Page 1 Lexmark™ C792 series Machine Type 5062-2xx • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PrintCryption and StapleSmart are trademarks of Lexmark International, Inc.
Page 3: Table Of Contents
5062 Table of contents Previous Notices and safety information ......... . xv Laser notice .
Page 4 5062 Horizontal lines ..............2-36 Previous Light colored line, white line, or incorrectly colored line .
Page 5 5062 200.45, 200.47—Paper Jam error service check ........2-104 Previous 201.03, 201.05, 201.07, 201.08—Paper Jam error service check .
Page 6 5062 Using the touch-screen buttons ............3-3 Previous Other touch-screen icons .
Page 7 5062 Par 1 Strobe Adj ............3-24 Previous EP SETUP .
Page 8 5062 Step 3: Develop ............. 3-36 Previous Step 4a: First transfer .
Page 9 5062 ITU block assembly removal ............4-80 Previous Left access door piston removal .
Page 10 5062 550-sheet tray left anti-tip latch removal ..........4-173 Previous 550-sheet tray pass thru sensor removal .
Page 11 5062 Finisher or stacker feed roller removal ..........4-259 Previous Finisher or stacker front cover removal .
Page 12 5062 HTU right bottom cover removal ........... .4-315 Previous HTU right inner cover removal .
Page 13 5062 Assembly 11: Finisher stapler assembly ..........7-28 Previous Assembly 12: Finisher/Stacker assembly (complete) .
Page 14 5062 Previous Next Go Back Service Manual...
Page 15: Notices And Safety Information
5062 Notices and safety information Previous The following laser notice labels may be affixed to this printer. Next Laser notice Go Back 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 16 5062 stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non Previous ricevano radiazioni laser superiori al livello della classe 1. Avisos sobre el láser Next 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 Go Back...
Page 17 5062 Previous Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) - lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Next Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
Page 18 5062 Previous Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
Page 19 5062 Previous Next Go Back Notices and safety information...
Page 20 5062 Previous Next Go Back Service Manual...
Page 21: Safety Information
5062 Previous 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. Next •...
Page 22 5062 Previous 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. Next • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
Page 23 5062 Previous 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 Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 24: Next
5062 Preface Previous 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 Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
Page 25: Change History
5062 Previous Change history Revision date Updates 2012/05/11 Updated MPF pick tires and wear parts FRU from 40X7150 to 40X7178 and its expected Next part life from 150K to 15K under “Individual maintenance part expected life” on page 6-1. 2012/05/04 Removed the following service checks: Go Back •...
Page 26: Conventions
5062 Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements: CAUTION Go Back A caution identifies something that might cause a servicer harm. CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working.
Page 27: General Information
Next The C792 represents the latest in Lexmark printer innovation, including a full-color eTask touch screen with improved messaging and animation, enhanced security features, remote operator panel access and control, customizable reports, and access to the growing list of downloadable and customizable solutions.
Page 28: Printer Configurations
If you purchased a multifunction printer (MFP) that scans, copies, and faxes, you may need additional furniture. For more information, see Go Back www.lexmark.com/multifunctionprinters. Some options may not be available for all models. Standard output bin...
Page 29: Options And Features
StapleSmart finisher or 5-bin mailbox (mailbox pictured) Options and features Lexmark C792 printers support only Lexmark C792 paper-handling options. These options are not compatible with any other Lexmark printer. Some of the following options are not available in every country or region.
Page 30: Printer Specifications
5062 • Firmware cards Previous – Bar Code – PrintCryption • Printer hard disk • Lexmark Internal Solutions Ports (ISP) – RS-232-C Serial ISP Next – Parallel 1284-B ISP – MarkNet N8250 802.11 b/g/n Wireless ISP – MarkNet N8130 10/100 Fiber ISP Go Back –...
Page 31 5062 Operating clearances Previous Next Go Back 152.4 mm (6 in.) Right 101.6 mm (4 in.) Front 609.6 mm (24 in.) Left 381 mm (15 in.) Rear 304.8 mm (12 in.) Allow additional clearance around the printer for adding options, such as additional input drawers, high-capacity output stacker, banner tray, StapleSmart finisher, or 5-bin mailbox.
Page 32 5062 – Maximum wet bulb temperature: 73° F (22.8° C) Previous – Altitude: 10,000 ft. (0 to 3,048 meters) – Atmospheric pressure: 74.6 kPa • Power off – Temperature: 50 to 110° F (10 to 43.3° C) – Relative humidity: 8 to 80% Next –...
Page 33: Paper Sizes Supported By The Printer
5062 Memory configuration Previous 512MB standard memory. Optional memory is available in 256MB, 512MB, and 1GB DIMM. There is only one DIMM slot available for optional memory. Supported paper sizes, types, and weights Next Paper sizes supported by the printer Go Back 550-sheet trays Optional...
Page 34: Paper Types And Weights Supported By The Printer
For more information, see the Card Stock & Label Guide available on the Lexmark Web site at http://support.lexmark.com. Use envelopes that lie flat when individually placed facedown on a table.
Page 35: Paper Types And Weights Supported By The Output Bins
(24 lb) xerographic, grain long paper. Business papers designed for general business use may also provide acceptable print quality. We recommend Lexmark part number 12A5950 letter-size glossy paper and Lexmark part number 12A5951 A4- size glossy paper. Always print several samples before buying large quantities of any type of media. When choosing any media, consider the weight, fiber content, and color.
Page 36: Paper Characteristics
Paper characteristics Previous The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. For detailed information, see the Card Stock & Label Guide available on the Lexmark Web site at http:// Next support.lexmark.com. Weight...
Page 37: Selecting Paper
5062 • Preprinted papers that require a registration (the precise print location on the page) greater than ±0.09 in., Previous such as optical character recognition (OCR) forms. In some cases, registration can be adjusted with the software application to successfully print on these forms. •...
Page 38: Tools Required For Service
5062 Previous Tools required for service Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic Next #2 Phillips screwdriver, magnetic short-blade Needlenose pliers Diagonal side cutters Go Back Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964 1-12...
Page 39: Acronyms
5062 Previous Acronyms ASIC Application-Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Next Cyan Cyclic Redundancy Check Customer Setup Go Back 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...
Page 40 5062 Previous Next Go Back 1-14 Service Manual...
Page 41: Diagnostic Information
5062 2. Diagnostic information Previous Next CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer. Go Back CAUTION The printer weight is greater than 32 kg (70 lb) and requires three or more trained personnel to lift it safely.
Page 42: Error Code Divisions
5062 Error code divisions Previous Error codes identifications have changed for this product. The following chart identifies the new code numbers that should be consistent across product lines. Next Range Description Go to page… Text prompts User prompts without code numbers “User prompts”...
Page 43: Paper Jams
5062 Previous Paper jams Understanding jam numbers and locations When a jam occurs, a message indicating the jam location appears on the display. To resolve any paper jam Next message, you must clear all jammed paper from the paper path. Go Back Area Jam number...
Page 44: Paper Jam
5062 Previous Area Jam number What to do Remove all paper from the multipurpose feeder, and “250 paper jam” on then remove the jammed paper. page 2-20 Next 200 paper jam Open the left access door. Go Back Firmly grasp the jammed paper, and then gently pull it out. Note: Make sure all paper fragments are removed.
Page 45 5062 Previous Error code Description Action 200.04 Input sensor flag broke early. 1. Clear away anything in the paper path that might cause the paper to jam. Possible cause: 2. Be sure the paper settings match the media. • Incorrect paper settings 3.
Page 46 5062 Previous Error code Description Action 200.35, Near narrow media sensor does not 1. Clear away anything in the paper path that might 200.37 break or breaks late. cause the paper to jam. 2. Be sure the paper settings match the media. •...
Page 47: Paper Jam
5062 Previous Error code Description Action 200.48 Narrow media sensor is never made “200.43” on page 2-6. or is made late. 200.49 S1 sensor is made when printer tries 1. Clear away anything in the paper path that might Next to print from an idle state.
Page 48 5062 Previous Error code Description Action 201.03 Bubble sensor is never made or is 1. Clear away anything in the paper path that might made late. cause the paper to jam. 2. If clearing a paper jam does not fix the problem, Possible causes: go to “201.03, 201.05, 201.07, 201.08—Paper...
Page 49: Paper Jams
5062 202–203 paper jams Previous Paper jam in the standard exit bin: Firmly grasp the paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed. Next Go Back From the operator panel, touch Continue, jam cleared. Paper jam in the fuser: Open the left access door.
Page 50 5062 Additional checks—202–203 paper jams Previous Error code Description Action 202.01 Exit sensor is made when printer tries 1. Check for anything in the paper path that might to print from an idle state. cause the paper to jam. Next 2.
Page 51 5062 Previous Error code Description Action 202.33 Bin-full sensor is never made or is 1. Clear away anything in the paper path that might made late. cause the paper to jam. 2. If clearing a paper jam does not fix the problem, go to “Pick arm stuck down service check”...
Page 52: Paper Jams
5062 Previous Error code Description Action 203.03 Redrive bubble sensor is never made 1. Clear away anything in the paper path that might or is made late. cause the paper to jam. 2. If clearing a paper jam does not fix the problem, Possible cause: Faulty redrive bubble go to “Redrive bubble sensor service check”...
Page 53 5062 Additional checks—230 paper jam Previous Error code Description Action 231.01 D1 sensor is made when printer tries 1. Check for anything in the paper path that might to print from an idle state. cause the paper to jam. Next 2.
Page 54: 24X Paper Jam
5062 Previous Error code Description Action 232.04 D2 sensor broke early. The D2 sensor may not be functioning properly. Go “D1 and D2 sensor service check” on Possible causes: page 2-147. • Damaged D2 sensor Next • Faulty fuser • Faulty system board 232.05, D2 sensor never broke.
Page 55 5062 Additional checks—24x paper jam Previous Error code Description Action 241.01 S1 sensor is made when printer 1. Clear away anything in the paper path that might powers up or covers are closed. cause the paper to jam. Next 2. If clearing a paper jam does not fix the problem, Possible causes: go to “Input, S1, narrow media, and near...
Page 56 5062 Previous Error code Description Action 241.21, Tray 1 motor stalled. 1. Remove all media present in the paper path. 241.22 2. Be sure the paper settings match the media. Possible causes: 3. Flex the media, and stack it flat in the tray or •...
Page 57 5062 Previous Error code Description Action 243.01 Tray 3 sensor is reached during POR 1. Clear anything in the paper path that might or after clearing the paper jam, tray 3 cause the paper to jam. sensor is still triggered. 2.
Page 58 5062 Previous Error code Description Action 244.01 Tray 4 sensor is reached during POR 1. Clear anything in the paper path that might or after clearing the paper jam, tray 4 cause the paper to jam. sensor is still triggered. 2.
Page 59 5062 Previous Error code Description Action 245.01 Tray 5 sensor is reached during POR 1. Clear anything in the paper path that might or after clearing the paper jam, tray 5 cause the paper to jam. sensor is still triggered. 2.
Page 60: Paper Jam
5062 250 paper jam Previous Remove all paper from the multipurpose feeder. Grasp the jammed paper on each side, and then gently pull it out. Note: Make sure all paper fragments are removed. Next Go Back Reload paper into the multipurpose feeder, and then adjust the paper guides. From the operator panel, touch Continue, jam cleared.
Page 61: Output Option Paper Jams
5062 Previous Output option paper jams 400–403 paper jams Additional checks—400–403 paper jams Next Error code Description Action Go Back 400.20 - 400.32 HTU motor error 1. POR the machine. 2. If the problem persists, replace the HTU transport motor. See “HTU transport motor removal”...
Page 62 5062 Previous Error code Description Action 402.05/402.07 HTU output sensor breaks late or 1. Clear away anything in the paper path that might never breaks paper jam cause the paper to jam. 2. Be sure the paper settings match the media. Possible cause: 3.
Page 63: Paper Jams
5062 431–432 paper jams Previous Additional checks—431–432 paper jams Error code Description Action Next 431.01 5-bin mailbox input sensor is made 1. Clear away anything in the paper path that might when the printer powers up. cause the paper to jam. 2.
Page 64: Paper Jams
5062 Previous Error code Description Action 432.03, 5-bin mailbox input sensor is never Go to “432.xx—5-bin mailbox pass thru sensor made or is made late. error service check” on page 2-123. 432.08 Next Possible cause: • Faulty 5-bin mailbox input sensor 432.04 5-bin mailbox passthru sensor early 1.
Page 65 5062 Previous Error code Description Action 450.32 Finisher/Stacker timer 0 overflow 1. Turn the machine off/on. (1ms timer did not get serviced for an 2. If the problem persists, go to “450.20, 450.21, entire 1ms). 450.22, 450.23, 450.32—Finisher/Stacker main motor error service check” on A software failure has occurred with Next page...
Page 66 5062 Previous Error code Description Action 453.31 Finisher/Stacker left tamper does not 1. Check all the connections on the output option move to home position failure. controller card. 2. Check the tamper drive belt for damage and The Finisher/Stacker sensor (left replace if needed.
Page 67 5062 Previous Error code Description Action 455.30 Finisher/Stacker staple ready home 1. Check all the connections on the controller card position jam. and the stapler assembly. 2. Remove the staple cartridge and remove all The sensor (self priming) within the jammed staples.
Page 68 5062 Previous Error code Description Action 456.05, Finisher stapler home sensor breaks 1. Clear away anything in the paper path that might 456.07 late or never breaks paper jam. cause the paper to jam. 2. Be sure the paper settings match the media. 3.
Page 69: Paper Jams
5062 461 paper jams Previous Additional checks—461 paper jams Error code Description Action Next 461.01 Hole punch sensor is made when the 1. Clear away anything in the paper path that might printer powers up cause the paper to jam. 2.
Page 70: Print Quality
5062 Previous Print quality Note: These symptoms may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge. Next Service tip: Before troubleshooting any print quality problems, do the following: Print a menu settings page, and then check the life status of all supplies.
Page 71: Background (Fog)
5062 Previous Symptom Action Print is too light Go to “Print is too light” on page 2-41 Random marks Go to “Random marks” on page 2-42 Repeating defects Go to “Repeating defects” on page 2-43 Next Shadow images Go to “Shadow images”...
Page 72 5062 Additional checks—background Previous Step Questions / actions Replace the print cartridge. Problem solved. Go to step 2. Next Does this fix the problem? Check the high voltage contact from the HVPS to the Replace the ITU Go to step 3. transfer module.
Page 73: Blank Page
5062 Blank page Previous Try one or more of the following: • MAKE SURE THERE IS NO PACKING MATERIAL LEFT ON THE PRINT CARTRIDGE Remove the print cartridge and make sure the packing material is properly removed. Reinstall the print Next cartridge.
Page 74: Blurred Or Fuzzy Print
5062 Blurred or fuzzy print Previous Try one or more of the following: • CHECK THE EP DRIVE ASSEMBLY AND TRANSFER MODULE Blurred or fuzzy print is usually caused by a problem in the EP drive assembly or in the transfer module. Next Check the EP drive assembly and transfer module for correct operation.
Page 75: Colors Not Properly Aligned
5062 Previous • CHECK THE PAPER SIZE SETTING Make sure the paper size setting matches the paper loaded in the tray: From the operator panel Paper menu, check the Paper Size setting. Before sending the job to print, specify the correct size setting: •...
Page 76: Horizontal Banding
5062 Horizontal banding Previous Leading edge Next Go Back Trailing edge Try one or more of the following: • MAKE SURE THERE IS NO DEFECTIVE PRINT CARTRIDGE Measure the distance between repeating bands. If the distance between bands either 37.7, 41.6 or 94.2 mm, then replace the defective print cartridge.
Page 77: Light Colored Line, White Line, Or Incorrectly Colored Line
5062 Additional checks—horizontal lines Previous Step Questions / actions Next 1. Check the media condition. Go to step 2. Problem solved. 2. Load new, dry, recommended media. 3. Re-print the defective image. Does the error continue? Go Back 1. Check the media transfer route. Go to step 3.
Page 78: Media Damage
5062 Media damage Previous Leading edge Next Go Back Trailing edge Additional checks—media damage Step Questions / actions 1. Check printer installation placement. Go to step 2. Correct the installation 2. Check the installation surface for irregularities. placement. 3. Check for missing printer foot. Is the setup surface normal? 1.
Page 79: Mottle (2-5Mm Speckles)
5062 Mottle (2–5mm speckles) Previous Leading edge Next Go Back Trailing edge The problem is caused by the photoconductor being dirty. Keep running prints through, and the problem normally clears up. If the problem persists, replace the cartridge of the color causing the spots. Paper curl •...
Page 80: Print Irregularities
5062 Print irregularities Previous Leading edge Next Go Back Trailing edge Try one or more of the following: • LOAD PAPER FROM A FRESH PACKAGE The paper may have absorbed moisture due to high humidity. Store paper in its original wrapper until you use it.
Page 81: Print Is Too Dark
5062 Print is too dark Previous Next Go Back Try one or more of the following: • LOAD PAPER FROM A FRESH PACKAGE The paper may have absorbed moisture due to high humidity. Store paper in its original wrapper until you use it.
Page 82: Random Marks
5062 Previous • CHECK THE PAPER TYPE SETTING Make sure the paper type setting matches the paper loaded in the tray: From the operator panel Paper menu, check the Paper Type setting. Before sending the job to print, specify the correct type setting from the computer: •...
Page 83: Repeating Defects
5062 Repeating defects Previous Next Go Back Print quality defect locator chart The printer has an internal copy of the defect locator chart under the Help Menu. From the home screen, navigate to: > Help > Print Defects Verify the proper image size by measuring any of the marks on the printed chart and comparing them to the corresponding measurement in the chart.
Page 84: Shadow Images
5062 Shadow images Previous Leading edge Next Go Back Trailing edge Try one or more of the following: • CHECK THE PAPER TYPE AND WEIGHT SETTINGS Make sure the paper type and weight settings match the paper loaded in the tray or feeder: From the operator panel Paper menu, check the Paper Type and Paper Weight settings.
Page 85: Skew
5062 Skew Previous Leading edge Next Go Back Trailing edge CHECK THE PRINTER SKEW Measure from the edge of the paper to the black line to find L1, L2, T1, T2, R1, R2, B1, and B2 as shown below: 2. Determine if the printer meets the skew specifications based on the values listed on the table. Skew Specification (L2-L1) (R2-R1)
Page 86 5062 Additional checks—skew Previous Step Questions / actions 1. Check printer installation placement. Go to step 2. Correct the Next installation 2. Check the installation surface for irregularities. placement. 3. Check for damaged printer caster. Is the setup surface normal? Go Back 1.
Page 87: Solid Color Or Black Pages
5062 Solid color or black pages Previous Next Go Back • MAKE SURE THE PRINT CARTRIDGES ARE INSTALLED CORRECTLY, ARE NOT DEFECTIVE AND NOT LOW ON TONER Remove and reinstall the print cartridges. Service tip: A solid color page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
Page 88: Toner Rubs Off
5062 Toner rubs off Previous Leading edge Next Go Back Trailing edge Try one or more of the following: • CHECK THE PAPER TYPE AND WEIGHT SETTINGS Make sure the paper type and weight settings match the paper loaded in the tray or feeder: From the operator panel Paper menu, check the Paper Type and Paper Weight settings.
