printer feeds eight pieces of media to the selected finisher output bin where they are stapled.

  • Page 135: Hole Punch Test

    5060-XXX If you select the Bin Level Sensor, the following is displayed. Bin Level Sensor NF=OP NF=Finisher Bin Near Full Sensor. Once the selected screen is displayed the selected sensor can be manually actuated. CL is displayed when the sensor is closed. OP is displayed when the sensor is open.

  • Page 136: Miscellaneous Tests

    5060-XXX Miscellaneous Tests Automated Motor Detection This test initiates an Automated Motor Detection. It must be performed if the NVRAM contents are erased such as when a RIP or engine board has been replaced. This test must be performed anytime the ITU motor, Fuser motor, or Cartridge drive motors are replaced.

  • Page 137: Print Quality Test Pages

    5060-XXX first envelope and the rest are blank. The Print Test page always prints single sided, regardless of the Duplex setting or the presence of the Duplex unit. To run the Print Test: Select Print Test from the menu. Select the paper source from the menu. Select either Single or Continuous from the menu.

  • Page 138: Print Line Length Page

    5060-XXX Print Line Length Page This test prints a color test page that is used to measure the temperature of the printheads and the reading from the PSD at calibration time. To run the Print Line Length Page, select Print Line Length Page from the menu. No buttons are active while the Print Line Length Page is printing.

  • Page 139: Itu Alignment

    5060-XXX ITU Alignment This alignment is required anytime you replace the ITU Assembly. Enter the Configuration Menu Group by pressing Select and Return at POST. Select ITU Alignment from the Configuration Menu Group. A test page is printed after ITU Alignment is selected. After the test page prints, enter alignment values for each alignment setting.

  • Page 140: Hcit Standalone Test Mode

    5060-XXX To verify that the margin values are correct, you must print the Alignment Test Pages. Press Go from the Alignment Test screen that displays each of the margin values. Pressing Go serves as a hot key to the Alignment Test Pages. Buttons are not active when the Alignment Test Pages are printing.

  • Page 141: Repair Information

    5060-XXX 4. Repair Information WARNING: Read the following before handling electronic parts. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: •...
  • Page 142 5060-XXX Position the printhead along the front (A) and rear (B) scribe lines. Run an Alignment Test Page from “Setting Printer Alignment” on page 3-19. Service Manual...
  • Page 143 5060-XXX Move the rear of the printhead to a position that allows the color of the printhead being adjusted to align over the black target on the left side of the Alignment Test Page. Tighten the right rear mounting screw (A). Run an Alignment Test Page to verify the printhead rear adjustment.

  • Page 144: Printhead Electronic Alignment

    5060-XXX Printhead Electronic Alignment Perform “Setting Printer Alignment” on page 3-19. 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.
  • Page 145 5060-XXX Reference Screw type Location Purpose number M3x6mm Taptite Ground Cable to Right Front Attach Metal Thread Cover Support and Upper Forming Frame. Ground Cable to Bottom Attach Support Plate and Engine Card Shield Back Lamp Brackets to Fuser Attach Frame Front Lamp Brackets to Fuser Attach...
  • Page 146 5060-XXX 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 Attach Shield Duplex Baffle to Lower Right Attach Door Front and Rear Latches to Mounting Lower Right Door Bias Latch Cover to Door...
  • Page 147 5060-XXX Reference Screw type Location Purpose number M3.5x1.35mm Frame Support Back Plate to Attach Plastite 6 long Lower Frame Door Latch Catch to Frame Attach Transfer HVPS to Lower Mounting Frame Fuser Top Duct to Lower Attach Frame Right Front Cover Support to Attach Lower Frame Front Lower Left Cover to...
  • Page 148 5060-XXX Reference Screw type Location Purpose number M3.5x8mm Top Cover Asm to Upper Front Attach Plastite Thread Cover Forming Top Cover Asm to RIP Shield Attach ITU Light Shield Asm to Upper Attach Front Guide ITU Ribs to Upper Redrive Door Mounting Upper Door Hinges to Upper Mounting...
  • Page 149 5060-XXX Reference Screw type Location Purpose number M3.5x10mm Transfer HVPS/RIP Fan Asm Attach Plastite Thread to RIP Shield Forming Front Left Light Shield to Left Attach Upper Cover Asm and Top Cover Front Right Light Shield to Attach Right Front Cover Support and Top Cover Cartridge Drive Assemblies to Mounting...

  • Page 150: Removal Procedures

    5060-XXX 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.

  • Page 151: Rip Board

    5060-XXX RIP Board Remove the “Outer EMC Shield” on page 4-10. Remove the “Left Rear Cover” on page 4-11. Remove the USB connector screw type “232” on page 4-5 (A). Remove the RIP board screw type “232” on page 4-5 (B).