Page 89: Transparency Print Quality Is Poor
5062 Transparency print quality is poor Previous Try one or more of the following: • CHECK THE TRANSPARENCIES Use only transparencies that meet the printer specifications. Next • CHECK THE PAPER TYPE SETTINGS Make sure the paper type settings match the paper loaded in the tray or feeder: Go Back From the operator panel Paper menu, check the Paper Type setting.
Page 90: Vertical Lines
5062 Vertical lines Previous Leading edge Next Go Back Trailing edge Step Check 1. Check the media condition. Go to step 2. Problem solved. 2. Load new, dry, recommended media. 3. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free Go to step 3.
Page 91: User Messages
5062 Previous User messages User prompts Next Error code Action Close Front Door Close the front door securely. If you continuously get this error, then the interlock switch may be bad. See “Interlock switch error service check” on page 2-155. Go Back Close Side Door Close the side door securely.
Page 92 5062 Previous Error code Action Load Manual <size> If paper loaded is in the manual feeder, the job continues. If paper is not in the feeder, pressing Select indicates to the printer it should search for a source with the proper size. Additional messages may include: Next •...
Page 93: User Attendance Messages (0-99)
5062 User attendance messages (0–99) Previous Error code Action 31 Defective or Missing • Reseat the specified print cartridge. <color> Cartridge Next • Inspect the print cartridge contacts for damage/contamination. Replace the print cartridge if defective. • Inspect the cartridge cable connection. Properly connect the cable if it is not connected properly.
Page 94 5062 Previous Error code Action 37 Insufficient memory, • The printer deleted some held jobs in order to process current jobs. Some Held Jobs Were • Select Continue to clear the message. Not Restored • If this does not fix the problem, replace the system board. See “System board removal”...
Page 95 5062 Previous Error code Action 54 Serial option <x> • Make sure the serial link is set up correctly and the appropriate cable is in use. error • Make sure the serial interface parameters (protocol, baud, parity, and data bits) are set correctly on the printer and host computer.
Page 96 5062 Previous Error code Action 58 Too Many Trays 1. Turn off and unplug the printer. Attached 2. Remove options until the supported number of options for that model. Models C734 supports three options and models C736 supports four options. 3.
Page 97 5062 Previous Error code Action • Show Me, View Supplies, and Tell Me More displays additional information. 80 Replace Fuser • Replace the fuser. See “Fuser assembly removal” on page 4-63. Note: Be sure to reset the fuser count as instructed on the sheet. •...
Page 98 5062 Previous Error code Action 82 Waste Toner Missing • Insert the waste toner box. • Check the cable in connector JBUMP1on the system board for defects and proper connection. If the cable wiring or the cable connection is defective, replace the bump multipurpose feeder/duplex motor assembly.
Page 99 5062 Previous Error code Action 84 <color> PC Unit • Scroll down the operator panel to see if the printer is showing that all four of the PC units Missing are missing. If so, check the HVPS cable between the system board and the HVPS. Ensure that the cable is not plugged in backwards on the HVPS.
Page 100: Service Errors
5062 Previous Service errors Printer hardware errors (100–199) Next Error code Description Action 110.xx An error has occurred in the • POR the printer. Printhead Error printhead. • If the error message persists, go to “110.xx— Go Back Printhead error service check” on page 2-67.
Page 101 5062 Previous Error code Description Action 146.01–146.22 Tray 1 motor has failed. • POR the printer. Autocomp Motor Error • If the error message persists, go to “146.xx— Autocomp (tray 1) motor error service check” on page 2-86. Next 147.01–147.22 The staging motor has failed.
Page 102: Firmware And/Or System Electronics (900-999)
5062 Firmware and/or system electronics (900–999) Previous Error code Description Action 900.00–900.99 An unrecoverable RIP software error Go to “900.xx System software error” on (except 900.05) occurred while an unknown process page 2-132. Next Software Error was running. 910.xx–915.xx An engine software error has •...
Page 103 5062 Previous Error code Description Action 938.21 A staging motor failure occurred. • POR the printer. Electronics Hardware • If the error message persists, go to “147.xx— Error Staging motor error service check” on page 2-87. Next 938.22 A printhead failure error occurred. •...
Page 104 5062 Previous Error code Description Action 956.xx except for 956.02 A processor failure has occurred. • POR the printer. System Card Failure • If the error message persists, replace the system board. See “System board removal” on page 4-151. Next 956.02 The processor fan has failed.
Page 105 5062 Previous Error code Description Action 990.00–990.29 An option error has occurred. Go to “990.xx—POST error service check” on Option Error page 2-142. 991.00–991.99 The specified device has detected an • POR the printer. Next <device> Error error. • If the error message persists, replace the system board.
Page 106: Symptoms
5062 Previous Symptoms Symptom table—base printer Next Symptom Action Dead printer Go to “Dead printer service check” on page 2-149. Tray linking will not work. Go to “Tray linking service check” on page 2-171. Go Back Paper pick mechanism—pick arm is stuck Go to “Pick arm stuck down service check”...
Page 107: Service Checks
5062 Previous Service checks 110.xx—Printhead error service check Next Step Questions / actions View the Event Log: Replace the printhead. See Go to step 2. “Printhead removal, Go Back 1. Turn off the printer, press and hold 3 and installation, and 6 and turn on the printer.
Page 108: Xx-Motor (Fuser) Error Service Check
5062 Previous Step Questions / actions Measure the resistance across fuse F13 on Replace the system board. Go to step 5. the system board. “System board removal” on page 4-151. Next Go Back Is the fuse blown? Perform the printhead verification to check Replace the printhead.
Page 109 5062 Previous Step Questions / actions Remove the rear cover. See “Rear cover Go to step 4. Reseat the cable. removal” on page 4-20. Check the BLDE Y & Fuser cable (B) for proper connection to the fuser motor. Next Go Back Is the cable properly connected? Is the BLDE Y &...
Page 110: Xx-Fuser Error Service Check
5062 121.xx—Fuser error service check Previous Step Questions / actions Replace the fuser. See “Fuser assembly Problem solved. Go to step 2. removal” on page 4-63. Next Does the error clear? Open the system board shield. Check the Go to step 3. Reseat the cable.
Page 111 5062 Previous Step Questions / actions Check the cable on the LVPS for damage. Replace the Fuser and Go to step 6. system card LVPS cable. Is the cable damaged? “Fuser system card and LVPS cable removal” Next on page 4-67.
Page 112: Xx, 145.Xx-Itu Error Service Check
5062 125.xx, 145.xx—ITU error service check Previous Step Questions / actions Replace the ITU assembly. See “ITU Problem solved. Go to step 2. assembly removal” on page 4-77. Next Does the error clear? Turn the printer off, open the system board Go to step 3.
Page 113: Xx-Lvps Error Service Check
5062 126.xx—LVPS error service check Previous Step Questions / actions Ask the customer if they’re having any Do nothing. Go to step 2. problem with their power lines, e.g., power Next outages or power failures. Is the customer having power line Go Back problems? Turn the printer off, open the system board...
Page 114: Xx-Cartridge Sensor Error Service Check
5062 133.xx—Cartridge sensor error service check Previous Step Questions / actions a. Power off the printer. Replace the Go to step 2. cartridge. b. Enter the Diagnostics mode, (press and hold 3 and 6, while Next turning on the printer). c.
Page 115 5062 Previous Step Questions / actions Error code Sensor Next 133.01 133.02 133.03 Go Back 133.04 Does the sensor go from “Open” to “Close?” Turn the printer off and open the system board shield. Check the Go to step 3. Reseat the cables in the indicated connectors for proper connection to the cable.
Page 116 5062 Previous Step Questions / actions Check the cables in the indicated connectors for proper connection to Go to step 4. Reseat the the system board. cable. Next Go Back 133.01 Black—D (JCMKM1) 133.02 Cyan—C (JCMCY1) 133.03 Magenta—D (JCMKM1) 133.04 Yellow—C (JCMCY1) Are the cables properly connected? 2-76 Service Manual...
Page 117 5062 Previous Step Questions / actions Check the cables in connectors JCMKM1 and JCMCY1 for damage, Replace the Go to step 3. and then remove all four cartridges and check the other ends of the cable. cables connected to the sensors on the memory blocks. Next Go Back 133.01 Black—B (JCMKM1)
Page 118 5062 Previous Step Questions / actions Replace the indicated cartridge memory block and cable. Problem Replace the solved. system board. “System Error Memory block Cable board code Next removal” on page 4-151. 133.01 Black JCMKM1 133.02 Cyan JCMCY1 Go Back 133.03 Magenta JCMKM1...
Page 119 5062 Previous Step Questions / actions 3. Rotate the developer input gear clockwise until the tab (H) is up against the tab on the larger gear (J). Next Go Back Print two demo pages: 1. Replace all cartridges. 2. Turn on the machine. 3.
Page 120: Xx-Black Cartridge Motor Error Service Check
5062 141.xx—Black cartridge motor error service check Previous Step Questions / actions Turn the printer off, open the system board Go to step 2. Reseat the cable. shield, and remove the connector shield. Next Check the cable in the connector JKI1 (BLDC K &...
Page 121: Xx-Cyan Cartridge Motor Error Service Check
5062 Previous Step Questions / actions Remove the system board cage. See Go to step 5. Reseat the cable. “System board cage with board removal” on page 4-155. Check the cable connected to the black Next cartridge motor. Go Back Is the cable connected properly? Replace the EP drive assembly.
Page 122 5062 Previous Step Questions / actions Check the cable for damage. Replace the BLDC C&M Go to step 3. cable. See “EP drive Is the cable damaged? assembly removal” on page 4-56. Next Measure the resistance across the fuse F4 on Replace the system board.
Page 123: Xx-Magenta Cartridge Motor Error Service Check
5062 143.xx—Magenta cartridge motor error service check Previous Step Questions / actions Turn the printer off, open the system board Go to step 2. Reseat the cable. shield, and remove the connector shield. Next Check the cable in the connector JCM1 (BLDC C&M cable) for proper connection to the system board.
Page 124: Xx-Yellow Cartridge Motor Error Service Check
5062 Previous Step Questions / actions Remove the system board cage. See Go to step 5. Reseat the cable. “System board cage with board removal” on page 4-155. Check the cable connected to the magenta Next cartridge motor. Go Back Is the cable connected properly? Replace the EP drive assembly.
Page 125 5062 Previous Step Questions / actions Check the cable for damage. Replace the BLDC Y & Go to step 3. Fuser cable. See “EP Is the cable damaged? drive assembly removal” on page 4-56. Next Measure the resistance across the fuse F1 on Replace the system board.
Page 126: Xx-Autocomp (Tray 1) Motor Error Service Check
5062 146.xx—Autocomp (tray 1) motor error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JTRAY1 (A) for proper connection to the system board.
Page 127: Xx-Staging Motor Error Service Check
5062 147.xx—Staging motor error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JSTAG1 (staging motor cable) for proper connection to the system board.
Page 128: Xx-Paper Path Redrive Motor Error Service Check
5062 Previous Step Questions / actions Replace the staging paper path reference Replace the system board. Problem solved. edge assembly. See “Staging paper path “System board reference edge assembly removal” on removal” on page 4-151. page 4-142. Next Dose the error reoccur? Go Back 149.xx—Paper path redrive motor error service check Step...
Page 129: Xx-Duplex Motor Error Service Check
5062 150.xx—Duplex motor error service check Previous Step Questions / actions Open the left access door assembly, and Replace the duplex Go to step 2. check the duplex assembly gears for damage. assembly. See “Duplex Next assembly removal” on page 4-53.
Page 130: Xx-Itu Motor Error Service Check
5062 Previous Step Questions / actions Remove the rear cover and the left cover. Go to step 5. Reseat the cable. See“Rear cover removal” on page 4-20 “Left cover removal” on page 4-11. Check the cable connection to the duplex Next motor.
Page 131: Xx-Main Fan Error Service Check
5062 Previous Step Questions / actions Check the cable in the connector JKI1 (BLDC Replace the BLDC K & ITU Go to step 3. K & ITU cable) for damage. cable. See “EP drive assembly removal” on page 4-56. Is the cable damaged? Next Remove the rear cover.
Page 132: Xx-Lvps Fan Error Service Check
5062 Previous Step Questions / actions Replace the main fan. See “Main fan Replace the system board. Problem solved. removal” on page 4-92. “System board removal” on page 4-151. Does the error reoccur? Next 172.xx—LVPS fan error service check Go Back Step Questions / actions Turn the printer off, and open the system...
Page 133: Xx-Blower Fan Error Service Check
5062 173.xx—Blower fan error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JBLW1 (blower & right side waste cable) for proper connection to the system board.
Page 134: Paper Jam Error Service Check
5062 200.02—Paper Jam error service check Previous Step Questions / actions Open the left access door. Check the input Replace the input sensor. Go to step 2. flag (A) for damage. “Sensor (input, S1, Next narrow media, near narrow media) removal” on page 4-138.
Page 135: 200.08-Paper Jam Error Service Check
5062 200.03, 200.08—Paper Jam error service check Previous Step Questions / actions Remove the input tray. Replace the pick tires. See Go to step 2. “Pick rolls removal” on Next page 4-122. Are the pick tires worn? Open the left access door. Check the input Replace the input sensor.
Page 136: 200.07-Paper Jam Error Service Check
5062 Previous Step Questions / actions Check the cable in connector JPP2 for any Replace the paper path Go to step 6. other damage. cable. See “Paper path cables” on page 7-56. Next Is the cable damaged? Remove the staging deflector assembly. See Go to step 7.
Page 137 5062 Previous Step Questions / actions Remove the staging deflector assembly. See Go to step 6. Reseat the cable. “Staging deflector assembly removal” on page 4-140. Next Is the cable connected correctly? Replace the input sensor. See “Sensor Replace the system board. Problem solved.
Page 138: Paper Jam Error Service Check
5062 200.32—Paper Jam error service check Previous Step Questions / actions Open the left access door. Check the near Replace the near narrow Go to step 2. narrow media sensor flag (D) for damage. media sensor. See Next “Sensor (input, S1, narrow media, near narrow media) removal”...
Page 139: 200.38-Paper Jam Error Service Check
5062 200.33, 200.38—Paper Jam error service check Previous Step Questions / actions Remove the input tray. Replace the pick tires. See Go to step 2. “Pick rolls removal” on Next page 4-122. Are the pick tires worn? Open the left access door. Check the near Replace the near narrow Go to step 3.
Page 140 5062 Previous Step Questions / actions Check the cable in connector JPP2 for any Replace the paper path Go to step 6. other damage. cable. See “Paper path cables” on page 7-56. Next Is the cable damaged? Remove the staging deflector assembly. See Go to step 7.
Page 141: 200.37-Paper Jam Error Service Check
5062 200.35, 200.37—Paper Jam error service check Previous Step Questions / actions Reseat the ITU. Problem solved. Go to step 2. Next Does the error clear? Open the left access door. Check the near Replace the near narrow Go to step 3. Go Back narrow media sensor flag (D) for damage.
Page 142: Paper Jam Error Service Check
5062 200.42—Paper Jam error service check Previous Step Questions / actions Open the left access door. Check the narrow Replace the narrow media Go to step 2. media flag (C) for damage. sensor. See “Sensor Next (input, S1, narrow media, near narrow media) removal”...
Page 143: 200.48-Paper Jam Error Service Check
5062 200.43, 200.48—Paper Jam error service check Previous Step Questions / actions Remove the input tray. Replace the pick tires. See Go to step 2. “Pick rolls removal” on Next page 4-122. Are the pick tires worn? Open the left access door. Check the narrow Replace the narrow media Go to step 3.
Page 144: 200.47-Paper Jam Error Service Check
5062 Previous Step Questions / actions Check the cable in connector JPP2 for any Replace the paper path Go to step 6. other damage. cable. See “Paper path cables” on page 7-56. Next Is the cable damaged? Remove the staging deflector assembly. See Go to step 7.
Page 145 5062 Previous Step Questions / actions Remove the staging deflector assembly. See Go to step 6. Reseat the cable. “Staging deflector assembly removal” on page 4-140. Next Is the cable connected correctly? Replace the near narrow media sensor. See Replace the system board. Problem solved.
Page 146 5062 Previous Step Questions / actions Open the left access door, remove the two Go to step 5. Reseat the cable. screws (A), and pull out the fuser autoconnect enough to check the cable for proper connection. Next Go Back Is the cable connected correctly? Check the cable for damage.
Page 147: Paper Jam Error Service Check
5062 202.32—Paper Jam error service check Previous Step Questions / actions Is the bin-full flag damaged? Replace the bin-full flag. Go to step 2. “Bin-full flag Next removal” on page 4-37. Go Back Remove the top cover assembly. Reseat the sensor. Contact your next level of support.
Page 148 5062 241.02—Paper Jam error service check Previous Step Questions / actions Open the left access door. Check the S1 Replace the S1 sensor. Go to step 2. sensor flag (B) for damage. “Sensor (input, S1, Next narrow media, near narrow media) removal” on page 4-138.
Page 149 5062 242.01, 243.01, 244.01, 245.01 —Paper Jam (550-sheet/2000-sheet input option) Previous service check Step Questions / actions Next Check for any obstruction on the paper path. Go to step 2. Clear paper path for obstructions. Is the paper path free of obstruction? Go Back Check if the jam clearance cover can close Go to step 3.
Page 150 5062 Previous Step Questions / actions For 550-sheet input option: For 550-sheet input option: Problem solved. Replace the 550-sheet Replace the controller card assembly. See drawer assembly. See “550-sheet tray controller card assembly “550-sheet drawer removal” on page 4-167. Next assembly removal”...
Page 151 5062 Previous Step Questions / actions Check if the pass thru sensor is seated Go to step 4. For 550-sheet input option: correctly and not damage. Replace the pass thru sensor. See “550-sheet tray pass thru sensor Next removal” on page 4-175.
Page 152 5062 Previous Step Questions / actions For 550-sheet input option: Replace the Go to step 8. Problem solved. controller card assembly. See “550-sheet tray controller card assembly removal” on page 4-167. Next For 2000-sheet input option: Replace the controller card assembly. See “2000-sheet Go Back high-capacity feeder controller card...
Page 153 5062 Previous Step Questions / actions Check if the pass thru sensor is seated Go to step 4. Install the pass thru sensor correctly and the sensor flag can move back correctly. to its original position when it is triggered. Next Go Back Is the pass-thru sensor free of...
Page 154 5062 Previous Step Questions / actions 1. Check the pick assembly for mechanical Go to step 7. For 550-sheet input option: wear or damage. Replace the pick assembly. “550-sheet tray pick 2. Check if the pick arm spring is not assembly removal”...
Page 155: 250.22-Mpf Motor Error Service Check
5062 250.21, 250.22—MPF motor error service check Previous Step Questions / actions Open the left access door. Go to step 3. Go to step 2. Next Does the MPF wheels turn freely? Remove the LVPS fan shield. See “LVPS Replace the MPF pick Replace the MPF paper Go Back exit duct removal”...
Page 156 5062 Previous Step Questions / actions Remove the input tray. Go to step 6. Reseat the cable. Is the input tray cable connected Next correctly? Remove the LVPS. See “Low-voltage Replace the MPF drive Go to step 7. power supply (LVPS) removal” on belt.
Page 157: Xx-Htu Input Sensor Error Service Check
5062 401.xx—HTU input sensor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off Go to step 2. Problem solved. the printer, press and hold 3 and 6, turn on the Next printer, and hold the buttons until the splash screen appears).
Page 158: Xx-Htu Output Sensor Error Service Check
5062 Previous Step Questions / actions Replace the HTU input sensor. See “HTU sensor Replace the HTU Problem solved. (input) removal” on page 4-322. controller card. “HTU controller card Next removal” on Does the error reoccur? page 4-289. Go Back 402.xx—HTU output sensor error service check Step Questions / actions...
Page 159: Xx-Htu Second Sensor Error Service Check
5062 403.xx—HTU second sensor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off Go to step 2. Problem solved. the printer, press and hold 3 and 6, turn on the Next printer, and hold the buttons until the splash screen appears).
Page 160 5062 Previous Step Questions / actions Remove the HTU rear standard bin cover. See “HTU Go to step 4. Reseat the rear standard bin cover removal” on page 4-312. connector. Next Check the cable in the indicated connector. Go Back Is the cable proper connected? Replace the HTU second sensor.
Page 161: Xx-5-Bin Mailbox Input Sensor Error Service Check
5062 431.xx—5-bin mailbox input sensor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 162 5062 Previous Step Questions / actions Remove the 5-bin mailbox rear cover. See “5-bin Go to step 4. Reseat the mailbox rear cover removal” on page 4-249. connector. Check the cable in the indicated connector. Next Go Back Is the cable proper connected? Replace the 5-bin mailbox input sensor.
Page 163: Xx-5-Bin Mailbox Pass Thru Sensor Error Service Check
5062 432.xx—5-bin mailbox pass thru sensor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 164 5062 Previous Step Questions / actions Remove the 5-bin mailbox rear cover. See “5-bin Go to step 4. Reseat the mailbox rear cover removal” on page 4-249. connector. Check the cable in the indicated connector. Next Go Back Is the cable proper connected? Replace the 5-bin mailbox pass thru sensor.
Page 165 5062 450.20, 450.21, 450.22, 450.23, 450.32—Finisher/Stacker main motor error service Previous check Step Questions / actions Next 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, and hold the buttons until the splash screen appears).
Page 166: Xx-Finisher/Stacker Sensor (Pass Thru) Error Service Check
5062 451.xx—Finisher/Stacker sensor (pass thru) error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 167: 456.08-Finisher Stapler Home Sensor Error Service Check
5062 Previous Step Questions / actions Remove the Finisher/Stacker front cover. See “Finisher Go to step 4. Reseat the or stacker front cover removal” on page 4-260. connector. Check the cable in the indicated connector. Next Go Back Is the cable proper connected? Replace the Finisher/Stacker sensor (pass thru).
Page 168: X-Finisher Stapler Motor Error Service Check
5062 456.3x—Finisher stapler motor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 169: X-Finisher/Stacker Paddle Motor Error Service Check
5062 458.3x—Finisher/Stacker paddle motor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 170: 461.08-Hole Punch Sensor Error Service Check
5062 461.01 - 461.08—Hole punch sensor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 171: 461.32-Hole Punch Motor Error Service Check
5062 461.31, 461.32—Hole punch motor error service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics menu (turn off the Go to step 2. Problem solved. printer, press and hold 3 and 6, turn on the printer, Next and hold the buttons until the splash screen appears).
Page 172: System Software Error
Note: Before troubleshooting, determine the operating system used when the error occured. If possible Go Back determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device. Step Action and questions POR the device.
Page 173 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.
Page 174 5062 Previous Step Action and questions Replace the faulty ISP option. Restart the device. Go to step 31. Go to step 26. Does the 900.xx error reoccur? Are there any more ISP options to install? Go to step 27 Problem Next resolved.
Page 175: Mpf Paper Out Sensor Error Service Check
5062 938.16—MPF paper out sensor error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JMPF1(MPF sensor cable) for proper connection to the system board.
Page 176: Waste Toner Sensor Error Service Check
5062 938.18—Waste toner sensor error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JWTB1 for proper connection to the system board.
Page 177: Waste Toner Full Sensor Error Service Check
5062 938.19—Waste toner full sensor error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JWTBF1 for proper connection to the system board.
Page 178: 938.29, 938.30-Weather Station Error Service Check
5062 938.27, 938.29, 938.30—Weather station error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JFSRD1 for proper connection to the system board.
Page 179: Remote Weather Station Error Service Check
5062 938.28—Remote weather station error service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Check the cable in connector Next JCCT2 (weather station compensation thermistor) for proper connection to the system board.
Page 180: 950.29-Eprom Mismatch Failure
5062 950.00–950.29—EPROM mismatch failure Previous Warning: When replacing any of the following components, replace only one component at a time or the printer will be rendered inoperable: • System board • OP panel UICC card Next Replace the required component, bring the printer up in Diagnostics mode (see “Diagnostics menu”...
Page 181: Processor Fan Failure Service Check
5062 956.02—Processor fan failure service check Previous Step Questions / actions Turn the printer off, and open the system Go to step 2. Reseat the cable. board shield. Next Check the cable in connector J3 (system board fan connector) for proper connection to the system board.
Page 182: Xx-Post Error Service Check
5062 990.xx—POST error service check Previous Step Questions / actions Is the option with the error, a 2000-sheet Go to step 3. Go to step 2. option? Next Properly connect the following connectors on Replace the 550-sheet Problem solved. the 550-sheet controller card and on the other drawer assembly.
Page 183 5062 Previous Step Questions / actions Replace the 2000-sheet high-capacity feeder Go to step 9. Problem solved. pick assembly. See “2000-sheet high- capacity feeder pick assembly removal” on page 4-218. Next Does the problem persist? Go Back Replace the 2000-sheet high-capacity feeder Go to step 10.
Page 184: Bin-Full Sensor Service Check
5062 Bin-full sensor service check Previous Step Questions / actions Is the bin-full flag damaged? Replace the bin-full flag. Go to step 2. “Bin-full flag Next removal” on page 4-37. Turn the printer off, and open the system Go to step 3. Reseat the cable.
Page 185: Bubble Sensor Service Check
5062 Bubble sensor service check Previous Step Questions / actions Open the left access door, and check the Replace the damaged Go to step 2. fuser bubble sensor flag. sensor. See “Sensor (D1, Next D2, and fuser bubble) removal” on page 4-137.
Page 186 5062 Previous Step Questions / actions Remove the duplex cable cover. Go to step 5. Reseat the cable. Next Go Back A (88A0323) Check the cable for proper connection. Is the cable connected correctly? Check the cable for damage. Replace the duplexer Go to step 6.
Page 187: D1 And D2 Sensor Service Check
5062 D1 and D2 sensor service check Previous Step Questions / actions Open the left access door, and open the Replace the damaged Go to step 2. duplex assembly. sensor. See “Sensor (D1, Next D2, and fuser bubble) removal” on page 4-137.
Page 188 5062 Previous Step Questions / actions Check the cable for damage. Replace the duplexer Go step 4. cable. Is the cable damaged? To access the cable, see “LVPS exit duct removal” Next on page 4-89 “Left cover removal” on Go Back page 4-11.
Page 189: Dead Printer Service Check
5062 Previous Step Questions / actions Check the cable for damage. Replace the duplexer Go to step 6. cable. To access the cable, see Is the cable properly connected? “LVPS exit duct removal” Next on page 4-89 “Left cover removal” on Go Back page 4-11.
Page 190: Double Feed (550-Sheet/2000-Sheet Input Option) Service Check
5062 Previous Step Questions / actions 1. Turn the printer off. Contact your next level of Go to step 6. support. 2. Disconnect the cables in J5, JFSR1, JHVPS, JCM1, JITM1, JKI1, JOOPT1, and JYF1. Next 3. Connect the JLVPS1 cable to the system board.
Page 191 5062 Previous Step Questions / actions 1. Check the pick assembly for damage. For 550-sheet input option: Go to step 4. Replace the pick assembly. 2. Check if the pick arm spring is not “550-sheet tray pick detached. assembly removal” on Next page 4-176.
Page 192: Input Option Not Detected (550-Sheet/2000-Sheet Input Option) Service Check
5062 Input option not detected (550-sheet/2000-sheet input option) service check Previous Step Questions / actions Check the autoconnect connector for any Go step 3. For 550-sheet input option: damage. Replace the drawer Next assembly. See “550-sheet drawer assembly removal” on page 4-166.
Page 193: Input, S1, Narrow Media, And Near Narrow Media Sensor Service Check
5062 Input, S1, narrow media, and near narrow media sensor service check Previous Step Questions / actions Open the left access door. Check the sensor Replace the input sensor. Go to step 2. flag for damage. “Sensor (input, S1, Next narrow media, near narrow media) removal”...
Page 194 5062 Previous Step Questions / actions Remove the staging deflector assembly, and Go to step 5. Reseat the cable. check the sensor cable connection. See “Staging deflector assembly removal” on page 4-140. Next Go Back A—Input sensor B—S1 sensor C—Narrow media sensor D—Near narrow media sensor Is the cable properly connected? Replace the sensor.
Page 195: Interlock Switch Error Service Check
5062 Interlock switch error service check Previous Step Questions / actions Has the printhead been replaced recently? Go to step 2. Go to step 3. Next Go Back Check to see if the printhead flat cables are Replace the printhead. See Reseat the cable.
Page 196: Jam Clearance Cover Open (550-Sheet/2000-Sheet Input Option) Service Check
5062 Jam clearance cover open (550-sheet/2000-sheet input option) service check Previous Step Questions / actions 1. Check if the jam clearance cover can Go to step 2. For 550-sheet input option: close properly. Replace the drawer Next assembly. See “550-sheet 2.
Page 197 5062 Previous Step Questions / actions 1. POR the printer. Go to step 4. For 550-sheet input option: Replace the drawer 2. Bring the printer up in Diagnostics mode assembly. See “550-sheet (turn off the printer, press and hold 3 and drawer assembly 6, turn on the printer, and hold the buttons Next...
Page 198: Media Size Error (550-Sheet/2000-Sheet Input Option) Service Check
5062 Media size error (550-sheet/2000-sheet input option) service check. Previous Step Questions / actions Is the media tray inserted properly? Go to step 2. Insert the media tray properly. Next Check for any obstructions between the Go to step 3. Clear any obstructions.
Page 199: Media Tray Missing (550-Sheet Input Option) Service Check
5062 Media tray missing (550-sheet input option) service check Previous Step Questions / actions Be sure that the 550-sheet tray pick assembly Go to step 2. Properly install the 550- is inserted to the correct hole and slot during sheet tray pick assembly. Next installation.
Page 200: Media Tray Missing (2000-Sheet Input Option) Service Check
5062 Previous Step Questions / actions Check for any damage or obstruction on the Replace the 550-sheet Clear any obstructions. tray slides assembly. drawer assembly. See “550-sheet drawer assembly removal” on Next page 4-166. Go Back Is the 550-sheet drawer assembly free of damage or obstruction? Media tray missing (2000-sheet input option) service check Step...
Page 201 5062 Previous Step Questions / actions Check if the pick arm assembly is not hanging Go to step 5. Go to step 6. down. Next Go Back Is the pick arm hanging? Press the actuator assembly (B) to lock the Go to step 6.
Page 202: Networking Service Check
Next interference. Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Go Back Step...
Page 203 5062 Previous Step Questions / actions Try using a different ethernet cable. Problem solved. Go to step 14. Is the problem solved? Have the network administrator check the Replace the system board. Contact the network Next network drop for activity. “System board administrator.
Page 204: Pick Arm Stuck Down Service Check
5062 Pick arm stuck down service check Previous Step Questions / actions With the assembly still in the printer, push up Problem solved. Replace the paper pick on the bar on the bottom of the pick arm to mechanism assembly. See Next raise the arm, and then pull the larger latch in “Paper pick mechanism...
Page 205: Redrive Bubble Sensor Service Check
5062 Redrive bubble sensor service check Previous Step Questions / actions Open the left access door, and remove the Replace the paper path Go to step 2. fuser. Check the redrive bubble sensor flag redrive assembly. See Next for damage. “Paper path redrive assembly with sensors removal”...
Page 206: Skew (550-Sheet Input Option) Service Check
5062 Skew (550-sheet input option) service check Previous Step Questions / actions 1. Bring the printer up in Diagnostics mode Go to “Skew” on Go to step 2. (turn off the printer, press and hold 3 and page 2-45. Next 6, turn on the printer, and hold the buttons until the splash screen appears).
Page 207: Skew (2000-Sheet Input Option) Service Check
5062 Previous Step Questions / actions 1. Check the 550-sheet tray drive assembly Replace the 550-sheet tray Replace the 550-sheet for damage. drive assembly. See “550- input option. sheet tray drive 2. Check the 550-sheet tray drive assembly assembly removal” on rollers if they are in contact when the jam Next page...
Page 208 5062 Previous Step Questions / actions Check if there’s a contact between the rollers Go to step 6. Replace the 2000-sheet of the 2000-sheet high-capacity feeder drive high-capacity feeder drive assembly and if the jam clearance cover is assembly. See “2000- properly closed.
Page 209: Tray Empty (2000-Sheet Input Option) Service Check
5062 Tray empty (2000-sheet input option) service check Previous Step Questions / actions Check if the paper level flag on the 2000- Go to step 2. Replace the 2000-sheet sheet high-capacity feeder pick assembly can high-capacity feeder pick Next freely move. assembly.
Page 210 5062 Previous Step Questions / actions Check if the lift drive coupling gear is Replace the 2000-sheet Go to step 5. damaged. high-capacity feeder lift drive motor assembly. See “2000-sheet high- Next capacity feeder lift drive motor assembly removal” on page 4-212.
Page 211: Tray Jam Indicator (550-Sheet/2000-Sheet Input Option) Service Check
5062 Tray jam indicator (550-sheet/2000-sheet input option) service check Previous Step Questions / actions 1. POR the machine. Go to step 2. Problem solved. 2. Simulate a paper jam by obstructing the Next pass thru sensor. 3. Turn on machine. Go Back Does the problem persist? Be sure that JM LD (Jam clearance cover...
Page 212 5062 Previous Next Go Back 2-172 Service Manual...
Page 213: Diagnostic Aids
5062 3. Diagnostic aids Previous This chapter provides basic information to help you navigate the printer menus and explains the tests and procedures used to identify printer failures and verify repairs have corrected the problem. Next Understanding the operator panel and menus Go Back Operator panel Item...
Page 214: Understanding The Home Screen
5062 Understanding the home screen Previous Buttons appearing on the home screen may vary depending on home screen customization settings. Next Go Back Item Description Change Language Allows you to change the primary language and reports on the display, and will remain in effect until changed Bookmarks Allows you to create, organize, and save a set of bookmarks (URLs) into a tree view of folders and file links...
Page 215: Using The Touch-Screen Buttons
5062 Using the touch-screen buttons Previous Button Function Up arrow Scrolls up Next Go Back Delete folder Deletes a print job Drag print jobs to the folder to delete them. Left arrow Scrolls left Right arrow Scrolls right Right scroll increase Increases a value Left scroll decrease Decreases a value...
Page 216: Other Touch-Screen Icons
5062 Other touch-screen icons Previous Icon Function Exit Exits from the current screen to the home screen Next Go Back Unselected radio Indicates that an item is not selected button Selected radio button Indicates a selection Index Displays information about the key functions of the printer, including instructions on how to operate it Search Lets you search for files and menus...
Page 217: Administrative Menus
5062 Administrative menus Previous Press to enter the Administrative menus. Some menu items may not be available based on the printer model or the options installed. Next Supplies Menu Paper Menu Reports Settings Cyan Cartridge Default Source Menu Settings Page General Settings Magenta Cartridge Paper Size/Type...
Page 218: Accessing Service Menus
5062 Previous Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics menu 1. Turn off the printer. The Diagnostics menu group Next contains the settings and 2. Press and hold 3 and 6. operations used while manufacturing and servicing the printer.
Page 219: Diagnostics Menu
5062 Previous Diagnostics menu To run the printer diagnostic tests described in this chapter, enter Diagnostics mode. Turn off the printer. Next Press and hold 3 and 6. Go Back Turn on the printer. Hold the buttons until the splash screen appears. Diagnostics menus Dual Diode Adjust “DUAL DIODE ADJUST”...
Page 220 5062 Multi-Purpose Feeder Previous Print Quality Pages “Print Quality Pages” on page 3-14 HARDWARE TESTS Panel Test “Panel Test” on page 3-14. Button Test “Button Test” on page 3-14. Next DRAM Test “DRAM Test” on page 3-14. Serial Wrap 1 (if installed) “Serial Wrap Test”...
Page 221: Exiting The Diagnostics Mode
5062 Par 1 Strobe Adj (if installed) “Par 1 Strobe Adj” on page 3-24. Previous EP SETUP EP Defaults “EP Defaults” on page 3-24. Fuser Temp “Fuser Temp” on page 3-24. DC Charge Adjust “DC Charge Adjustment” on page 3-24. Next Dev Bias Adj “Dev Bias Adj”...
Page 222: Registration
5062 REGISTRATION Previous Note: Before adjusting the Registration or Alignment settings, you must adjust the dual diode alignment. See “DUAL DIODE ADJUST” on page 3-9. Use REGISTRATION to align the black image on the page. Use Alignment to align the individual colors. The Next black image should be aligned before the individual colors are aligned.
Page 223: Alignment Menu
5062 Alignment Menu Previous Aligns the image on the page for the individual colors: cyan, yellow, and magenta. The black image should be aligned using REGISTRATION before the individual colors are aligned. Warning: Read the instructions for the alignment carefully. Next Setting alignment for color Go Back...
Page 224: Drift Sensors
5062 Touch (-) to decrease the value or (+) to increase the value. Once the value appears, touch to save the Previous value or Back to cancel. Reprint the Quick Test to evaluate the changes. Continue until each adjustment is correct. Repeat steps 4 through 6 if required.
Page 225: Misc Tests
5062 MISC TESTS Previous Toggle ITU The test is used to verify that ITU belt retraction, BOR, hardware is functioning properly. Two options are available: Raise Belt and Lower Belt. If the belt is already in the requested position, no action occurs. Otherwise Next the belt will move to the requested position.
Page 226: Print Quality Pages
5062 Print Quality Pages Previous The print quality test consists of five pages. Pages one and two contain a mixture of graphics and text. The remainder of the pages only contain graphics. See “Print tests” on appendix page A-1 for samples of the Print Quality Pages.
Page 227: Serial Wrap Test
5062 Once the maximum pass count or fail count is reached, or once all the DRAM has been tested, the test stops Previous and the final results appear. Serial Wrap Test Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. If the Next test fails, replace the system board.