  • Page 152: Hvps Transfer Board

    5060-XXX HVPS Transfer Board Remove the “Left Rear Cover” on page 4-11. Remove the HVPS transfer board screw type “323” on page 4-7 (A). Disconnect the five spade terminals (B) from the transformers. Remove the HVPS transfer board. Rear Fan Cover Remove the “Left Rear Cover”...

  • Page 153: Main Fan

    5060-XXX Main Fan Remove the “Rear Fan Cover” on page 4-12. Disconnect the main fan cable from connector J2 (B) on the engine board. Remove the main fan screws (A), part number 12G6529 and remove the fan. Engine Board Remove the “Rear Fan Cover”...

  • Page 154: Lvps

    5060-XXX LVPS Remove the “Rear Fan Cover” on page 4-12. Remove the “Fuser” on page 4-15. Remove the LVPS screw type “121” on page 4-4 (A) from the rear of the printer. Remove the right rear cover screw type “121” on page 4-4 (A).

  • Page 155: Fuser

    5060-XXX Open the redrive cover and remove the screw type “121” on page 4-4 (A) from the top of the LVPS and remove the LVPS from the printer. Fuser CAUTION: Be sure the fuser assembly has cooled before you remove it. Open the fuser access cover.

  • Page 156: Fuser Drive Assembly

    5060-XXX Fuser Drive Assembly Remove the “Fuser” on page 4-15. Remove the fuser drive assembly mounting screws (A) and remove the assembly. Fuser Access Cover Open the fuser access cover. Carefully flex the fuser access cover to free the hinges from the mounting posts. Remove the fuser access cover.

  • Page 157: Fuser Top Duct

    5060-XXX Fuser Top Duct Remove the “Rear Fan Cover” on page 4-12. Remove the fuser top duct screw type “323” on page 4-7 (A,B) and remove the top duct. Fuser Bottom Duct Remove the “Fuser Top Duct” on page 4-17. Remove the “Main Fan”...

  • Page 158: Fuser Web Oiler Motor Assembly

    5060-XXX Fuser Web Oiler Motor Assembly Remove the “Fuser” on page 4-15. Remove the paper path access door cover right mounting screw. Remove the “Front Right Handle Cover Assembly” on page 4-28. Disconnect the web oiler motor assembly cable. 4-18 Service Manual...
  • Page 159 5060-XXX Remove the fuser web oiler motor assembly mounting screws and remove the assembly. 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 is routed away from gears (B).

  • Page 160: Redrive Door

    5060-XXX Redrive Door Open the redrive door. Loosen the redrive door upper hinge screw type “324” on page 4-9 (A). Lift the redrive door from the hinge (B) and remove the redrive door. Front Cover Assembly Open the front cover assembly. Remove the detent post tension spring (B).

  • Page 161: Top Cover

    5060-XXX Top Cover Remove the “Front Cover Assembly” on page 4-20. Remove the “Redrive Door” on page 4-20. Remove the redrive cap. Remove the light shield screw type “324” on page 4-9 “323” on page 4-7 (A). Remove the shield. 4-21 Repair Information...
  • Page 162 5060-XXX Remove the front upper pivot cover screw (A) and remove the pivot cover. Open the MPF and remove the top cover mounting screw (B) from the left side of the printer. Remove the top cover mounting screw (A) from the rear of the printer. 4-22 Service Manual...
  • Page 163 5060-XXX Remove the top cover mounting screws (A) from the front of the printer. Remove the operator panel bezel. Open the redrive door and loosen the redrive assembly screw type “323” on page 4-7 (A). 4-23 Repair Information...
  • Page 164 5060-XXX Lift the top cover and disconnect the operator panel cable. Remove the bin full sensor (C), flag (A), and upper options auto connect (B) from the top cover. Remove the top cover. 4-24 Service Manual...

  • Page 165: Operator Panel

    5060-XXX Operator Panel Remove the “Front Cover Assembly” on page 4-20. Remove the operator panel bezel. Unlatch the operator panel latches (A). 4-25 Repair Information...

  • Page 166: Cartridge Drive Motor Assembly (Yellow)

    5060-XXX Disconnect the operator panel cable from the operator panel and remove the operator panel. Cartridge Drive Motor Assembly (Yellow) Remove the “Rear Fan Cover” on page 4-12. Remove the cartridge drive motor assembly mounting screws (A). Disconnect the cable from the cartridge drive motor assembly. Remove the cartridge drive motor assembly.

  • Page 167: Cartridge Drive Motor Assembly (Cyan, Magenta, Black)

    5060-XXX Cartridge Drive Motor Assembly (Cyan, Magenta, Black) Remove the “RIP Card Shield Assembly” on page 4-36. Remove the “Engine Board” on page 4-13. Remove the cartridge drive motor assembly mounting screws (A). Disconnect the cable (B) from the cartridge drive motor assembly. Remove the cartridge drive motor assembly.

  • Page 168: Front Right Handle Cover Assembly

    5060-XXX Front Right Handle Cover Assembly Open the front cover. Remove the light shield screw type “324” on page 4-9 “323” on page 4-7 (A). Remove the light shield. Remove the “Paper Path Access Door Cover/Front Lower Left Cover” on page 4-30.

  • Page 169: Front Left Handle Cover Assembly

    5060-XXX Front Left Handle Cover Assembly Open the front cover. Remove the front left handle cover assembly screw type “323” on page 4-7 and remove the assembly. ITU Door Remove the “Front Left Handle Cover Assembly” on page 4-29. Remove the ITU door screw type “323”...

  • Page 170: Paper Path Access Door Cover/Front Lower Left Cover

    5060-XXX Paper Path Access Door Cover/Front Lower Left Cover Remove the “Front Left Handle Cover Assembly” on page 4-29 (B). Open the paper path access door, remove screw type “323” on page 4-7 (A), and remove the door. Separate the paper path access door cover from the front lower left cover (C). Be careful not to lose the door spring (D).

  • Page 171: Multipurpose Feeder (Mpf)

    5060-XXX Multipurpose Feeder (MPF) Open the MPF. Remove the front MPF left upper pivot cover hinge screw type “323” on page 4-7 (A). Remove the MPF strap screw type “412” on page 4-9 (A). Disconnect the MPF switch cable from the engine board at connector J10. Remove the MPF.

  • Page 172: Waste Container Access Door

    5060-XXX Waste Container Access Door Open the waste container access door. Flex the door and remove it from the hinges (A). Left Lower Cover Remove the “ITU Door” on page 4-29. Remove the left lower cover screw type “323” on page 4-7 and remove the cover.

  • Page 173: Printheads

    5060-XXX Printheads Remove the “Top Cover” on page 4-21. Remove the printhead screw type “484” on page 4-9 (B) through the holes (A) in the top of the rear printer frame. Remove the printhead mounting screw (A) from the front of the printhead assembly. Disconnect the printhead cables (B) from the printhead.

  • Page 174: Psd Sensor Assembly

    5060-XXX PSD Sensor Assembly Remove “Printheads” on page 4-33. Remove the PSD sensor assembly mounting screws. Disconnect the PSD sensor assembly cable and remove the assembly. Note: Be careful not to lose shim (A) under the PSD sensor assembly. When you reinstall the assembly, pull forward on tab (B) and install the front mounting screw first.

  • Page 175: Redrive Assembly

    5060-XXX Redrive Assembly Open the redrive door. Remove the redrive assembly screw type “323” on page 4-7 (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).

  • Page 176: Rip Card Shield Assembly

    5060-XXX RIP Card Shield Assembly Remove the “Top Cover” on page 4-21. Remove the “Rear Fan Cover” on page 4-12. Remove the “Left Rear Cover” on page 4-11. Remove the “RIP Board” on page 4-11. Remove the “HVPS Transfer Board” on page 4-12.

  • Page 177: Vtb Fan

    5060-XXX Disconnect the HVPS developer board cables (B) and remove the board. VTB Fan Remove the “RIP Card Shield Assembly” on page 4-36. Remove the VTB fan with a flatblade screwdriver. 4-37 Repair Information...

  • Page 178: Cartridge Drive Assembly

    5060-XXX Cartridge Drive Assembly Remove the “Cartridge Drive Motor Assembly (Yellow)” on page 4-26 “Cartridge Drive Motor Assembly (Cyan, Magenta, Black)” on page 4-27 according to which cartridge drive assembly you are replacing. Remove the cartridge drive assembly mounting screws (A), disconnect cable (B), and remove the assembly.

  • Page 179: Engine Board Shield

    5060-XXX Engine Board Shield Remove the “Engine Board” on page 4-13. Remove the engine board shield screw type “323” on page 4-7 (A), screw type “232” on page 4-5 (B), and remove the shield. Waste Toner Auger Assembly Remove the “RIP Card Shield Assembly”...

  • Page 180: Itu Assembly

    5060-XXX ITU Assembly Open the front cover. Remove the toner cartridges. Open the MPF. Press the ITU release lever (A) and slide the ITU from the printer. Waste Toner Latch Remove the “Paper Size Sensor Assembly” on page 4-41. Use a flatblade screwdriver to release the waste toner latch from the paper size sensor assembly.

  • Page 181: Paper Size Sensor Assembly

    5060-XXX Paper Size Sensor Assembly Note: The paper size sensor assembly contains components that easily fall apart as you remove the assembly. Be careful not to lose any of the components. Remove the “Left Rear Cover” on page 4-11. Remove the “Rear Fan Cover”...

  • Page 182: Bor Housing Assembly

    5060-XXX BOR Housing Assembly Open the front cover. Remove the yellow toner cartridge. Remove the BOR housing assembly screw type “323” on page 4-7 and remove the assembly. Note: Gear (B) can easily fall from the assembly. Be careful not to lose the gear. Cartridge Contact Assembly Remove the “Cartridge Drive Assembly”...