Page 228: Usb Hs Test Mode
5062 USB HS Test Mode Previous If the test fails, replace the failing USB cable. 1. From the Diagnostics menu, navigate to: HARDWARE TESTS > USB HS Test Mode Next 2. Select the desired Port. 3. Select the desired Test. Go Back Ports Tests...
Page 229: Input Tray Tests
5062 INPUT TRAY TESTS Previous Feed Test This test feeds blank pages through the paper path. Next Note: This test can run using any of the paper or envelope sizes supported by the printer. The pages are placed in the default output bin; however, the Feed Test menu lets you select the input source. From the Diagnostics menu, navigate to: Go Back INPUT TRAY TESTS >...
Page 230: Output Bin Tests
5062 OUTPUT BIN TESTS Previous Feed Test Note: If the “Configure Bins” printer setting is link rather than mailbox, the printer selects its own internal bin linking regardless of which output bin is selected for the feed test. Next This test verifies that media can be fed to a specific output bin. No information is printed on the media because the printhead is not turned on during this test.
Page 231: Diverter Test
5062 Previous Horizontal High Capacity Standard Sensor Transport Unit Output 5-bin Mailbox output bin (HTU) Stacker Media In Puncher Next Top Position Mailbox Empty Go Back This sensor toggles between empty and not empty. This sensor toggles between near fulland not near full. This sensor toggles between full and not full.
Page 232: Finisher Feed Test
5062 Finisher Feed Test Previous This test verifies that media can be fed from the default source to a finisher output bin. Any size paper that is supported can be used. The printer feeds a single blank sheet of media from the default source to a default finisher output bin.You can Next also specify which bin to test by using the Output Bin feed tests (see “Feed Test”...
Page 233: Base Sensor Test
5062 BASE SENSOR TEST Previous 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: Nearly Narrow Media Next Input–S1 Fuser Exit NarrowMedia Go Back K TMC Sensor (black) M TMC Sensor (magenta) C TMC Sensor (cyan)
Page 234: Disk Test/Clean
5062 Disk Test/Clean Previous Warning: This test destroys all data on the disk and should not be attempted on a good disk. This test may run approximately 1½ hours depending on the disk size. From the Diagnostics menu, navigate to: DEVICE TESTS >...
Page 235: Serial Number
5062 PAGE COUNTS Previous This menu lets you view the total page counts of the printer or the page counts broken down into color and mono pages printed. Unlike in previous printers, none of these values can be changed. Touch Back to return to the Diagnostics menu. Next Serial Number Go Back...
Page 236: Cal Ref Adj
5062 Cal Ref Adj Previous Warning: This setting should not be changed without specific instructions from the next level of support. Cal Ref Adj adjusts the printer’s toner density and alignment setting. Next Par 1 Strobe Adj Parallel Strobe Adjustment enables you to change the amount of time the strobe is sampled in order to Go Back determine if data is available on the parallel port.
Page 237: Print Log
5062 Print Log Previous The Print Log menu item prints a detailed report of each event in the log. The first page of the event log contains a Printer Information section similar to what is printed on a Menu Setting Page. Printed at the top of each page is the model name and serial number to assist in tracking each page of a report to a specific printer.
Page 238: Configuration Menu
5062 Previous Configuration Menu The Configuration Menu contains a set of menus, settings, and operations which are infrequently used by a user. Generally, the options made available in this menu are used to configure a printer for operation. Next Note: An asterisk (*) in the value list in the following menus indicates the default value. Entering the Configuration Menu Go Back Turn off the printer.
Page 239: Exiting The Configuration Menu
5062 Configuration Menu Previous Key Repeat Initial “Key Repeat Initial Delay” on page 3-30. Delay Key Repeat Rate “Key Repeat Rate” on page 3-30. Clear Custom Status “Clear Custom Status” on page 3-30. Next USB Speed “USB Speed” on page 3-30.
Page 240: Size Sensing
5062 SIZE SENSING Previous Automatic size sensing can be disabled or enabled in this menu. Only paper sources that support Auto Size Sensing are displayed. Select SIZE SENSING from the Configuration menu. Next Select a tray. Only those trays with size sensing appear. Select Auto to turn size sensing on for that tray, or select Off to disable size sensing.
Page 241: Auto Align Adj
5062 Auto Align Adj Previous The printer automatically runs a Toner Patch Sensing (TPS) diagnostic after certain key events. If necessary, the printer will automatically adjust the alignment. If Auto Align Adj is set to Off, then the diagnostic still runs, but the printer will not use the resulting data to Next automatically adjust alignment.
Page 242: Wipe Disk
5062 Wipe Disk Previous This setting performs a wipe of the printer hard disk, erasing all data. Warning: Wipe Disk deletes all data on the printer hard disk, including downloaded fonts, macros, and held jobs. Do not initiate a disk wipe if you have information on the printer that you want to save. Next •...
Page 243: Theory Of Operation
5062 Previous Theory of operation Paper path, transport components In order for an image to be printed, the paper or specialty media has to be moved from an input source (such as Next a tray) into the printer and eventually exit into an output source. The most important component in this process is this paper itself.
Page 244: Transport Components
5062 Transport components Previous The paper is fed from the tray into the printer by a pick roll and sent to two sets of feed rollers which time the paper to enter the Electrophotographic Process (EP Process) at just the right moment. The feed rollers push the paper to the transfer roll (ITU) where the image is transferred to the page.
Page 245: Print Engine Theory
5062 Print engine theory Previous Electrophotographic Process (EP Process) The method that all laser and LED printers use to print is called the electrophotographic process. These machines use differences in charge to manipulate and move toner from the print cartridge to the printed page. Next Even though the basic EP Process is the same for every laser and LED printer, the specifics for each printer are different.
Page 246: Step 1: Charge
5062 Step 1: Charge Previous During the charge step, voltage is sent from the HVPS to the charge roller beside each of the four photoconductors. In this printer, the charge roll is part of the photoconductor unit in the print cartridges. The charge roller puts a uniform negative charge over the entire surface of the photoconductor to prepare it for Next the laser beam.
Page 247: Step 2: Expose
5062 Step 2: Expose Previous During the expose step, the laser fires a focused beam of light at the surface of each photoconductor and writes an invisible image, called a latent image or electrostatic image, for each color. The laser beam only discharges the surface where the beam hits the photoconductor. This creates a difference Next in charge potential between the exposed area and the rest of the photoconductor surface.
Page 248: Step 3: Develop
5062 Step 3: Develop Previous Once the laser exposes the photoconductor, the HVPS sends charge to the developer roll. For each color, the print cartridge engages the photoconductor so it is in contact with the surface. Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser, the toner is attracted to areas of the photoconductor surface exposed by the laser.
Page 249: Step 4A: First Transfer
5062 Step 4a: First transfer Previous When the latent images are developed on each Photoconductor, the HVPS sends voltage to the 1st Transfer Rollers inside the ITU. The charge difference between the developed toner image on the Photoconductor surface and the 1st Transfer Next Roller causes the images to transfer to the surface of the ITU belt for each color.
Page 250: Step 4B: Second Transfer
5062 Step 4b: Second transfer Previous Once the four planes of color are transferred to the transfer belt from the photoconductors, the image is carried toward the transfer roll, which is also part of the ITU. Based on the speed of the transfer belt, the proper time to send the signal to pick the paper from an input source is determined.
Page 251: Step 5: Fuse
5062 Step 5: Fuse Previous Once the image has been fully transferred to the paper, the transfer roll helps move the paper into the fuser area. The fuser applies heat and pressure to the page to melt the toner particles and bond them permanently to the Next paper.
Page 252: Step 6: Clean/Erase
5062 Step 6: Clean/Erase Previous There are two main cleaning processes that take place during the EP Process. One process cleans the transfer belt, and the other cleans the photoconductors. Transfer Unit Clean Next Once the toner image on the transfer belt has been transferred to the page, the transfer belt rotates around and is cleaned by the cleaning blade (G).
Page 253: Printhead Verification
5062 Previous Printhead verification You can verify that the printhead is the failing FRU by following this procedure: Turn the printer off, and remove the power cord from the outlet. Remove all cords and cables from the Next printer before beginning. Place the printer on a corner of a work area so the front and back can be accessed.
Page 254 5062 Swing the shield open about an inch, and then slide the shield to the left to remove it. Previous Next Go Back Carefully unplug the printhead video cables (B) and the printhead motor cable (C) from the system board, and carefully connect the printhead video and motor cables from the new printhead to the system board.
Page 255: Repair Information
5062 4. Repair information Previous Warning: Read the following before handling electronic parts. Next Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent Go Back 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 256: Arrangement Of Removals In This Chapter
5062 Screws and fasteners Previous Screw and fastener part numbers appear with the graphic callouts. See “Screw and retainer identification table” on page 7-59 for descriptions and actual-size illustrations of the screws. Arrangement of removals in this chapter Next The removals in this chapter are arranged by area of the printer: Go Back “Base printer cover removals”...
Page 257: Base Printer Cover Removals
5062 Previous Base printer cover removals Front access door assembly removal “Top, right, and front covers” on page 7-3 for the part number. Next Remove the operator panel assembly. See “Operator panel (OP) assembly removal” on page 4-110. Remove the three screws (A) from the front access door pivot. Go Back A (88A0323) Repair information...
Page 258 5062 Use a flat-blade screwdriver to carefully pry up the front access door pivot, and lift the pivot enough to Previous remove the door. Next Go Back Service Manual...
Page 259: Left Access Door Assembly Removal
5062 Left access door assembly removal Previous “Left and rear covers” on page 7-5 for the part number. Open the left access door assembly. Next Go Back Remove the three screws (A) from the cable cover, and remove the cable cover. A (88A0323) Repair information...
Page 260 5062 Lift the locking tabs (B) on the connectors to disconnect the two cables. Previous Next Go Back Remove the cables from the cable retainers (C). Close the left access door. Service Manual...
Page 261 5062 Open the multipurpose feeder. Previous Slide the paper guide all the way to the left. Carefully use a flat-blade screwdriver to lift the multipurpose feeder inner cover, and remove. Note: Be careful not to scratch or mar the cover. Next Go Back Note: Using a flat-blade screwdriver, pry out the back pin (D) far enough to be able to grasp the ends.
Page 262 5062 Open the left access cover slightly, grasp one of the pins, and move the left access door back and forth Previous gently while pulling the pin out. This aligns the holes, so the pins come out easily. Next Go Back Remove the other pin (E) in the same manner.
Page 263 5062 Open the left access door all the way, and disconnect the rear piston by pulling apart the clamps (F) from Previous the tabs. Next Go Back Remove the E-clip (G) from the front piston. G (1126829) Repair information...
Page 264 5062 While holding the front piston, pull out the pin (H) to disconnect the piston from the printer. Previous Note: The piston is under pressure from the spring. Hold the piston firmly as you remove the post. Next Go Back Lift the door up slightly and out to remove it.
Page 265: Left Cover Removal
5062 Left cover removal Previous Lower left cover removal Next “Left and rear covers” on page 7-5 for the part numbers. Remove the rear cover. See “Rear cover removal” on page 4-20. Go Back Use a flat-blade screwdriver to disconnect the cable from the low-voltage power supply. Open the MPF door enough to remove the screw (A) from the lower left cover under it.
Page 266 5062 Open the left access door, and remove two screws (B) from the top and middle of the left cover. Previous Next Go Back B (88A0323) Open the standard media tray, and remove the screw (C) from the front of the printer. C (88A0323) 4-12 Service Manual...
Page 267 5062 Lift the top cover enough to free the top of the left cover. Previous Next Go Back Close the left access door, and use a flat-blade screwdriver to pop out the front of the lower left cover. 4-13 Repair information...
Page 268 5062 Use a flat-blade screwdriver to free the latches in the middle of the cover. Previous Next Go Back Open the left access door, and disconnect the rear piston by pulling apart the clamps (F) from the tabs. Slide the left cover over the piston arm to remove the left cover and lower left cover together. Note: If you are removing the left cover to access another part, then leave the left cover attached to the lower left cover.
Page 269 5062 Slide the lower left cover down to remove it from the left cover. Previous Next Go Back 4-15 Repair information...
Page 270: Lower Frame Cable Cover Removal
5062 Lower frame cable cover removal Previous “Front” on page 7-7 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-77. Remove the screw (A). Next Go Back A (88A0323) Slide the cover toward the rear of the printer, and lift to remove it. 4-16 Service Manual...
Page 271: Multipurpose Feeder (Mpf) Cover Removal
5062 Multipurpose feeder (MPF) cover removal Previous “Left and rear covers” on page 7-5 for the part number. Remove the left access door assembly. See “Left access door assembly removal” on page 4-5. Separate the MPF from the left access door assembly. Next Go Back 4-17...
Page 272: Op Panel Bezel Removal
5062 OP panel bezel removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the logo panel. See “Logo panel removal” on page 4-85. Use a flat-blade screwdriver to pry up the three tabs (A), and then remove the bezel. Next Note: Three bezels are in the FRU.
Page 273: Printhead Access Cover Removal
5062 Printhead access cover removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the rear upper cover. See “Rear upper cover removal” on page 4-22. Remove the top cap cover. See “Top cap cover removal” on page 4-29.
Page 274: Rear Cover Removal
5062 Rear cover removal Previous “Left and rear covers” on page 7-5 for the part number. Remove the rear upper cover. See “Rear upper cover removal” on page 4-22. Remove the system board shield. See “System board shield removal” on page 4-27.
Page 275 5062 Push in the indicated areas of the right side and left side covers, and pull out the rear cover tabs. Previous Next Go Back Note: On the right cover side, start with the top tab. On the left cover side, start with the bottom tab. Remove the rear cover.
Page 276: Rear Upper Cover Removal
5062 Rear upper cover removal Previous “Left and rear covers” on page 7-5 for the part number. Open the system board shield door, and remove the two screws (A) and the one screw (B). Next Go Back B (88A0212) A (88A0323) Pull toward the rear, and lift the corner off the rear upper cover post.
Page 277 5062 Separate the system board shield door from the rear upper cover. Previous Next Go Back 4-23 Repair information...
Page 278: Right Cover Removal
5062 Right cover removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-150. Remove the rear cover. See “Rear cover removal” on page 4-20.
Page 279 5062 Remove the screw (B). Previous Next Go Back B (88A0212) Remove the four screws (C). C (88A0323) 4-25 Repair information...
Page 280 5062 Pull the tabs (D) away from the pins, and then pull out and down on the rear of the right cover to remove it. Previous Next Go Back 4-26 Service Manual...
Page 281: System Board Shield Door Removal
5062 System board shield door removal Previous To remove the system board shield door, remove the rear upper cover. See “Rear upper cover removal” on page 4-22. System board shield removal Next “Left and rear covers” on page 7-5 for the part number. Go Back Open the system board shield door, and remove the two screws (A) on the system board shield.
Page 282 5062 Swing the shield open about an inch, and slide the shield to the left to remove the shield. Previous Next Go Back 4-28 Service Manual...
Page 283: Top Cap Cover Removal
5062 Top cap cover removal Previous “Top, right, and front covers” on page 7-3 for the part number. Squeeze the cover and rock it back to disengage the latches. Next Go Back With the cover tilted back, and pull up to remove it. 4-29 Repair information...
Page 284: Top Cover Removal
5062 Top cover removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the printhead access cover. See “Printhead access cover removal” on page 4-19. Remove the rear cover. See “Rear cover removal” on page 4-20.
Page 285 5062 Open the left access door, and remove the screw (C). Previous Next Go Back C (88A0323) On the top, remove two metal screws (D). D (88A0212) 4-31 Repair information...
Page 286 5062 On the right side, remove two screws (E) and one screw (F). Previous Next Go Back F (88A0212) E (88A0323) Pull the tabs away from the pins, and lift the top cover. 4-32 Service Manual...
Page 287 5062 Clip the cable tie (G), and disconnect the cable (H) from the bin-full sensor. Previous Next Go Back Remove the top cover. Note: If you are removing the top cover to replace the cover or the cables tied to it, then clip the four cable ties and remove the operator panel and sensor cables.
Page 288: Waste Toner Left Cover Removal
5062 Waste toner left cover removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-150. Remove the logo panel. See “Logo panel removal” on page 4-85.
Page 289: Waste Toner Sensor Cover Removal
5062 Pinch the release tab (D) and disconnect the beacon cable. Previous Next Go Back Waste toner sensor cover removal Remove the waste toner container. See “Waste toner container removal” on page 4-158. Remove the screw (A) to remove the cover. A (88A0323) 4-35 Repair information...
Page 290: Base Printer Removals
5062 Previous Base printer removals ACM bias spring removal “Left” on page 7-11 for the part number. Next Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on page 4-120. Go Back Remove the screw (A) to remove the spring. A (88A0323) 4-36 Service Manual...
Page 291: Bin-Full Flag Removal
5062 Bin-full flag removal Previous “Top, right, and front covers” on page 7-3 for the part number. Pull the flag forward out of the clips. Next Go Back Rotate the flag, and pull to remove it. 4-37 Repair information...
Page 292: Bin-Full Sensor Removal
5062 Bin-full sensor removal Previous “Sensors parts packet, including” on page 7-7 for the part number. Remove the top cover. See “Top cover removal” on page 4-30. Press in the tabs to remove the sensor from under the top cover. Next Go Back 4-38...
Page 293: Cartridge Blower Assembly Removal
5062 Cartridge blower assembly removal Previous “Front” on page 7-7 for the part number. Remove the right cover. See “Right cover removal” on page 4-24. Remove the front access door. See “Front access door assembly removal” on page 4-3. Next Remove the screw (A) in the top cover.
Page 294 5062 Lift the blower assembly slightly up and to the left to free the bottom. Previous Next Go Back Flex the top cover up, and rotate the blower assembly to the right to free the hook at the top. 4-40 Service Manual...
Page 295 5062 Press the release tab (B) to disconnect the cable from the assembly. Previous Next Go Back 4-41 Repair information...
Page 296: Cartridge Contact Block Assembly Removal
5062 Cartridge contact block assembly removal Previous “Front (continued)” on page 7-9 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-158. Remove the print cartridges. Next Remove the three screws (A) from the cartridge contact block assembly. Go Back A (88A0212) Remove the assembly.
Page 297 5062 Installation note: Be sure to line up the notches in the HVPS board with the ridges on the cartridge contact block Previous assembly. Next Go Back 4-43 Repair information...
Page 298: Cartridge Memory Block Removal
5062 Cartridge memory block removal Previous “Front (continued)” on page 7-9 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-77. Remove the system board shield. See “System board shield removal” on page 4-27. Next Disconnect the cable (A, B, C, or D) for the memory block you want to remove.
Page 299 5062 From the memory block you are removing, press the lever (E) to access the sensor, push the right side of Previous the sensor to remove it, and then disconnect the cable from the sensor. Next Go Back Remove the two screws (F), and pull to remove the memory block. As you pull the cable through, be sure to leave the string in the path from the memory block to the system board.