  • Page 183: Connector Locations

    5060-XXX 5. Connector Locations Engine Board 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 PHB OUT + Oiler PHA OUT - Oiler PHB OUT - J4 VTB Fan FAN2 Stall IN...
  • Page 184 5060-XXX Connector Pin No. Signal J8 ITU Belt/Fuser Drive Motor Y ON OUT FUSER ON OUT +5 V dc +5 V dc Y DIR OUT FUSER DIR OUT +24 V dc +24 V dc Ground Ground Y CLK OUT FUSER CLK OUT Y HALL IN FUSER HALL IN Y LOCK IN...
  • Page 185 5060-XXX Connector Pin No. Signal J10 Fuser EXIT SENSOR IN FUSER CAM1 IN FUSER CAM2 IN OILER ENC A IN OILER ENC B IN HR THERM IN BR THERM IN Ground +5 V dc switched ZERO Xing IN HR HEAT ON OUT BR HEAT ON OUT J11 Bin Full +5 V dc switched...
  • Page 186 5060-XXX Connector Pin No. Signal J20 HVPS - Developer (-CART METER K IN) K AC B EN OUT SC K CHIP DEV 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 SC C CHIP M DEV PWM OUT...
  • Page 187 5060-XXX Connector Pin No. Signal J45 RIP Interface I2C DATA RIP I2C CLK RIP (-NOTIFY RIP) Ground (-VSYNC Y OUT) FPIRQ RIP (-VSYNC M OUT) (-VSYNC C OUT) Ground (-VSYNC K OUT) (-HSYNC Y IN) (-HSYNC C IN) (-HSYNC M IN) (-HSYNC K IN) (-RIP PRESENT OUT) Ground...
  • Page 188 5060-XXX Connector Pin No. Signal J47 C/W Cart Not used 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 M CLK OUT C CLK OUT M HALL IN C HALL IN...
  • Page 189 5060-XXX Connector Pin No. Signal J64 ITU/K Cart K ON OUT ITU ON OUT +5 V dc +5 V dc K DIR OUT ITU DIR OUT +24 V dc ITU and K +24 V dc ITU and K Ground Ground K CLK OUT ITU CLK OUT K HALL IN...
  • Page 190 5060-XXX Connector Pin No. Signal J68 NM/Prism Media 1 Narrow Media IN +5 V dc switched Ground PRISM LED VOLT Ground PRISM SENSOR IN +5 V dc switched J69 Paper Out/Low XPAR Media 2 +5 V dc switched PAPER OUT IN PAPER LOW IN Ground LED VCC...
  • Page 191 5060-XXX 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 Y TX PWM OUT M SERVO INTO...
  • Page 192 5060-XXX Connector Pin No. Signal J73 Autocompensator Motor1 (+5 V dc switched) AUTOCOMP ENC IN Ground Ground AUTOCOMP OUT 2 AUTOCOMP OUT 1 J86 Cover Interlock +24 V dc to Cover SW +24 V dc switched Engine Board 5-10 Service Manual...

  • Page 193: Rip Board

    5060-XXX RIP Board Connector Pin No. Signal J1 Operator Panel Connector OP I2CDATA +5 V dc OP I2CClk Ground OP I2R- J2 Printhead Yellow Connector Ground HSYNC-/SOS thermistor +5 V dc Hsync Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr J3 Printhead Yellow Connector...
  • Page 194 5060-XXX Connector Pin No. Signal J4 Printhead Ground Yellow/Cyan Connector lexhsync/eos ALTHERM +5 V dc EOS card Ground lexhsync/eos ALTHERM +5 V dc EOS card J5 Printhead Cyan Connector Ground HSYNC-/SOS thermistor +5 V dc Hsync Ground mm ref freq mm lock mm strt/en Ground...
  • Page 195 5060-XXX Connector Pin No. Signal J7 Printhead Magenta Connector Ground HSYNC-/SOS thermistor +5 V dc Hsync DC Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr J8 Printhead Magenta Connector laser en Ground laser adj Ground laser PWM +5 V dc head...
  • Page 196 5060-XXX Connector Pin No. Signal J10 Printhead Black Connector Ground HSYNC-/SOS thermistor +5 V dc Hsync DC Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr J11 Printhead Black Connector laser en Ground laser adj Ground laser PWM +5 V dc head...
  • Page 197 5060-XXX Connector Pin No. Signal J19 Option DRAM Socket 2 J20 Option DRAM Socket 1 J21 Base DRAM Socket J23 Power Connector Ground 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...
  • Page 198 5060-XXX Connector Pin No. Signal J24 Engine to RIP Connector ITU Zone CLk ITU Zone HB RIPPRES N Ground HSYNCN M TSYNCN K HSYNCN Y HSYNCN C Ground VSYNCN K VSYNCN M VSYNCN C VSYNCN Y VSYNCN OWL PIO NOTIFY R Ground OP I2DATA R OP I2CLK R...
  • Page 199 5060-XXX RIP Board 5-17 Connector Locations...

  • Page 200: Lvps Cable Connectors To Engine Board & Rip Board

    5060-XXX LVPS Cable Connectors to Engine Board & RIP Board Connector Pin No. 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 V dc Rtn Ground Return +5 V dc Rtn...
  • Page 201 5060-XXX Connector Pin No. Signal Engine Board Cable FusExitSen BURCam1 WebEncoderA WebEncoderB HRThermistor BURThermistor Ground +5 V dc switched ZCSense Heat On #1 Heat On #2x 5-19 Connector Locations...

  • Page 202: Lvps Fuser Connectors

    5060-XXX LVPS Fuser Connectors Connector Pin No. Signal LVPS AC Fuser Connector AC Load #1 AC Common Ground AC Load #2x LVPS DC Fuser Control Connector FusExitSen BURCam1 WebEncoderA WebEncoderB HRThermistor BURThermistor Return - Analog Ground +5 V dc switched N/Cx 5-20 Service Manual...

  • Page 203: High Capacity 2000-Sheet Board

    5060-XXX High Capacity 2000-Sheet Board 5-21 Connector Locations...

  • Page 204: Hvps

    5060-XXX 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 I-Txpwm I-Srvo out I-Txcurpwm I-Txenable T102 Transformer HV Terminal I HV Transformer output to 2nd (ITU) Transfer Roll Cable...
  • Page 205 5060-XXX HVPS Board 5-23 Connector Locations...

  • Page 206: Hvps Developer Board

    5060-XXX HVPS Developer Board Connector Pin No Signal CN1 Developer HVPS Input Ground +24 V dc return +24 V dc Y-Ctsense Y-Devpwm Y-TnrSense C-Devpwm C-CtSense M-Devpwm C-TnrSense CYM-Acenable M-CtSense CYM-Chgpwm M-TnrSense K-Chgpwm K-CtSense K-Devpwm K-TnrSense K-Acenable CN2 Smart Cartridge Black K-CtSense K-TnrSense (Gnd Return) CN3 Smart Cartridge Magenta...
  • Page 207 5060-XXX HVPS Developer Board 5-25 Connector Locations...
  • Page 208 5060-XXX 5-26 Service Manual...

  • Page 209: 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 210: Scheduled Maintenance

    5060-XXX 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: •...

  • Page 211: Parts Catalog

    • PP: (Parts Packet) in the Description column indicates the part is contained in a parts packet. The Lexmark C750 (5060-XXX) laser printer is available in three models: 5060-001 5060-002 5060-003 The parts catalog uses these designations to identify model specific FRUs.

  • Page 212: Assembly 1: Covers

    5060-XXX Assembly 1: Covers Service Manual...
  • Page 213 5060-XXX Assembly 1.0: Covers Asm- Part Units Description Index number 12G6410 Top Cover Assembly 12G6507 250 Output Flag 12G6506 Bin Full Sensor 12G6319 Cable, Options - Stacker 12G6409 Redrive Cap Cover Assembly 12G6389 Top Front Support Bracket 12G6396 Right Rear Cover Screw, PP 12G6530 12G6356 Right Lower Door Assembly...
  • Page 214 5060-XXX Assembly 1.1: Covers Service Manual...
  • Page 215 5060-XXX 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 12G6398 Left Lower Pivot Cover 12G6395 Left Lower Cover 12G6400 Waste Container Door 12G6390 Rear Cover 12G6401 Rear Fan Cover 12G6340...

  • Page 216: Assembly 2: Fuser

    5060-XXX Assembly 2: Fuser Asm- Part Units Description Index Number 12G6301 Fuser Assembly 115V 500W 12G6302 Fuser Assembly 220V 500W 12G6514 Fuser Assembly, WEB Oiler 115V 500W 12G6515 Fuser Assembly, WEB Oiler 220V 500W 12G6337 Fuser Lamp, 115V 500W Hot Roll 12G6341 Fuser Lamp, 220V 500W Hot Roll 12G6338...
  • Page 217 5060-XXX Assembly 2.1: Fuser Asm- Part Units Description Index Number 2.1-1 12G6414 Fuser Drive Assembly Screws PP 12G6309 12G6543 WEB Oiler Index Drive Assembly 12G6545 WEB Oiler Assembly Parts Catalog...

  • Page 218: Assembly 3: Vacuum Belt Transport Assembly

    5060-XXX Assembly 3: Vacuum Belt Transport Assembly Asm- Part Units Description Index Number 12G6489 Vacuum Belt Transport Assembly 12G6488 Transfer Plate Assembly 12G6428 Second Transfer Roll Service Manual...