Page 300: Cartridge Metering Cable Removal
5062 Cartridge metering cable removal Previous “M+K cartridge metering cable” on page 7-55 “C+Y cartridge metering cable” on page 7-55 for the part number. Remove the system board shield. See “System board shield removal” on page 4-27. Next Remove the ITU assembly. See “ITU assembly removal”...
Page 301: Cartridge Rail Removal
5062 Installation notes: Previous Connect the cable to the system board. Tie the correct strings to the sensor ends of the cable. From the inside of the printer, pull the strings to feed the sensor cables through to the memory blocks.
Page 302 5062 Installation notes: Previous Insert the tab on the rail into the slot (B) in the back, and then lift and slide the rail into the notches (C) on the top. Next Go Back Apply the correct color label to new rail. 4-48 Service Manual...
Page 303: Cpu Cooling Fan Removal
5062 CPU cooling fan removal Previous “Rear” on page 7-15 for the part number. Open the system board shield door, and remove the two screws (A) on the system board shield. Next Go Back A (27S2839) 4-49 Repair information...
Page 304 5062 Open the shielddoor. Previous Next Go Back Disconnect the cable (A) from the system board, and remove the four screws (B). Remove the fan from the heatsink. 4-50 Service Manual...
Page 305: Datum Bell Crank Removal
5062 Datum bell crank removal Previous “Left” on page 7-11 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-77. Remove the fuser. See “Fuser assembly removal” on page 4-63. Next Front crank Remove the waste toner left cover. See “Waste toner left cover removal”...
Page 306 5062 Rear crank Previous Remove the left cover. See “Left cover removal” on page 4-11. Remove two screws (B) and the four screws (C) to remove the rear fuser guide. Next Go Back C (88A0212) B (10J1046) Remove the E-clip (D). Unhook the spring (E), and pull to remove the bell crank.
Page 307: Duplex Assembly Removal
5062 Duplex assembly removal Previous “Left and rear covers” on page 7-5 for the part number. Remove the left access door assembly. See “Left access door assembly removal” on page 4-5. Remove the screw (A) that secures the duplex assembly to the left access cover. Next Go Back Lift the duplex assembly from the left access door.
Page 308 5062 Installation notes: Previous If you are replacing the duplex drive belt, then carefully check the routing as you install the new belt. Next Go Back Align the edge (A) of the duplex assembly under the back edge of the left access door assembly. 4-54 Service Manual...
Page 309 5062 Align the top edge of the duplex assembly with the post, and then replace the screw. Previous Next Go Back 4-55 Repair information...
Page 310: Ep Drive Assembly Removal
5062 EP drive assembly removal Previous “Rear” on page 7-15 for the part number. Remove the system board cage with board. See “System board cage with board removal” on page 4-155. Next Disconnect the cable (A) from the fuser motor. Go Back Note: If you are replacing the cables, remove the toroids from the old cables and use cable ties to attach the toroids to the new cables.
Page 311 5062 Push the assembly up and pull to remove it. Previous Next Go Back 4-57 Repair information...
Page 312: Esd Bracket Removal
5062 ESD bracket removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the operator panel assembly. See “Operator panel (OP) assembly removal” on page 4-110. Remove the screw (A) securing the ESD bracket to the top cover. Next Go Back A (88A0232)
Page 313 5062 Push on the wall of the top cover, and rotate the front of the ESD bracket upward. Previous Next Go Back Slide the ESD bracket off the bin full bracket. 4-59 Repair information...
Page 314: Exit Cooling Duct Removal
5062 Exit cooling duct removal Previous “Rear” on page 7-15 for the part number. Remove the system board cage with board. See “System board cage with board removal” on page 4-155. Next Remove the main fan. See “Main fan removal” on page 4-92.
Page 315: Front Access Door Beacon Removal
5062 Front access door beacon removal Previous “Waste toner left cover with beacon” on page 7-3 for the part number. Remove the waste toner left cover. See “Waste toner left cover removal” on page 4-34. Remove the two screws (A) from the beacon cover, and then lift off the cover. Next Carefully pull the cable through the holes (B) to remove it.
Page 316 5062 • Be sure the beacon LED extends through the opening in the waste toner left cover before attaching the Previous beacon cover screws. Next Go Back 4-62 Service Manual...
Page 317: Fuser Assembly Removal
5062 Fuser assembly removal Previous CAUTION Be sure the fuser assembly has cooled before you remove it. Next “Left” on page 7-11 for the part numbers. Go Back Open the left access door assembly. Pull down the two fuser latches (A). 4-63 Repair information...
Page 318 5062 Pull to remove the fuser assembly. Previous Next Go Back Installation note: After inserting the fuser assembly, push up the handles and then push up the tab under the right handle. 4-64 Service Manual...
Page 319: Fuser Drive Assembly Removal
5062 Fuser drive assembly removal Previous “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-20. Remove the fuser assembly. See “Fuser assembly removal” on page 4-63. Next Remove the E-clip (A) and the washer under it from the fuser gears, and then slide the gears off the post. Go Back A (1126829) 4-65...
Page 320 5062 Disconnect the cable (B) from the fuser motor. Previous Next Go Back Remove the three screws (C). C (88A0212) Remove the fuser drive assembly. Installation note: Be sure to apply grease to the gear and post using the instruction sheet and two kinds of grease that came with the fuser drive assembly.
Page 321: Fuser System Card And Lvps Cable Removal
5062 Fuser system card and LVPS cable removal Previous “Left (continued)” on page 7-13 for the part number. Remove the ITU. See “ITU assembly removal” on page 4-77. Remove the fuser. See “Fuser assembly removal” on page 4-63. Next Remove the waste toner left cover. See “Waste toner left cover removal”...
Page 322 5062 Remove two screws (C), and then remove the cable end and support guide from the frame. Previous Next Go Back Note: If you are just testing the cable as part of a service check, then stop here. Remove the OP panel. See “Operator panel (OP) assembly removal”...
Page 323 5062 Disconnect the fuser system card cable (D) from the system board. Previous Next Go Back Push in the tab (E) to disconnect the cable from the LVPS, and remove the cable. 4-69 Repair information...
Page 324: Fuser Thermistor Removal
5062 Fuser thermistor removal Previous “Fuser thermal guide assembly” on page 7-58 for the part number. Remove the fuser. See “Fuser assembly removal” on page 4-63. Disconnect the cable (A). Next Remove four screws (B) to remove the thermistor. Go Back B (88A0212) 4-70 Service Manual...
Page 325: High-Voltage Power Supply (Hvps) Board Removal
5062 High-voltage power supply (HVPS) board removal Previous “Front” on page 7-7 for the part number. Remove the ITU block assembly. See “ITU block assembly removal” on page 4-80. Remove the rear cover. See “Rear cover removal” on page 4-20. Next Remove the two screws (A) to remove the connector shield from the system board.
Page 326 5062 Remove three screws (C), and then pull out the cartridge contact block assembly. Previous Next Go Back C (88A0212) Remove the screw (D) from the center of the plate over the HVPS. D (88A0121) Pull the HVPS board forward. 4-72 Service Manual...
Page 327 5062 Disconnect the cable from the HVPS board. Previous Next Go Back Pull the board all the way out of the printer. Note: If you are replacing only the HVPS cable, then stop here. Remove the screw (E) and three screws (F) from the bottom of the board to remove the metal post (G) and the plastic contact bracket (H).
Page 328 5062 Installation notes: Previous • Be sure the HVPS cable sits in the groove under the HVPS board. Next Go Back • Be sure the ITU block assembly sits flat before attaching the three screws to reinstall it. 4-74 Service Manual...
Page 329: Host Usb Cable Removal
5062 Host USB cable removal Previous “Front host USB cable” on page 7-57 for the part number. Remove the operator panel assembly. See “Operator panel (OP) assembly removal” on page 4-110. Remove two screws (A) from the USB cable. Next Go Back A (88A0323) Disconnect the cable from the UICC card to remove it.
Page 330 5062 Disconnect the cable (B) from the sensor, and remove three screws (C). Previous Next Go Back C (88A0323) A (88A0323) Disconnect the cable from the system board (JCVR1). Route the cable through the printer to remove the assembly. Clip and remove cable ties as needed. Note: Observe the cable routing for reinstallation.
Page 331: Itu Assembly Removal
5062 ITU assembly removal Previous “Left (continued)” on page 7-13 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-158. Remove the print cartridges. Next Open the left access door assembly all the way. Grasp the ITU handle (A), and carefully slide the ITU assembly from the printer.
Page 332: Itu Autoconnect Removal
5062 ITU autoconnect removal Previous “Left” on page 7-11 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-20. Remove the right cover. See “Right cover removal” on page 4-24. Next Remove the ITU assembly. See “ITU assembly removal”...
Page 333 5062 Clip the cable tie and remove the toroid. Previous Note: Be sure to replace the toroid during reinstallation. Next Go Back From the right side and back of the printer, remove four screws (C). 4-79 Repair information...
Page 334: Itu Block Assembly Removal
5062 Pull to remove the autoconnect. Previous Next Go Back ITU block assembly removal “Front” on page 7-7 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-77. Remove the three screws (A) from the ITU block assembly. A (88A0323) 4-80 Service Manual...
Page 335 5062 Pull up to remove the assembly. Previous Next Go Back Installation note: Be sure the ITU block assembly sits flat before attaching the three screws to reinstall it. 4-81 Repair information...
Page 336: Left Access Door Piston Removal
5062 Left access door piston removal Previous “Left (continued)” on page 7-13 for the part number. Open the left access door assembly. Front piston Next Remove the E-clip (G) from the front piston. Go Back G (1126829) 4-82 Service Manual...
Page 337 5062 Remove the post (H) from the piston where it attaches to the printer. Previous Note: The piston is under pressure from the spring. Hold the piston firmly as you remove the post. Next Go Back Remove the E-clip (I) and post (J) from the other end to remove the piston. I (1126830) 4-83 Repair information...
Page 338 5062 Rear piston Previous Disconnect the piston by pulling apart the clamps (F) from the tabs. Next Go Back Remove the E-clip (G) and post (H) from the piston where it attaches to the printer. G (1126830) 4-84 Service Manual...
Page 339: Logo Panel Removal
5062 Remove the E-clip (I) and post (J) from the other end to remove the piston. Previous Next Go Back I (1126827) Logo panel removal “Top, right, and front covers” on page 7-3 for the part number. Open the front access door. Remove the three screws (A).
Page 340: Low-Voltage Power Supply (Lvps) Removal
5062 Rotate the panel up and pull to remove it. Previous Next Go Back Low-voltage power supply (LVPS) removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-20. Push the release (A) to disconnect the power cable (B) and the fuser cable (C). 4-86 Service Manual...
Page 341 5062 Remove two screws (D) to remove the connector shield from the system board. Previous Next Go Back D(88A0232) Disconnect the LVPS cables (E) from the system board. 4-87 Repair information...
Page 342 5062 Disconnect the thermistor cable from the system board. Previous Next Go Back Remove the three screws (F) and the two screws (G). G (88A0323) F (88A0212) Remove the LVPS. 4-88 Service Manual...
Page 343: Lvps Exit Duct Removal
5062 Installation note: If you are replacing the LVPS FRU, then clip the cable tie to remove the thermistor from the Previous old LVPS, and then attach the thermistor to the replacement LVPS with a new cable tie (10B1648). Next Go Back LVPS exit duct removal “Rear”...
Page 344: Lvps Fan Removal
5062 Remove two screws (B). Previous Next Go Back B (88A0323) LVPS fan removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-20. Disconnect the fan cable (A) from the system board. 4-90 Service Manual...
Page 345 5062 Push in to open the cable clip (B) behind the system board shield. Previous Next Go Back Feed the cable through the slot in the system board cage and the clip. Remove the two screws (C). C (10B1580) 4-91 Repair information...
Page 346: Main Fan Removal
5062 Feed the cable through the slot in the fan housing (D) as you remove the fan. Previous Next Go Back Main fan removal “Rear” on page 7-15 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-20.
Page 347 5062 Remove the screws (B). Previous Next Go Back B (10B1580) Feed the cable through the slot in the system board cage, and remove the fan. 4-93 Repair information...
Page 348: Media Tray Rail Removal
5062 Media tray rail removal Previous “Front (continued)” on page 7-9 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-150. Remove the waste toner container. See “Waste toner container removal” on page 4-158.
Page 349 5062 Lift the rail out of the printer. Previous Next Go Back Right rail Remove the screw (C) to release the tension on the right side cover. C (88A0323) 4-95 Repair information...
Page 350 5062 Shut the front access door. Previous Gently lay the printer on its back. Remove the screw (D) on the bottom of the printer, and the screw (E) and screw (F) on the front of the printer. Next Go Back E (88A0323) F (88A0212) D (10J1046)
Page 351 5062 Pull aside the right side cover. Previous Next Go Back Pull up and to the left to remove the rail from the printer. 4-97 Repair information...
Page 352: Mpf Breakaway Assemblies Removal
5062 Installation note: Be sure to align the rails with the slots in the back of the printer to slide them into place, and Previous then fit them over the pins on the front of the printer. Next Go Back MPF breakaway assemblies removal “Left”...
Page 353 5062 Remove seven screws (A) and two screws (B), and remove the bottom plate. Previous Next Go Back B (10J1046) B (10J1046) A (88A0323) Note: If you are replacing the input option cable, then push it up through the frame, and then stand the printer back up to remove the cable.
Page 354 5062 Front breakaway assembly Previous Remove two screws (E). Next Go Back E (88A0323) Using a flat-blade screwdriver, pry out the top, and then pull to remove the assembly. 4-100 Service Manual...
Page 355: Mpf Paper Pick Assembly Removal (Including The Mpf Ratchet Collar And Mpf Drive Pulley)
5062 MPF paper pick assembly removal (including the MPF ratchet collar and MPF drive Previous pulley) “Left and rear covers” on page 7-5 for the part numbers. Remove the left cover. See “Left cover removal” on page 4-11. Next Remove the waste toner left cover. See “Waste toner left cover removal”...
Page 356 5062 Remove the ratchet collar (C), and remove the bushing under it. Previous Next Go Back From the front of the printer, rotate the front bushing so the tabs line up with the slots in the frame. 4-102 Service Manual...
Page 357 5062 Slide the rod toward the front of the printer to free the rear side. Previous Next Go Back Installation note: Be sure to replace the thrust washer in the ratchet collar before installing the MPF drive pulley. 4-103 Repair information...
Page 358: Mpf Pick Rolls And Special Wear Strip Removal
5062 MPF pick rolls and special wear strip removal Previous “Left and rear covers” on page 7-5 for the part number. Always replace both pick rolls and the special wear strip at the same time. Open the left access door. Next Remove the screw (A) in the top cover.Remove the rubber rolls (A) from the hubs.
Page 359 5062 Installation notes: Previous • Slide the edge of a pick tire between the rear hub extension and the printer frame, and then slide the roll down to the hub. Next Go Back • Be sure the flaps on the pick rolls slant away from the direction the rolls turn. 4-105 Repair information...
Page 360: Mpf Drive Assembly Removal
5062 • Verify the rolls turn freely. Previous Next Go Back MPF drive assembly removal “Rear” on page 7-15 for the part number. Remove the LVPS exit duct. See “LVPS exit duct removal” on page 4-89. Slide the belt off the MPF redrive pulley. 4-106 Service Manual...
Page 361 5062 Remove four screws (A), and remove the assembly. Previous Next Go Back Remove the E-clip (B) and the gear (C) to remove the belt from the assembly. 4-107 Repair information...
Page 362: Mpf Sensor Plate Assembly Removal
5062 Installation note: When reinstalling the belt, be sure the belt sits on the teeth at the base of the gear. Previous Next Go Back MPF sensor plate assembly removal “Left and rear covers” on page 7-5 for the part number. Open the left access door assembly.
Page 363: Mpf Wear Strips Removal
5062 Disconnect the sensor cable (A), and remove the assembly. Previous Next Go Back MPF wear strips removal “Left and rear covers” on page 7-5 for the part numbers. Open the left access door assembly. Insert a flat-blade screwdriver behind the top of the strip, and then twist the screwdriver to pop out the strip. 4-109 Repair information...
Page 364: Operator Panel (Op) Assembly Removal
5062 Operator panel (OP) assembly removal Previous Remove the top cap cover. See “Top cap cover removal” on page 4-29. Note: If you have any output options installed, then the top cap cover is already removed. Remove the output options and HTU redrive unit instead. Next Remove the OP panel bezel.
Page 365 5062 Disconnect the cables (B) going from the UICC card to the printer. Previous Next Go Back Remove the operator panel assembly. 4-111 Repair information...
Page 366: Op Panel Button Removal
5062 OP panel button removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the OP panel UICC card. See “OP panel UICC card removal” on page 4-114. Remove the button you want by squeezing in the latches (A) and pushing the button through the front of Next the operator panel.
Page 367: Op Panel Display Removal
5062 OP panel display removal Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the OP panel UICC card. See “OP panel UICC card removal” on page 4-114. Remove the four screws (A) and lift off the holder. Next Go Back A (88A0323)
Page 368: Op Panel Uicc Card Removal
5062 Remove the ESD ground (B), and remove the display. Previous Next Go Back Installation note: Be sure to secure the ESD ground on top of the UICC card. OP panel UICC card removal “Top, right, and front covers” on page 7-3 for the part number.
Page 369 5062 Pull up the levers (A) to disconnect the display cable, and then disconnect all other cables from the UICC Previous card. Remove the five screws (B), and remove the card. Next Go Back B (88A0323) Installation notes: Put the new UICC card in place, and attach the ribbon cable. Replace the five screws to secure the card.
Page 370: Pad Removal
5062 Pad removal Previous “Left and rear covers” on page 7-5 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-150. Remove the waste toner container. See “Waste toner container removal” on page 4-158.
Page 371: Paper Auto-Size Sensor Removal
5062 Paper auto-size sensor removal Previous “Front” on page 7-7 for the part number. Remove the standard media tray. See “Standard media tray removal” on page 4-150. Push down on the sensor to remove it from the rear frame, and then disconnect the cable (A). Next Go Back Paper path redrive assembly with sensors removal...
Page 372 5062 Disconnect the sensor cables (A). Previous Next Go Back Clip the cable tie, and route the cables through the frame. 4-118 Service Manual...
Page 373 5062 Remove six screws (B), three from the rear and three from the front. Previous Next Go Back B B (88A0323) Insert a flat-blade screwdriver angled toward the top of the front side of the assembly, and deflect the front plate enough to drop down the front end of the assembly.
Page 374: Paper Pick Mechanism Assembly Removal
5062 Installation note: Be sure the sensor cables are routed as shown before you reinstall the assembly. Previous Next Go Back Paper pick mechanism assembly removal “Front (continued)” on page 7-9 for the part number. Remove the standard media tray. See “Standard media tray removal”...
Page 375 5062 Lower the pick arm all the way. Previous Next Go Back Rotate the release lever (B), pull it toward you, and then lower the assembly to remove it from the printer. Installation note: See “Pick arm stuck down service check” on page 2-164 to out the pick arm back to its original position.