  • Page 219: Assembly 4: Printheads

    5060-XXX Assembly 4: Printheads Asm- Part Units Description Index Number 12G6322 4 Printhead Assembly Screw, PP 12G6534 Screw, PP 12G6539 12G6523 PSD Assembly 12G6535 Guide Assembly, Cartridge Left Side 12G6536 Guide Assembly, Cartridge Right Side Parts Catalog...

  • Page 220: Assembly 5: Paper Feed Output (Redrive)

    5060-XXX Assembly 5: Paper Feed Output (Redrive) 7-10 Service Manual...
  • Page 221 5060-XXX Assembly 5.0: Paper Feed Output (Redrive) Asm- Part Units Description Index number 56P0107 Anchor, Bracket Mounting 12G6493 Upper Door Hinge Screw, PP 12G6533 12G6492 Redrive Assembly, Inner 12G6355 Right Upper Door Assembly 12G6513 Lower Rear Door Latch 12G6512 Lower Front Door Latch Screw, PP 12G6530 12G6356 Right Lower Door Assembly...

  • Page 222: Assembly 6: Multipurpose Feeder (Mpf)

    5060-XXX Assembly 6: Multipurpose Feeder (MPF) 7-12 Service Manual...
  • Page 223 5060-XXX Assembly 6.0: Multipurpose Feeder (MPF) Asm- Part Units Description Index number 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 MPD Support Bracket Cover 12G6456...

  • Page 224: Assembly 7: 500-Sheet Integrated Tray

    5060-XXX Assembly 7: 500-Sheet Integrated Tray 7-14 Service Manual...
  • Page 225 5060-XXX Assembly 7.0: 500-Sheet Integrated Tray Asm- Part Units Description Index number 12G6416 500-Sheet Tray Assembly 12G6419 Back Restraint Latch 12G6418 Back Restraint 12G6424 Size Sensing Gear Cover 12G6423 Size Sensing Gear 12G6422 Size Sensing Barrel Cam 12G6538 Screw, M 3x5mm 12G6425 Tray Bias Bellcrank Assembly Screw, PP 12G6533...

  • Page 226: Assembly 8: Autocompensator Assembly

    5060-XXX Assembly 8: Autocompensator Assembly Asm- Part Units Description Index Number 12G6474 Transparency Sensor 12G6471 Tray Interlock Bellcrank 12G6558 Pick Arm Lift Bellcrank 12G6557 Bellcrank Lift Spring 12G6427 Pick Assembly 500-Tray 99A0070 Pick Rolls 12G6475 Transparency Lift Arm 12G6473 Transparency Lift Link 12G6476 Paper Level Sensing Assembly 12G6461...

  • Page 227: Assembly 9: Itu Assembly

    5060-XXX Assembly 9: ITU Assembly Asm- Part Units Description Index Number 12G6300 ITU Assembly 12G6518 ITU Drive Assembly Screw, PP 12G6309 12G6434 Rear V-Block Guide 12G6435 Front V-Block Guide 12G6436 Bellcrank, ITU Black Transfer Front 12G6437 Bellcrank, ITU Transfer Front 12G6443 ITU Bias Spring 12G6444...

  • Page 228: Assembly 10: Cartridge Contact Assembly

    5060-XXX Assembly 10: Cartridge Contact Assembly 7-18 Service Manual...
  • Page 229 5060-XXX Assembly 10.0: Cartridge Contact Assembly Asm- Part Units Description Index number 10-1 12G6374 Developer Pin Spring 12G6372 Plug Spring 12G6375 Toner Level Spring 12G6362 Spring Toner Plug 12G6371 Contact Pin 12G6363 Housing, Cartridge Contacts 12G6378 Cartridge Support Roller 12G6367 TAR Contact 12G6366 Developer Roll Contact...