Page 376: Pick Rolls Removal
5062 Pick rolls removal Previous “Front (continued)” on page 7-9 for the part number. Note: Replace both rolls at the same time. Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on Next page 4-120. Remove the screws (A) from both sides to release the pick roll hubs. Go Back A (88A0412) Remove the pick rolls.
Page 377: Printhead Removal, Installation, And Alignment
5062 Printhead removal, installation, and alignment Previous “Top, right, and front covers” on page 7-3 for the part number. Remove the printhead access cover. See “Printhead access cover removal” on page 4-19. Remove the system board shield. See “System board shield removal” on page 4-27.
Page 378 5062 Remove the six screws (B) from the brackets, and remove the brackets. Previous Next Go Back B (10J3568) Tilt the printhead forward, and lift to remove it. 4-124 Service Manual...
Page 379: Installing And Coarse Aligning The Printhead
5062 Installing and coarse aligning the printhead Previous Place the printhead into the printer angled forward, sliding the adjustment screws into the slots in the printer frame. Next Go Back Lower the back of the printhead until the post on the back right corner drops into the hole in the printer frame.
Page 380 5062 Route the three printhead cables (A) through the frame, and then connect them to the system board. Previous Warning: Be careful reconnecting the printhead ribbon cables. Flat ribbon cables can easily be damaged and should be connected gently by hand. Next Go Back Slide the left side of the printhead toward the back of the printer until the bottom of the coarse alignment...
Page 381 5062 Attach the three mounting brackets loosely to the printhead. Previous Note: Do not tighten the six screws in the mounting brackets yet. The printhead needs to be able to move as you align it. Align the printhead to the printer frame until the gaps between the printhead and the four slots in the frame are as equal as possible.
Page 382 5062 Attach the front bracket, and tighten the screws (E). Previous Next Go Back Reprint the alignment page and adjust the screw if necessary. 4-128 Service Manual...
Page 383: Aligning The Printhead
5062 Aligning the printhead Previous There is one printhead that houses the four color planes. The black plane is aligned to the printer, and the color planes are aligned to black. After you install the printhead and adjust the course alignment with the alignment screws, use the Diagnostic menu to fine tune the alignment.
Page 384: Registration (Black)
5062 Registration (black) Previous Top Margin From the Diagnostic menu, navigate to: REGISTRATION > Quick Test Next An alignment test page prints. Go Back Select Top Margin. Adjust the values to move the top alignment marks to the top edge of the page. •...
Page 385: Color Alignment (Cyan, Yellow, And Magenta)
5062 Color alignment (cyan, yellow, and magenta) Previous Open the front access door, and remove the cyan and magenta print cartridges. Locate the “Color skew adjustment tool” page that came with the printhead instructions. To use the skew tool, punch a screwdriver through the center of the wheel. Using a mark on the screwdriver handle as a point of reference, turn the paper until 0 lines up with your mark.
Page 386 5062 Holding the skew wheel with the 0 at the mark on your screwdriver, place the screwdriver in the yellow Previous adjustment screw (E) next to the yellow cartridge, and then turn the screwdriver to the number indicated on the alignment page—clockwise for a positive number, counterclockwise for a negative number. Next Go Back Replace all the cartridges, and then reprint the test page and continue adjusting the screw until you are...
Page 387 5062 From the Yellow menu, navigate to: Previous Linearity > Quick Test A test page similar to the following prints: Next Go Back If the Linearity alignment is correct, the gray stripe near the center of each color on the test page should be within the 12 to -12 range.
Page 388: Redrive Gears Removal
5062 Redrive gears removal Previous “Left” on page 7-11 for the part number. Remove the top cover. See “Top cover removal” on page 4-30. Remove the E-clip (A) and the washer behind it, and then remove the gears. Next Note: You might need to use a flat-blade screwdriver to carefully pry the gears from the posts. Go Back 4-134 Service Manual...
Page 389: Redrive Motor Removal
5062 Redrive motor removal Previous “Left” on page 7-11 for the part number. Remove the top cover. See “Top cover removal” on page 4-30. Slide off the cap (A). Next Go Back 4-135 Repair information...
Page 390 5062 Disconnect the cable (B) from the motor. Previous Next Go Back Remove the two screws (C) to remove the motor. C (88A0212) 4-136 Service Manual...
Page 391: Sensor (D1, D2, And Fuser Bubble) Removal
5062 Sensor (D1, D2, and fuser bubble) removal Previous Open the left access door. Remove two screws (A) from the duplex unit, and remove the rail cover. Next Go Back Pull out the sensor assembly, and rotate it up. Slide out the sensor you are replacing: fuser bubble (A), D1 (B), D2 (C). 4-137 Repair information...
Page 392: Sensor (Input, S1, Narrow Media, Near Narrow Media) Removal
5062 Disconnect the cable to remove the sensor. Previous Installation note: Place the plastic clip in the notch in the duplex unit before you reattach the rail cover. Next Go Back Sensor (input, S1, narrow media, near narrow media) removal “Left”...
Page 393: Speaker Removal
5062 Remove the sensor retainer (E), and then press the tabs to release the sensor. Previous Next Go Back Disconnect the sensor cable to remove the sensor. Installation note: Reinstall a sensor retainer after you attach the new sensor. Speaker removal “Top, right, and front covers”...
Page 394: Staging Deflector Assembly Removal
5062 Staging deflector assembly removal Previous “Left” on page 7-11 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-77. Push the top of the deflector down and rotate it back to release the upper hooks. Next Go Back Disconnect the cables (A) from the four sensors.
Page 395 5062 Installation notes: Previous • Be sure the cables are routed through the cable hooks (B) before you snap the assembly into place. Use the cable lengths as a guide to make sure you connect the correct cable to each sensor. Next Go Back •...
Page 396: Staging Paper Path Reference Edge Assembly Removal
5062 Staging paper path reference edge assembly removal Previous “Front” on page 7-7 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-20. Remove the left cover. See “Left cover removal” on page 4-11. Next Remove the fuser.
Page 397 5062 Set the deflector assembly out of the way as far as the sensor cables will allow. Previous Next Go Back Remove the screw (A) to remove the ground cable. 4-143 Repair information...
Page 398 5062 Remove two screws (C) from the ITU DS roller plate, and then remove the plate. Previous Next Go Back Remove two screws (D). 4-144 Service Manual...
Page 399 5062 Lift the bottom of the staging assembly and then rock it back to free it from the frame. Previous Next Go Back Disconnect the two cables from the motors to remove the assembly. Installation notes: • Be sure the duplex motor cable is not pinched or bound by the reference edge assembly. 4-145 Repair information...
Page 400 5062 • Place the slot in the ITU DS roller plate over the ridge on the frame, and then swing the plate into place to Previous reattach the two screws. Next Go Back • Check the alignment of the reference edge. See “Aligning the staging paper path reference edge”...
Page 401: Staging Paper Path Reference Edge Adjustment
5062 Staging paper path reference edge adjustment Previous After installing a new staging paper path reference edge assembly, use the following instructions to make sure it is properly aligned. Aligning the staging paper path reference edge Next Verify that the media is square. Do the following steps. Remove two consecutive pieces of paper from the ream.
Page 402 5062 Tap the two pages on a flat surface until the bottom edge is aligned. Previous Next Go Back Look closely at the top edge of the media to see if the sheets are aligned. Square Media: Top and sides are perfectly aligned The two pages do not align perfectly at the top or sides.
Page 403 5062 • For Macintosh users, select the paper source from the Print dialog and pop-up menus. Previous POR the printer, and enter Diagnostics mode: press and hold 3 and 6, turn on the printer, and release the buttons when the splash screen appears. From the Diagnostics menu, navigate to: REGISTRATION >...
Page 404: Standard Media Tray Removal
5062 Standard media tray removal Previous “Top, right, and front covers” on page 7-3 for the part number. Pull the tray out and lift slightly. The tray will lift out of the slides (A), and the slides will retract. Next Go Back 4-150 Service Manual...
Page 405: System Board Removal
5062 System board removal Previous “Rear” on page 7-15 for the part number. Warning: The following components contain mirrored NVRAM. When replacing any one of the following components, replace only one component at a time: Next • System board • UICC card Replace the required component, and then perform a POR before replacing a second component listed above.
Page 406 5062 Disconnect all cables from the system board. Previous Note: Some cables have special connectors that require you to press in tabs to disconnect the cables. Next Go Back Note: The cables may or may not include a pigtail connector (B). Remove any options from the system board.
Page 407 5062 Remove the nine screws (D), and then remove the system board by sliding it to the left so the Ethernet port Previous (E) clears the shield. Next Go Back D (88A0232) 4-153 Repair information...
Page 408 5062 Installation notes: Previous Install the new system board, and be sure all cables are securely connected. Be sure to reinstall any toroids you had to remove. Note: Some connectors have the same number of pins, so be sure each cable is connected to the correct connector.
Page 409: System Board Cage With Board Removal
5062 System board cage with board removal Previous Remove the LVPS. See “Low-voltage power supply (LVPS) removal” on page 4-86. Remove two screws (A) to remove the connector shield from the system board. Next Go Back A (88A0232) Disconnect all cables from the system board and feed them through the slots in the system board cage. Note: Some cables have special connectors that require you to press in tabs to disconnect the cables.
Page 410 5062 Remove the screw (C). Previous Next Go Back C (88A0212) Tilt the cage forward and slide it up to remove it. 4-156 Service Manual...
Page 411 5062 Installation notes: Previous • Be sure to reinstall any toroids you had to remove. • Some connectors have the same number of pins, so be sure each cable is connected to the correct connector. For diagrams and tables showing where each cable connects, see “Locations”...
Page 412: Waste Toner Container Removal
5062 Waste toner container removal Previous Open the front access door. Open the standard media tray. Flip the green handles forward and pull out the waste toner container. Next Go Back Waste toner gears removal “Rear” on page 7-15 for the part number. Remove the EP drive.
Page 413: Waste Toner Sensor Removal
5062 Waste toner sensor removal Previous “Front” on page 7-7 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-158. Remove the screw (A), and remove the waste toner sensor cover. Next Go Back A (88A0323) From the left side of the printer, push in the clips, and then pull the sensor out from the front.
Page 414: Waste Toner Cable Removal
5062 Waste toner cable removal Previous “Waste toner cable” on page 7-58 for the part number. Remove the waste toner sensor cover. See “Waste toner sensor cover removal” on page 4-35. Remove the waste toner left cover. See “Waste toner left cover removal” on page 4-34.
Page 415: Waste Toner Full Cable Removal
5062 Remove the screw (A) to disconnect the cable from the beacon, and then disconnect the cable from the Previous two sensors (B). Next Go Back A (88A0313) Clip any cable ties holding the cable, and then pull the cable through the frame to remove it. Waste toner full cable removal “Waste toner full cable”...
Page 416: Waste Toner Full Sensor Removal
5062 Disconnect the cable from the sensor, and pull the cable through the frame. Previous Next Go Back Waste toner full sensor removal “Front” on page 7-7 for the part number. Remove the waste toner container. See “Waste toner container removal” on page 4-158.
Page 417: Waste Toner Tray Bracket Removal
5062 Waste toner tray bracket removal Previous “Front” on page 7-7 for the part number. Remove the lower frame cable cover. See “Lower frame cable cover removal” on page 4-16. Disconnect the cable. Next Go Back Using a short screwdriver, remove five screws (D), four from the bottom of the tray and one from the front. 4-163 Repair information...
Page 418 5062 Pull the right frame back to free the side of the tray, and then pull the tray forward to remove it. Previous Next Go Back 4-164 Service Manual...
Page 419: Input Option Removals
5062 Previous Input option removals 550-sheet tray Next Go Back Note: Carefully remove the 550-sheet tray option from the base printer before proceeding. 4-165 Repair information...
Page 420: 550-Sheet Drawer Assembly Removal
5062 550-sheet drawer assembly removal Previous “Optional 550-sheet tray” on page 7-17 for the part number. Remove the 550-sheet media tray assembly from the 550-sheet drawer assembly. The 550-sheet drawer assembly remains. Next Go Back 550-sheet media tray assembly removal See“Optional 550-sheet tray”...
Page 421: 550-Sheet Tray Controller Card Assembly Removal
5062 Slide the 550-sheet media tray assembly out of the drawer. Previous Next Go Back 550-sheet tray controller card assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-166.
Page 422 5062 Remove the 550-sheet tray controller card assembly from the shield. Previous Next Go Back 4-168 Service Manual...
Page 423: 550-Sheet Tray Deflector Removal
5062 550-sheet tray deflector removal Previous Remove the top metal cover. See “550-sheet tray top metal cover removal” on page 4-183. Disconnect the pass thru sensor connector (A) from the pass thru sensor. Remove the pass thru sensor cable. Remove the screw (B) securing the deflector to the drawer. Next Go Back Remove the 550-sheet tray deflector.
Page 424: 550-Sheet Tray Drive Assembly Removal
5062 Installation note: Previous Be sure that the tabs are inserted in their corresponding hole. Next Go Back 550-sheet tray drive assembly removal Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-166. Remove the top metal cover. See “550-sheet tray top metal cover removal”...
Page 425 5062 Release the cord with a prying tool. Previous Next Go Back Remove the six screws (A) and one screw (B) securing the drive assembly to the drawer. B (88A0001) A (88A0323) Open the jam clearance cover. Lift the left side of the drive assembly to access the controller card assembly. 4-171 Repair information...
Page 426 5062 Disconnect the three drive connectors (C) from the controller card assembly. Previous Next Go Back Pull up the left side of the drive assembly until the left tip (D) clears the drawer. 4-172 Service Manual...
Page 427: 550-Sheet Tray Left Anti-Tip Latch Removal
5062 Remove the 550-sheet tray drive assembly. Previous Next Go Back 550-sheet tray left anti-tip latch removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-166.
Page 428 5062 Warning: Do not forcefully separate the bottom cover from the drawer; the ground cable (C) is still Previous attached to it. Next Go Back Remove the two screws (D) securing the left anti-tip latch assembly to the drawer. D (88A0232) 4-174 Service Manual...
Page 429: 550-Sheet Tray Pass Thru Sensor Removal
5062 Remove the left anti-tip latch assembly. Previous Next Go Back 550-sheet tray pass thru sensor removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the top metal cover. See “550-sheet tray top metal cover removal” on page 4-183.
Page 430: 550-Sheet Tray Pick Assembly Removal
5062 Remove the pass thru sensor. Previous Next Go Back 550-sheet tray pick assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-166. Disconnect the pick assembly connector (A) from the drive assembly.
Page 431 5062 Turn the shaft clockwise until the tab (B) aligns with the opening. Previous Next Go Back Pull down the pick arm to release the pick assembly. 4-177 Repair information...
Page 432 5062 Pull out the pick assembly. Previous Next Go Back Remove the 550-sheet tray pick assembly. Warning: Do not change the location of the spring. 4-178 Service Manual...
Page 433 5062 Installation notes: Previous Align the shaft to the left hole of the drive assembly. Next Go Back Insert the shaft into the hole. 4-179 Repair information...
Page 434: 550-Sheet Tray Pick Roll Assembly Removal
5062 Be sure that the tab is aligned in the opening and then turn the shaft counterclockwise. Previous Next Go Back 550-sheet tray pick roll assembly removal See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal”...
Page 435 5062 This is the photo of the pick roll assembly. Previous Next Go Back Installation note: Before installing the pick tire, be sure that the pick tire is fully aligned against one end of the hub. 4-181 Repair information...
Page 436: 550-Sheet Tray Right Anti-Tip Latch Assembly Removal
5062 550-sheet tray right anti-tip latch assembly removal Previous See“Optional 550-sheet drawer assembly” on page 7-19 for the part number. Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-166. Remove the top metal cover. See “550-sheet tray top metal cover removal”...
Page 437: 550-Sheet Tray Top Metal Cover Removal
5062 550-sheet tray top metal cover removal Previous Remove the media tray assembly. See “550-sheet media tray assembly removal” on page 4-166. Remove the 10 screws (A) and one screw (B) securing the top metal cover to the drawer. B (88A0001) Next Go Back A (88A0323)
Page 438: 2000-Sheet High-Capacity Feeder
5062 Previous 2000-sheet high-capacity feeder Next Go Back Note: Carefully remove the 2000-sheet high-capacity feeder option from the base printer before proceeding. 2000-sheet high-capacity feeder bellcrank assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal”...
Page 439: 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal
5062 This is the photo of the 2000-sheet high-capacity feeder bellcrank assembly. Previous Next Go Back 2000-sheet high-capacity feeder controller card assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-228.
Page 440: 2000-Sheet High-Capacity Feeder Drive Assembly Removal
5062 Remove the controller card assembly from the shield. Previous Next Go Back 2000-sheet high-capacity feeder drive assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal”...
Page 441 5062 Remove the screw (A) to disconnect the ground cable from the rear. Previous Next Go Back A (88A0231) Remove the three drive assembly connectors (B) from the controller card assembly. 4-187 Repair information...
Page 442 5062 Release the three drive assembly cables from the cable guides (C). Previous Next Go Back 4-188 Service Manual...
Page 443 5062 Remove the three screws (D) securing the drive assembly to the drawer. Previous Next Go Back D (88A0442) Remove the drive assembly. 4-189 Repair information...
Page 444: 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal
5062 This is the photo of the 2000-sheet high-capacity feeder drive assembly. Previous Next Go Back 2000-sheet high-capacity feeder elevator home sensor removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-228.
Page 445 5062 Remove the three screws (B) securing the controller card housing. Previous Next Go Back B (88A0231) 4-191 Repair information...
Page 446 5062 Detach the controller card housing. Previous Note: The controller card housing does not need to be completely removed from the machine. It may be allowed to hang on the side. Next Go Back Remove the screw (C) securing the elevator home sensor. C (88A0312) 4-192 Service Manual...
Page 447 5062 Press the latch (D) to remove the elevator home sensor. Previous Next Go Back Remove the elevator home sensor cable. 4-193 Repair information...
Page 448: 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal
5062 2000-sheet high-capacity feeder jam clearance cover removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-215. Next Remove the jam clearance top cover. See “2000-sheet high-capacity feeder jam clearance top cover removal”...
Page 449 5062 Release the jam clearance cover cable from the cable guides (B). Previous Next Go Back Open the jam clearance cover. Remove the 4 screws (C) securing the jam clearance cover to the drawer. C (88A0231) Close the jam clearance cover. 4-195 Repair information...
Page 450 5062 Pull out the jam clearance cover to clear the slots from the frame. Previous Next Go Back Press the metal tab to release the jam clearance cover, and pull up to remove the jam clearance cover. 4-196 Service Manual...
Page 451 5062 Warning: Be careful not to damage the jam clearance cover sensor. Previous Next Go Back This is the photo of the 2000-sheet high-capacity feeder jam clearance cover. 4-197 Repair information...
Page 452: 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal
5062 2000-sheet high-capacity feeder jam clearance top cover removal Previous Open the jam clearance cover. Remove the two screws (A) and one screw (B) securing the jam clearance top cover to the drawer. Next Go Back A (88A0414) B (88A0231) Lift the right side of the jam clearance top cover to clear it from the LED bracket.
Page 453: 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal
5062 Remove the jam clearance top cover. Previous Next Go Back 2000-sheet high-capacity feeder jam door clearance sensor removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal”...
Page 454 5062 Release the jam clearance cover cable from the cable guides (B). Previous Next Go Back Remove the screw (C) and press the latch (D) to release the jam clearance cover sensor. C (88A0312) 4-200 Service Manual...
Page 455: 2000-Sheet High-Capacity Feeder Led Bracket Removal
5062 Remove the jam clearance cover sensor. Previous Next Go Back 2000-sheet high-capacity feeder LED bracket removal Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-228. Remove the left side cover. See “2000-sheet high-capacity feeder left side cover removal” on page 4-204.
Page 456: 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal
5062 Remove the two screws (A) securing the LED bracket to the drawer. Previous Next Go Back A (88A0231) Detach the LED bracket. Note: The LED bracket does not need to be completely removed from the machine. It may be allowed to hang on the side.
Page 457 5062 Remove the two screws (A) securing the left anti-tip latch assembly to the drawer. Previous Note: Hold the left anti-tip latch assembly to prevent it from falling off after removing the screws. Next Go Back A (88A0231) This is the photo of the left anti-tip latch assembly. 4-203 Repair information...
Page 458: 2000-Sheet High-Capacity Feeder Left Side Cover Removal
5062 Installation note: Previous The right anti-tip latch assembly (A) is thinner compared to the left-anti-tip latch assembly (B). Next Go Back 2000-sheet high-capacity feeder left side cover removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the rear cover.
Page 459 5062 Remove the left side cover by slightly lifting it. Previous Next Go Back This is the photo of the 2000-sheet high-capacity feeder left side cover. 4-205 Repair information...
Page 460: 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal
5062 Installation note: Previous Be sure that the latch is inside the slot. Next Go Back 2000-sheet high-capacity feeder lift drive gear assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal”...
Page 461 5062 Disconnect the lift drive motor connector from the controller card assembly. Previous Next Go Back Release the lift drive motor cable from the cable guide (A). Remove the four screws (B) to remove the bracket. 4-207 Repair information...
Page 462 5062 Remove the E-clip securing the elevator gear (C) to the frame. Previous Note: The spring from gear (C) will pop out when removing the E-clip. Next Go Back Remove the elevator gear (C). Remove the E-clip securing the elevator gear (D) to the frame. Remove the elevator gear (D).
Page 463 5062 Remove the E-clip securing the elevator gear (E) to the frame. Previous Next Go Back Remove the elevator gear (E). Remove the E-clip securing the elevator gear (F) to the bracket. Remove the elevator gear (F). 4-209 Repair information...
Page 464 5062 Remove the bearing (G). Previous Next Go Back This is the photo of the 2000-sheet high-capacity feeder lift motor drive assembly. 4-210 Service Manual...
Page 465 5062 Installation notes: Previous Make sure that the bearing is reinstalled as shown in the picture. Next Go Back Make sure that the gear is reassembled as shown in the picture. 4-211 Repair information...
Page 466: 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal
5062 2000-sheet high-capacity feeder lift drive motor assembly removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-215. Next Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal”...
Page 467 5062 Release the lift drive motor cable from the cable guide (A). Previous Remove the four screws (B) to remove the bracket. Next Go Back Remove the two screws (C) securing the motor to the bracket. C (18B1199) 4-213 Repair information...
Page 468 5062 Remove the motor from the bracket. Previous Next Go Back 4-214 Service Manual...
Page 469: 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal
5062 2000-sheet high-capacity feeder media tray assembly removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Open the media tray assembly until it stops. Next Go Back Slightly pull the media tray to the right, push the latch on the media tray slide, and push the slide until it clears the tray.
Page 470 5062 Slightly lift the tray to clear it from the stopper and pull to remove the media tray assembly out of the Previous drawer. Next Go Back 4-216 Service Manual...
Page 471: 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal
5062 2000-sheet high-capacity feeder pass thru sensor removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Open the media tray assembly. Open the jam clearance cover. Next Disconnect the pass thru sensor connector (A) from the pass thru sensor. Release the latch (B) securing the pass thru sensor.
Page 472: 2000-Sheet High-Capacity Feeder Pick Assembly Removal
5062 Remove the pass thru sensor. Previous Next Go Back 2000-sheet high-capacity feeder pick assembly removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-215.
Page 473 5062 Remove the five screws (A) and one screw (B) securing the pick assembly to the drawer. Previous Next Go Back B (88A0414) A (88A0442) Disconnect the four pick assembly connectors (C) from the controller card assembly. 4-219 Repair information...
Page 474 5062 Release the pick assembly cables from the cable guide (D). Previous Next Go Back Remove the two screws (E) securing the cave light to the drawer. E (88A0231) 4-220 Service Manual...
Page 475 5062 Lift the lower right side of the pick assembly and pull to remove it. Previous Next Go Back This is the photo of the 2000-sheet high-capacity feeder pick assembly. 4-221 Repair information...
Page 476 5062 Installation note: Previous Align the upper left part of the pick assembly. Next Go Back Align the frame tabs to their corresponding pick arm slots. 4-222 Service Manual...
Page 477 5062 Installation note: Previous Make sure that the pick arm lever (A) is on top of the actuator lever (B). If the pick arm is hanging, press the actuator lever as shown in the picture. Next Go Back Make sure that the pick arm is positioned as shown in the picture. 4-223 Repair information...
Page 478: 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal
5062 2000-sheet high-capacity feeder pick roll assembly removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the media tray assembly. See “2000-sheet high-capacity feeder media tray assembly removal” on page 4-215. Next Open the jam clearance cover. Push down the pick arm until it clicks.
Page 479 5062 Press down the black latch (A) to release the pick tire. Previous Next Go Back Remove the pick roll tire. Repeat steps 4-5 to remove the pick tire on the other side. 4-225 Repair information...
Page 480 5062 This is the photo of the 2000-sheet high-capacity feeder pick roll assembly. Previous Next Go Back Installation note: Be sure that the pick arm lever (A) is on top of the actuator lever (B). If the pick arm is hanging, press the actuator lever as shown in the picture. 4-226 Service Manual...
Page 481 5062 Be sure that the pick arm is positioned as shown in the picture. Previous Next Go Back 4-227 Repair information...
Page 482: 2000-Sheet High-Capacity Feeder Rear Cover Removal
5062 2000-sheet high-capacity feeder rear cover removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the two screws (A) securing the rear cover to the drawer. Next Go Back A (88A0442) Position the printer so that the rear cover is over the edge of the table. 4-228 Service Manual...
Page 483 5062 Release the two latches, and remove the rear cover. Previous Next Go Back This is the photo of the 2000-sheet high-capacity feeder rear cover. 4-229 Repair information...
Page 484: 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal
5062 2000-sheet high-capacity feeder right anti-tip latch assembly removal Previous See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the rear cover. See “2000-sheet high-capacity feeder rear cover removal” on page 4-228. Remove the right side cover. See “2000-sheet high-capacity feeder right side cover removal”...
Page 485: 2000-Sheet High-Capacity Feeder Right Side Cover Removal
5062 Installation note: Previous The right anti-tip latch assembly (A) is thinner compared to the left-anti-tip latch assembly (B). Next Go Back 2000-sheet high-capacity feeder right side cover removal See“Optional 2000-sheet high-capacity feeder” on page 7-23 for the part number. Remove the rear cover.
Page 486 5062 Pull the upper back portion of the right side cover. Previous Next Go Back Lift the right side cover to remove it. 4-232 Service Manual...
Page 487 5062 This is the photo of the 2000-sheet high-capacity feeder right side cover. Previous Next Go Back 4-233 Repair information...
Page 488: Output Option Removals
5062 Previous Output option removals 5-bin mailbox Next 5-bin mailbox access door removal Go Back See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Remove the mailbox from the printer. Remove the front cover. See “Finisher or stacker front cover removal” on page 4-260.
Page 489: 5-Bin Mailbox Backup Roll Plate Assembly Removal
5062 Remove five screws (B) to remove the beacon LED and cover. Previous Next Go Back 5-bin mailbox backup roll plate assembly removal See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. Remove the mailbox from the printer. Remove the mailbox rear cover.
Page 490 5062 Flex the sides to remove the roller frame. Previous Next Go Back 4-236 Service Manual...
Page 491: 5-Bin Mailbox Bin-Full Beacon Card And Light Pipe Removal
5062 5-bin mailbox bin-full beacon card and light pipe removal Previous See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Remove the mailbox from the printer. Remove the mailbox front cover. See “5-bin mailbox front cover removal” on page 4-242.
Page 492: 5-Bin Mailbox Controller Card Removal
5062 Remove the screw (C), and then disconnect the cable (B) from the card to remove the beacon. Previous Next Go Back Note: Observe the cable routing for reinstallation. To replace the cable, remove the rear cover and disconnect the cable from the printer circuit board. See “5-bin mailbox rear cover removal”...
Page 493: 5-Bin Mailbox Diverter Solenoid Removal
5062 5-bin mailbox diverter solenoid removal Previous See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. Remove the mailbox from the printer. Remove the 5-bin mailbox feed motor with plate. See “5-bin mailbox feed motor with plate removal” on Next page 4-241.
Page 494: 5-Bin Mailbox Diverter Spring Removal
5062 5-bin mailbox diverter spring removal Previous See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. Remove the mailbox option from the printer. Open the left access door. Next Using a spring hook or needlenose pliers, remove the spring off the hooks. Go Back 4-240 Service Manual...
Page 495: 5-Bin Mailbox Feed Motor With Plate Removal
5062 5-bin mailbox feed motor with plate removal Previous See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. Remove the mailbox from the printer. Remove the mailbox front cover. See “5-bin mailbox front cover removal” on page 4-242. Next Remove the printer circuit board.
Page 496: 5-Bin Mailbox Front Cover Removal
5062 5-bin mailbox front cover removal Previous See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Remove the mailbox from the printer. Remove two screws (A) from the bottom. Next Go Back From the left side, use a flat-blade screwdriver to pry up and disengage the tabs. 4-242 Service Manual...
Page 497 5062 Pull out on the right side to disengage the tabs, and then remove the cover. Previous Next Go Back Disconnect the cable from the beacon card. Note: If you are replacing the cover FRU, then remove the bin-full beacon card. See “5-bin mailbox bin-full beacon card and light pipe removal”...
Page 498: 5-Bin Mailbox Media Bin Full Actuator Removal
5062 5-bin mailbox media bin full actuator removal Previous See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. 1. Remove the front cover. See “5-bin mailbox front cover removal” on page 4-242. 2. Pry the front hinge of the media bin full actuator towards the rear until the front boss is released from its Next socket.
Page 499: 5-Bin Mailbox Option Cable Removal
5062 5-bin mailbox option cable removal Previous Remove the mailbox from the printer. Remove the rear cover. See “5-bin mailbox rear cover removal” on page 4-249. Press the tabs to release the cable, and push the cable through the frame. Next Go Back Disconnect the cable (A) from the controller card, and press the latch to disconnect cable (B) from the...
Page 500: 5-Bin Mailbox Output Bin Deflector Removal
5062 5-bin mailbox output bin deflector removal Previous See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. Remove the mailbox option from the printer. Remove the mailbox access door roller assembly. Next Remove the rear cover. See “5-bin mailbox rear cover removal” on page 4-249.
Page 501: 5-Bin Mailbox Output Bin Paper Bail Removal
5062 5-bin mailbox output bin paper bail removal Previous See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Top bail: Next Remove the mailbox from the printer. Remove the top cover. See “5-bin mailbox top cover removal” on page 4-253.
Page 502: 5-Bin Mailbox Output Bin Roller Removal
5062 5-bin mailbox output bin roller removal Previous Remove the mailbox option from the printer. Remove the 5-bin mailbox output deflector for the roller you want to remove. Rotate the clips forward that are holding the roller in place. Next Go Back Lift the roller out of the mailbox.
Page 503: 5-Bin Mailbox Paper Jam Beacon Removal
5062 5-bin mailbox paper jam beacon removal Previous See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Remove the mailbox from the printer. Remove the mailbox front cover. See “5-bin mailbox front cover removal” on page 4-242. Next Remove the mailbox access door.
Page 504 5062 Use a flat-blade screwdriver to pry out the right side to disengage the latches. Previous Next Go Back Use the screwdriver to disengage the two latches on the left side, and then remove the cover. 4-250 Service Manual...
Page 505: 5-Bin Mailbox Roller Removal
5062 5-bin mailbox roller removal Previous See“5-bin mailbox assembly (interior)” on page 7-37 for the part number. Remove the 5-bin mailbox option from the printer. Remove the output bin deflector that covers the roller to be removed. See “5-bin mailbox tray extension Next removal”...
Page 506: 5-Bin Mailbox Sensor (Input) Assembly Removal
5062 5-bin mailbox sensor (input) assembly removal Previous Remove the 5-bin mailbox option from the printer. Remove the bottom mailbox output bin roller. See “5-bin mailbox output bin roller removal” on page 4-248. Release the tabs holding the sensor, and then remove the sensor with its cable. Next Go Back 5-bin mailbox sensor (pass thru) assembly removal...
Page 507: 5-Bin Mailbox Top Cover Removal
5062 5-bin mailbox top cover removal Previous See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Remove the mailbox from the printer. Remove the front cover. See “5-bin mailbox front cover removal” on page 4-242. Next Remove the two screws (A), and remove the top cover. Go Back Remove the rear cover.
Page 508: 5-Bin Mailbox Tray Extension Removal
5062 5-bin mailbox tray extension removal Previous See“5-bin mailbox assembly (covers)” on page 7-35 for the part number. Pull out the extension until it stops. Push to release the two tabs (A) on the bottom of the extension, and then pull the extension out to remove Next Go Back 4-254...
Page 509: Staplesmart Finisher And High-Capacity Output Stacker
5062 Previous StapleSmart finisher and High-capacity output stacker Finisher or stacker access door beacon LED and beacon housing removal “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Next Remove the option from the printer. Remove the left access door assembly. See “Finisher or stacker left access door assembly removal”...
Page 510: Finisher Or Stacker Bin-Full Spring Removal
5062 Finisher or stacker bin-full spring removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. To remove the front spring, remove the front cover. See “Finisher or stacker front cover removal” on Next page 4-260.
Page 511: Finisher Or Stacker Bottom Cover Removal
5062 Finisher or stacker bottom cover removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the standard output bin LED and LED lens. See “Finisher or stacker standard output bin LED Next and LED lens removal”...
Page 512: Finisher Or Stacker Controller Card Assembly Removal
5062 Finisher or stacker controller card assembly removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the front cover. See “Finisher or stacker front cover removal” on page 4-260. Next Disconnect all cables from the controller card.
Page 513: Finisher Or Stacker Feed Roller Removal
5062 Finisher or stacker feed roller removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Open the option left access door. Next Using a screwdriver, force the rear hinge (A) out of the slot by pushing the door to the front. Go Back Remove the screw (B) to remove the roller you are replacing.
Page 514: Finisher Or Stacker Front Cover Removal
5062 Finisher or stacker front cover removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the two screws (A) on the inside of the exit bin compartment. Next Go Back 4-260 Service Manual...
Page 515 5062 Using a flat-blade screwdriver, pry up to disengage the tabs on the right, left, and top sides of the cover. Previous Next Go Back Remove the left cover. 4-261 Repair information...
Page 516: Finisher Or Stacker Led Sensor Cover Removal
5062 Finisher or stacker LED sensor cover removal Previous Remove the option from the printer. Remove the standard output bin LED lens. See “Finisher or stacker standard output bin LED and LED lens removal” on page 4-277. Remove the sensor (finisher media bin present). See “Finisher or stacker sensor (finisher bin media Next present) removal”...
Page 517 5062 Disconnect the cable (D) from the beacon card. Previous Remove the beacon lens (E), and remove the door assembly Next Go Back 4-263 Repair information...
Page 518: Finisher Or Stacker Media Stack Flap And Media Stack Flap Actuator Removal
5062 Finisher or stacker media stack flap and media stack flap actuator removal Previous “Finisher/High-capacity output stacker assembly (continued)” on page 7-27 for the part number. Remove the option from the printer. Remove the top cover. See “Finisher or stacker top cover removal” on page 4-280.
Page 519: Finisher Or Stacker Option Cable Removal
5062 Finisher or stacker option cable removal Previous Remove the option from the printer. Remove the rear cover. See “Finisher or stacker rear cover removal” on page 4-269. Remove the front cover. See“Finisher or stacker front cover removal” on page 4-260.
Page 520: Finisher Or Stacker Output Bin Extension Removal
5062 Finisher or stacker output bin extension removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. While pulling out the extension, push in the left and right tabs, and pry up the center tab. Next Go Back Finisher or stacker output bin LED and LED lens removal “Finisher/High-capacity output stacker assembly”...
Page 521: Finisher Or Stacker Paddle Drive Gear Removal
5062 Finisher or stacker paddle drive gear removal Previous Remove the option from the printer. Remove the paddle drive motor. See “Finisher or stacker paddle drive motor assembly removal” on page 4-267. Remove the E-clip (A), and remove the gear. Next Go Back Finisher or stacker paddle drive motor assembly removal...
Page 522 5062 Remove the three screws (A) securing the two paddle drive motor assemblies. Previous Next Go Back Remove the paddle drive motor assembly. Installation note: Be sure to line up the locator (B) when you install the motor. 4-268 Service Manual...
Page 523: Finisher Or Stacker Rear Cover Removal
5062 Finisher or stacker rear cover removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the four screws (A) from the bottom of the option. Next Using a flat-blade screwdriver, pry out the bottom plate, and then remove it. Go Back 4-269 Repair information...
Page 524 5062 Remove the two screws (B) on the inside of the exit bin compartment. Previous Next Go Back Pull out on the right side of the cover to disengage the tabs, and remove the cover. 4-270 Service Manual...
Page 525: Finisher Or Stacker Sensor (Bin-Full Receive) Removal
5062 Finisher or stacker sensor (bin-full receive) removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the option rear cover. See “Finisher or stacker rear cover removal” on page 4-269.
Page 526: Finisher Or Stacker Sensor (Bin-Full Send) Removal
5062 Finisher or stacker sensor (bin-full send) removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the finisher or stacker controller card assembly. See “Finisher or stacker controller card Next assembly removal”...
Page 527: Finisher Or Stacker Sensor (Finisher Bin Media Present) Removal
5062 Finisher or stacker sensor (finisher bin media present) removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove two screws (A), and pull out the sensor cover. Next Go Back Press the tabs to remove the sensor from the cover.
Page 528: Finisher Or Stacker Sensor (Paddle Hp) Removal
5062 Finisher or stacker sensor (paddle HP) removal Previous “Finisher/High-capacity output stacker assembly (continued)” on page 7-27 for the part number. Remove the option from the printer. Remove the paddle drive motor. See “Finisher or stacker paddle drive motor assembly removal” on Next page 4-267.