  • Page 230: Assembly 11: Electronics

    5060-XXX Assembly 11: Electronics 7-20 Service Manual...
  • Page 231 5060-XXX Assembly 11.0: Electronics Asm- Part Units Description Index number 11-1 11A9095 Power Cord Set U.S., Canada (LV), Brazil (LV), Colombia (LV), Costa Rica (LV), Dominican Republic (LV), Equador (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...
  • Page 232 5060-XXX Assembly 11.1: Electronics 7-22 Service Manual...
  • Page 233 5060-XXX Assembly 11.1: Electronics Asm- Part Units Description Index number 11.1-1 Screw, PP 12G6309 12G6331 RIP Card Ground Shield 12G6325 RIP Card Assembly - Network 12G6334 INA Riser Support Bracket 12G6326 Riser Card Assembly w/o Support Brackets 12G6335 Standoff, INA RIP Spacer 56P9910 SDRAM DIMM 128MB, Model 5060-003 12G6509...
  • Page 234 5060-XXX Assembly 11.2: Electronics Asm- Part Units Description Index Number 11.2-1 12G6327 High Voltage Power Supply - Transfer Screw, PP 12G6309 Screw, PP 12G6530 12G6541 Standoff, High Voltage Power Supply - Developer Screw, PP 12G6540 12G6328 High Voltage Power Supply - Developer 12G6339 Contact Assembly, Black Terminal 12G6340...
  • Page 235 5060-XXX Assembly 11.3: Electronics Asm- Part Units Description Index Number 11.3-1 12G6336 Engine Card Shield Assembly Screw, PP 12G6531 12G6323 Engine Card Assembly 12G6387 Ground Strap Screw, PP 12G6309 7-25 Parts Catalog...
  • Page 236 5060-XXX Assembly 11.4: Electronics Asm- Part Units Description Index Number 11.4-1 12G6343 RIP Fan Duct 12G6361 RIP Fan Assembly Screws, PP 12G6530 12G6479 VTB Fan 12G6382 Fuser Fan 12G6529 Screws, Fuser Fan Mounting 12G6490 VTB Fan Gap Cover 7-26 Service Manual...
  • Page 237 5060-XXX Assembly 11.5: Electronics Asm- Part Units Description Index Number 11.5-1 12G6494 Waste Toner Container 12G6470 Waste Container Latch Spring 12G6469 Waste Container Latch 12G6467 Size Sensing Spring 12G6468 Size Sensing Bracket Screw, Size Sensing Assembly Mounting PP 12G6531 12G6466 Size Sensing Link 12G6472 Bracket Tray Interlock...
  • Page 238 5060-XXX Assembly 11.6: Electronics Asm- Part Units Description Index Number 11.6-1 Screw, PP 12G6530 12G6526 Cartridge Drive Motor Assembly, Cyan/Magenta/Black 12G6527 Cartridge Drive Motor Assembly, Yellow 7-28 Service Manual...
  • Page 239 5060-XXX Assembly 11.7: Electronics Asm- Part Units Description Index Number 11.7-1 12G6446 BOR Drive Assembly Screw, PP 12G6309 12G6438 BOR Spring, Yellow 56P0171 BOR Spring, Magenta 56P0172 BOR Spring, Cyan 56P0173 BOR Spring, Black 7-29 Parts Catalog...

  • Page 240: Assembly 12: Output Expander

    5060-XXX Assembly 12: Output Expander 7-30 Service Manual...
  • Page 241 5060-XXX Assembly 12: Output Expander Asm- Part Units Description Index number 12-1 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 242 5060-XXX Assembly 12.1: Output Expander 7-32 Service Manual...
  • Page 243 5060-XXX Assembly 12.1: Output Expander Asm- Part Units Description Index number 12.1-1 56P0405 Door Assembly, Right Jam Access 99A0368 Shaft Assembly, Lower Also order PP 99A0572 99A0363 Pulley, Drive 56P0410 Bracket, Attach Screw, PP 56P0167 56P0400 Cover, Front 99A0361 Belt, 160 Gear 99A0362 Arm Assembly, Belt Idler 99A0364...

  • Page 244: Assembly 13: 5-Bin Mailbox

    5060-XXX Assembly 13: 5-Bin Mailbox 7-34 Service Manual...
  • Page 245 5060-XXX Assembly 13: 5-Bin Mailbox Asm- Part Units Description Index number 13-1 99A1512 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 99A1723 Shaft Asm, Drive 99A1724...
  • Page 246 5060-XXX Assembly 13.1: 5-Bin Mailbox 7-36 Service Manual...
  • Page 247 5060-XXX Assembly 13.1: 5-Bin Mailbox Asm- Part Units Description Index number 13.1-1 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 248: Assembly 14: 500-Sheet Tray Option

    5060-XXX Assembly 14: 500-Sheet Tray Option 7-38 Service Manual...
  • Page 249 5060-XXX Assembly 14.0: 500-Sheet Tray Option Asm- Part Units Description Index number 14-1 56P0168 Drive Assembly, 500 Option 2 Screw, PP 12G6309 12G6550 500 Option Tray Pick Assembly 12G6565 Paper Level Sensing Assembly 12G6471 Tray Interlock Bellcrank 12G6556 Cover, Frame 12G6553 Pass Thru Sensor 12G6562...
  • Page 250 5060-XXX Assembly 14.1: 500-Sheet Tray Option 7-40 Service Manual...
  • Page 251 5060-XXX Assembly 14.1: 500 Sheet Tray Option Asm- Part Units Description Index number 14.1-1 12G6416 500-Sheet Tray Assembly 12G6419 Back Restraint Latch 12G6418 Back Restraint 12G6424 Size Sensing Gear Cover 12G6423 Size Sensing Gear 12G6422 Size Sensing Barrel Cam 12G6538 Screw, M 3x5mm 12G6425 Tray Bias Bellcrank Assembly...

  • Page 252: Assembly 15: Duplex Unit

    5060-XXX Assembly 15: Duplex Unit Asm- Part Units Description Index number 56P0430 Duplex Card Assembly 56P0431 Stepper Motor 56P0432 Duplex Front Jam Tray Assembly 56P0433 Right Jam Clearance Tray Assembly 56P0434 Right Side Front Tray Guide 56P0435 Duplex Shaft Mount 56P0436 Upper RIB Assembly 56P0437...
  • Page 253 5060-XXX Asm- Part Units Description Index number 99A1789 Retainer, C - Clip 99A1717 32PPM Drive Gear 56P0462 Autoconnect Cable Assembly 56P0463 DC Forward/Reverse Motor Assembly 56P0464 DC Duplex Feed Motor 56P0465 Drive Alignment Shaft Assembly 56P0466 Spur Drive Gear 56P0467 26T Duplex Gear 56P0468 Pass Thru Spring...

  • Page 254: Assembly 16: Hcit

    5060-XXX Assembly 16: HCIT Asm- Part Units Description Index number 56P0490 Jumper, AC Power Cord 56P0491 Caster, Movable 56P0492 Caster, Fixed 56P0493 F Adjuster 56P0494 System Control Board 56P0495 LVPS 56P0496 Size Sensing Assembly 56P0497 AC Inlet 56P0498 AC Outlet 56P0499 Feed Unit 56P0500...

  • Page 255: Assembly 17: Options

    Hard Disk, 5GB or larger with/Adapter (formatted) 56P9939 Hard Disk, 5GB or larger ISP Hard Disk (unformatted) 56P9926 Forms Software 56P9927 Forms Director Software 56P9928 Lexmark Forms 4MB DIMM 56P9929 Lexmark Forms 8MB DIMM 56P9930 Lexmark Forms 16MBMB DIMM 56P9931 Lexmark Forms 32MB DIMM 56P9932...

  • Page 256: Assembly 18: Miscellaneous

    5060-XXX Assembly 18: 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 257: Index

    5060-XXX Index Diagnostics Error Code Table Acronyms 2-43 Service Checks 2-15 Sub Error Code Table Symptom Table 3-13 Base Sensor Test 2-18 System Board LED Error Code Table Button Test 2-23 User Attendance Message Table 2-19 2XX Paper Jam Message Table Disk Test/Clean Connector Locations Duplex Tests...
  • Page 258 5060-XXX 7-42 4-33 Duplex Unit Printheads 7-20 4-34 Electronics PSD Sensor Assembly 4-12 Fuser Rear Fan Cover 7-44 4-35 HCIT Redrive Assembly 7-17 4-20 ITU Assembly Redrive Door 7-46 4-11 Miscellaneous RIP Board 7-12 4-36 Multipurpose Feeder (MPF) RIP Card Shield Assembly 7-45 4-34 Options...
  • Page 259 5060-XXX 7-23 7-19 12G6315 12G6373 7-23 7-19 12G6316 12G6374 7-23 7-19 12G6317 12G6375 7-23 7-19 12G6318 12G6376 7-3, 7-23 7-19 12G6319 12G6377 7-23 7-19 12G6320 12G6378 7-23 7-19, 7-23 12G6321 12G6379 7-3, 7-39 12G6322 12G6380 7-25 7-26 12G6323 12G6382 7-23 12G6324 12G6383 7-23...
  • Page 260 5060-XXX 7-17 12G6437 12G6511 7-29 7-11 12G6438 12G6512 7-24 7-11 12G6442 12G6513 7-17 12G6443 12G6514 7-17 12G6444 12G6515 7-17 7-17 12G6445 12G6518 7-29 12G6446 12G6523 7-13 7-26 12G6447 12G6529 7-13, 7-23 7-46 12G6448 12G6530 7-13 7-46 12G6449 12G6531 7-13 7-46 12G6450 12G6532 7-13...
  • Page 261 5060-XXX 7-43 56P0170 56P0463 7-29 7-43 56P0171 56P0464 7-29 7-43 56P0172 56P0465 7-29 7-43 56P0173 56P0466 7-33 7-43 56P0400 56P0467 7-31 7-43 56P0401 56P0468 7-31 7-43 56P0402 56P0469 7-33 7-43 56P0405 56P0470 7-31 7-43 56P0407 56P0471 7-31 7-43 56P0408 56P0472 7-31 7-43 56P0409...
  • Page 262 5060-XXX 7-16, 7-39 7-37 99A0070 99A1730 7-31, 7-35 7-37 99A0104 99A1731 7-31 7-37 99A0107 99A1732 7-15 7-37 99A0120 99A1734 7-42 7-35 99A0267 99A1735 7-42 7-35 99A0299 99A1736 7-42, 7-43 7-35 99A0323 99A1737 7-33 7-37 99A0351 99A1738 7-33 7-35 99A0361 99A1740 7-33 7-37 99A0362...

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