Page 529: Finisher Or Stacker Sensor (Pass Thru) Removal
5062 Finisher or stacker sensor (pass thru) removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the finisher from the printer. Remove the finisher rear cover. See “Finisher or stacker rear cover removal” on page 4-269.
Page 530: Finisher Or Stacker Sensor (Tamper Hp Left And Right) Removal
5062 Press the tabs to remove the sensor. Previous Next Go Back Finisher or stacker sensor (tamper HP left and right) removal Remove the option from the printer. Remove the option top cover. See “Finisher or stacker top cover removal” on page 4-280.
Page 531: Finisher Or Stacker Standard Output Bin Led And Led Lens Removal
5062 Finisher or stacker standard output bin LED and LED lens removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove two screws (A), and pull out the sensor cover. Next Go Back To remove the LED, remove the screw (B), and then disconnect the cable from the LED card.
Page 532: Finisher Or Stacker Tamper Drive Belt Removal
5062 Finisher or stacker tamper drive belt removal Previous “Finisher/High-capacity output stacker assembly (continued)” on page 7-27 for the part number. Remove the option from the printer. Remove the tamper drive motor from the belt you need to replace. See “Finisher or stacker tamper drive Next motor assembly removal”...
Page 533: Finisher Or Stacker Tamper Recoil Spring Removal
5062 Clip the cable tie (D). Previous Use a spring hook to remove the tamper recoil spring (E) for the motor you are removing. Remove the two screws (F) from the motor you are removing, and remove the motor assembly. Next Go Back Finisher or stacker tamper recoil spring removal...
Page 534: Finisher Or Stacker Top Cover Removal
5062 Finisher or stacker top cover removal Previous “Finisher/High-capacity output stacker assembly” on page 7-25 for the part number. Remove the option from the printer. Remove the front cover. See “Finisher or stacker front cover removal” on page 4-260. Next Remove the rear cover.
Page 535: Finisher Stapler Unit Assembly Removal
5062 Remove two screws (C). Previous Next Go Back Pull up to remove the top cover. Finisher stapler unit assembly removal “Finisher stapler assembly” on page 7-29 for the part number. Remove the finisher from the printer. Remove the finisher rear cover. See “Finisher or stacker rear cover removal”...
Page 536: Horizontal Transport Unit (Htu) And Holepunch Unit
5062 Previous Horizontal transport unit (HTU) and Holepunch unit HTU access door removal Remove all output options from the printer. Next Open the access door, and disconnect the beacon cable. Go Back Insert a flat-blade screwdriver below the bottom hinge, and flex the door enough to pull out the hinge. Remove the door.
Page 537: Htu Access Door Paper Jam Beacon (With Cover And Cable) Removal
5062 HTU access door paper jam beacon (with cover and cable) removal Previous Remove all output options from the printer. Remove the HTU access door. See “HTU access door removal” on page 4-282. Remove six screws (A), and turn over the beacon cover. Next Go Back A (3015189)
Page 538: Htu Access Door Rollers Removal
5062 HTU access door rollers removal Previous Remove all output options from the printer. Remove the HTU access door. See “HTU access door removal” on page 4-282. Remove the screw (A) from the roller you are replacing, and remove the roller. Next Go Back A (3015189)
Page 539 5062 Installation note: Rollers (B) are different from rollers (C). Make sure that the color of the roller you will reinstall Previous matches the color of the roller you have removed. Next Go Back 4-285 Repair information...
Page 540: Htu Bin Diverter Gate Spring Removal
5062 HTU bin diverter gate spring removal Previous Remove all output options from the printer. Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Next Use a spring hook to remove the spring (A). Go Back HTU bin media exit spring removal Remove all output options from the printer.
Page 541: Htu Card (Bin-Full Receive Card And Lens) Removal
5062 HTU card (bin-full receive card and lens) removal Previous Remove all output options from the printer. Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Next Remove the two screws (A), and then remove the sensor card. Go Back Disconnect the cable to remove the sensor.
Page 542: Htu Card (Bin-Full Send Card And Lens) Removal
5062 HTU card (bin-full send card and lens) removal Previous Remove all output options from the printer. Remove the HTU controller card. See “HTU controller card removal” on page 4-289. Next Remove the two screws (A), and then remove the sensor card. Go Back Disconnect the cable from the sensor to remove the sensor.
Page 543: Htu Controller Card Removal
5062 HTU controller card removal Previous Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Next Disconnect all cables connected to the controller card. Remove the four screws (A). Go Back Installation note: Be sure to connect the solenoid cables into the correct connector.
Page 544: Htu Drive Belt Removal
5062 HTU drive belt removal Previous Remove all output options from the printer. Remove the HTU controller card. See “HTU controller card removal” on page 4-289. Next Remove three screws (A) and one screw (B). Go Back Slide the belt off the lowest gear. 4-290 Service Manual...
Page 545: Htu Drive Gear Spring Removal
5062 HTU drive gear spring removal Previous Remove all output options from the printer. Remove the controller card. See “HTU controller card removal” on page 4-289. Next Use a spring hook to remove the spring. Go Back 4-291 Repair information...
Page 546: Htu Engagement Roller Removal
5062 HTU engagement roller removal Previous Remove all output options from the printer. Lay the HTU on its back. Next Remove the screw (A) to remove the roller you are replacing. Go Back 4-292 Service Manual...
Page 547: Htu Exit Roller Removal
5062 HTU exit roller removal Previous Remove the upper exit shaft. See “HTU upper exit shaft removal” on page 4-331. Unsnap the left side of the roller from the cover and remove the roller. Next Go Back HTU front redrive cover removal Remove all output options from the printer.
Page 548: Htu Front Standard Bin Cover Removal
5062 HTU front standard bin cover removal Previous Remove all output options from the printer. Remove two screws (A) from the bottom. Next Go Back Remove the screw (B) from the top. 4-294 Service Manual...
Page 549: Htu Locking Lever Removal
5062 Remove the screw (C) inside the output bin, and remove the cover. Previous Next Go Back HTU locking lever removal Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Remove the two E-Clips (A) and the one E-clip (B) holding the locking lever. 4-295 Repair information...
Page 550 5062 Use a flat-blade screwdriver to slide the lever out. Previous Next Go Back Remove the screw (C). 4-296 Service Manual...
Page 551: Htu Locking Lever Card Removal
5062 HTU locking lever card removal Previous Remove the locking lever. See “HTU locking lever removal” on page 4-295. Disconnect the cable to remove the locking level card. Next HTU lower redrive guide removal Go Back Remove all output options from the printer. Remove the upper guide.
Page 552 5062 Remove the three screws (C) from the front of the transport unit. Previous Next Go Back C (3015189) Press the tabs to remove the connector from the rear frame. 4-298 Service Manual...
Page 553 5062 Lift the back edge of the plate, and then slide the plate to the rear to remove it. Previous Next Go Back Installation note: When installing the guide, be sure to use a screwdriver to clear the post (A) from the belt (B) as shown.
Page 554: Htu Option Hook Removal
5062 HTU option hook removal Previous Remove all output options from the printer. Front hook Next Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Go Back Remove one screw (A), and then remove the hook. Installation note: From the back of the hook, turn the spring arm 1/2 turn counterclockwise, and then hold the arm in place while you install the hook.
Page 555 5062 Rear hook Previous Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Remove the screw (A), and then remove the hook. Next Go Back Installation note: From the back of the hook, turn the spring arm 1/2 turn counterclockwise, and then hold the arm in place while you install the hook.
Page 556: Htu Option Roller Removal
5062 HTU option roller removal Previous Remove all output options from the printer. Front roller Next Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Go Back Remove the screw (A) to remove the roller. Rear roller Remove the rear standard bin cover.
Page 557: Htu Output Bin Removal
5062 HTU output bin removal Previous Remove the output option from the HTU. Rotate the bin up, and then pull back to remove it. Next Go Back Installation note: If you are replacing the output bin FRU, then remove the wire stop. See “HTU output bin wire stop removal”...
Page 558: Htu Output Bin Solenoid Removal
5062 Press the tabs (A) to release the latches, and then pull to remove the extension. Previous Next Go Back HTU output bin solenoid removal Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312.
Page 559: Htu Output Bin Wire Stop Removal
5062 Disconnect the plunger (B) from stopper diverter and the spring (C) from the solenoid. Previous Remove the two screws (D) and remove the solenoid. Next Go Back HTU output bin wire stop removal Remove the output option from the HTU. Rotate the extension cover down.
Page 560: Htu Output Option Removal
5062 HTU output option removal Previous Press the release lever, slide the top option to the right, and lift the top option off. Next Go Back 4-306 Service Manual...
Page 561 5062 Open the top access door, press the lever, and slide the HTU to the right to remove. Previous Next Go Back 4-307 Repair information...
Page 562: Htu Output Option Guide Removal
5062 HTU output option guide removal Previous Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Slide the cables through the rear standard bin cover. Next Go Back HTU output option solenoid removal Remove the rear standard bin cover.
Page 563: Htu Output Sensor Removal
5062 Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Previous Disconnect the plunger (B) from the stopper diverter, and the spring (C) from the solenoid. Remove the two screws (D). and then remove the solenoid. Next Go Back HTU output sensor removal...
Page 564: Htu Outer Front Cover Removal (Aio Only)
5062 HTU outer front cover removal (AIO only) Previous Remove all output options from the printer. Push up the tabs to release the latches, and rotate the cover up to remove it. Next Go Back HTU rear redrive cover removal Remove all output options from the printer.
Page 565 5062 Remove the screw (B) from the rear. Previous Next Go Back B (3014523) Use a screwdriver to release the two tabs, and remove the cover. 4-311 Repair information...
Page 566: Htu Rear Standard Bin Cover Removal
5062 HTU rear standard bin cover removal Previous Remove all output options from the printer. Remove two screws (A) from the bottom. Next Go Back Remove the screw (B) inside the output bin. 4-312 Service Manual...
Page 567 5062 Remove the screw (C) from the left side. Previous Next Go Back Remove two screws (D) and one screw (E) from the top. LIft off the output option connector bracket (F), and then lift off the rear standard bin cover. 4-313 Repair information...
Page 568 5062 Disconnect the cable (F), and press the tab to disconnect the cable (G) from the controller card. Previous Note: If you are replacing the rear standard bin cover FRU, then feed the cables through the slot in the cover. Next Go Back 4-314...
Page 569: Htu Right Bottom Cover Removal
5062 HTU right bottom cover removal Previous Remove all output options from the printer. Remove three screws (A) from the inside. Next Go Back Remove two screws (B) from the bottom, and remove the cover. 4-315 Repair information...
Page 570: Htu Right Inner Cover Removal
5062 HTU right inner cover removal Previous Remove all output option from the printer. Remove the output bin. See “HTU output bin removal” on page 4-303. Next Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294.
Page 571 5062 Remove the right lower cover. Previous Next Go Back Note: Observe the routing of cable (G) through the side frame. 4-317 Repair information...
Page 572 5062 Remove the two screws (H). Previous Next Go Back Remove the two screws (I), and two screws (J). 4-318 Service Manual...
Page 573 5062 Lift up the frame and slide the right inner cover out. Previous Next Go Back 4-319 Repair information...
Page 574: Htu Sensor (Access Door Interlock) Removal
5062 HTU sensor (access door interlock) removal Previous Remove all output options from the printer. Remove the front redrive cover. See “HTU front redrive cover removal” on page 4-293. Press the outer tabs (A) to remove the sensor cover. Press the inner tabs (B) to pull out the sensor. Next Go Back Disconnect the cable to remove the sensor.
Page 575: Htu Sensor (Empty Bin) Removal
5062 HTU sensor (empty bin) removal Previous Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Next Disconnect the sensor cable (A) from the controller card. Go Back Remove the output bin.
Page 576: Htu Sensor (Input) Removal
5062 HTU sensor (input) removal Previous Remove all output options from the printer. Remove the HTU lower redrive guide. See “HTU lower redrive guide removal” on page 4-297. Next Press the tabs to release the sensor, and then disconnect the cable to remove the sensor. Go Back 4-322 Service Manual...
Page 577: Htu Sensor (Output Option Position) Removal
5062 HTU sensor (output option position) removal Previous Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Next Press the tabs to pull out the sensor. Go Back Disconnect the cable to remove sensor.
Page 578: Htu Sensor (Second) Removal
5062 HTU sensor (second) removal Previous Remove all output options from the printer. Remove the HTU lower redrive guide. See “HTU lower redrive guide removal” on page 4-297. Next Press the tabs to release the sensor, and then disconnect the cable to remove the sensor. Go Back HTU sensor cable (bin-full send and receive) removal Remove all output options from the printer.
Page 579: Htu Stopper Diverter Removal
5062 HTU stopper diverter removal Previous Remove the front standard bin cover. See “HTU front standard bin cover removal” on page 4-294. Remove the solenoid plunger and spring from the stopper diverter, and then slide the stopper diverter off Next the option.
Page 580: Htu Timing Belts (Rear) Removal
5062 HTU timing belts (rear) removal Previous Remove all output options from the printer. Remove the rear redrive cover. See “HTU rear redrive cover removal” on page 4-310. Next Remove one of the gears (A) to remove the belt you are replacing. Note: Remove the center belt to access the other two belts.
Page 581: Htu To Printer Cable Removal
5062 HTU to printer cable removal Previous Remove the right inner cover. See “HTU right inner cover removal” on page 4-316. Remove the screw (A) to disconnect the ground cable. Next Go Back Press on the tabs to release the connector. 4-327 Repair information...
Page 582: Htu Top Redrive Cover Removal
5062 HTU top redrive cover removal Previous Remove all output options from the printer. Remove the front redrive cover. See “HTU front redrive cover removal” on page 4-293. Next Remove two screws (A). Go Back Remove the rear redrive cover. See “HTU rear redrive cover removal”...
Page 583: Htu Top Right Cover Removal
5062 HTU top right cover removal Previous Remove all output options from the printer. Remove the rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Next Remove two screws (A) from the top. Go Back Remove two screws (B) from the rear, and then remove the top cover.
Page 584: Htu Transport Gear Removal
5062 HTU transport gear removal Previous Remove the HTU drive belt. See “HTU drive belt removal” on page 4-290. Use a flat screwdriver to remove the gear (A). Next Remove the E-clip (B) and E-clip (C), and then slide the gears off their posts. Go Back 4-330 Service Manual...
Page 585: Htu Transport Motor Removal
5062 HTU transport motor removal Previous Remove the right inner cover. See “HTU right inner cover removal” on page 4-316. Remove the two screws (A), and then remove the transport motor. Next Go Back HTU upper exit shaft removal Remove the right inner cover. See “HTU right inner cover removal”...
Page 586: Htu Upper Guide Removal
5062 Unsnap the upper exit shaft out of the cover. Previous Next Go Back HTU upper guide removal Remove all output options from the printer. Remove the top redrive cover. See “HTU top redrive cover removal” on page 4-328. Remove the two screws (A) from the front. A (3015189) 4-332 Service Manual...
Page 587 5062 Slide the guide to the left, and remove. Previous Next Go Back 4-333 Repair information...
Page 588: Htu Punch Motor Removal
5062 HTU punch motor removal Previous Remove the HTU rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Disconnect the punch motor cable (A) from the HTU controller card. Next Go Back Remove the three screws (B), and remove the motor with the bracket. B (3014523) 4-334 Service Manual...
Page 589 5062 Remove the two screws (C), and then remove the bracket. Previous Next Go Back C (3014523) 4-335 Repair information...
Page 590: Htu Punch Unit Removal
5062 HTU punch unit removal Previous Remove the HTU rear standard bin cover. See “HTU rear standard bin cover removal” on page 4-312. Remove the HTU top right cover See“HTU top right cover removal” on page 4-329. Remove the E-clip (A), and then remove the gear and gear cap. Next Go Back Disconnect the cable (B) from the punch unit.
Page 591: Htu Punch Gear Removal
5062 Remove the two screws (C) and one screw (D). Previous Next Go Back Move the punch unit to the left and right while you pull it out of the frame. HTU punch gear removal Remove the HTU rear standard bin cover. See “HTU rear standard bin cover removal”...
Page 592 5062 Previous Next Go Back 4-338 Service Manual...
Page 593: Connector Locations
5062 5. Connector locations Previous Locations Next System board cabling reference For more information, see the connector diagram for the “System board” on page 5-2. Go Back Connector locations...
Page 594: Connectors
5062 Previous Connectors System board Next Go Back Service Manual...
Page 595 5062 System board Previous System board connectors with no cables attached Connector Next Go Back JBOOT1 JCCT1 JCFT1 JTLBT1 JTRIG1 JTWF1 JWETH1 JXT1 JXT2 System board connectors “System board” on page 5-2. Connector Pin # Signal Pin # Signal UI REset NR OP panel UICC card TX1- TX1+...
Page 596 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal +5V_ENG_CONN +5V_RIP Next LVPS +5V_RIP +24v Cable: In FRU +24v +24v Go Back Optional hard drive JBLW1 S_BLOW_FG Cartridge Blower Cable: 10J0953: Blower V20_BLT_BLOWER &...
Page 597 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal JCMKM1 VS10_CM_K Next M+K Metering Cable: 10J0940 M+K S_CART_MTR_K_IN Cart Metering S_CART_MTR_M_IN Go Back VS10_CM_M JCVR1 VDO_5V_SUPPLY Cover Open Switch Cable: 10J0946 Part of VDO_5V_SOURCE Housing V48_+24V_SW_FU...
Page 598 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal JFSR1 3.3V_ENG_L I2C_DATA_FSR Next Fuser Low Voltage I2C_CLK_FSR Cable: 10J0938 Fuser BR_THERM_IN SYSCARD & LVPS S_EXIT_SENSOR_IN Go Back F_B_SNS_IN S_FUSER_CAM_IN HR_THERM_IN +5V_SW S_FLED13 JFSRD1 VIN+ VIN-...
Page 599 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal JITM1 I2C_ITM_CLK Next +3.3v_ENG I2C_ITM_DATA Cable: 10J0944 ITU TPS2L_SNS VS10_TPS_LED_OUT Autoconnect TPS1L_SNS Go Back TPS2H_SNS VS10_ACR_LED S_ACR_ENC TPS1H_SNS V10_ACR_MTR- V10_ACR_MTR+ JKI1 K_BLDC_HOME V45_I_WIND_W K* ITU Blck K_BLDC_HALL_U V45_I_WIND_V...
Page 600 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal JMM1 MM_REF_KM +24V_MM Next Printhead MM_LOCK_KM Cable: Part of printhead +3.3V_A1 START_CY START_KM Go Back MM_LOCK_CY +24V_MM MM_REF_CY JMPF1 VS10_MPF_OUT Multipurpose feeder sensor S_MPF_OUT_SNS Cable: 10J0929 MPF sensor cable...
Page 601 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal JPP2 VS10_NNMS_LED S_NNM_SNSR_IN Next Paper path Sensors VS10_S1S Cable: 10J0927 Paper S_S1S_FB path VS10_NMS Go Back S_NMS_FB VS1-_S2S S_S2S_FB JPY1 V_CART_3V Yellow Memory XP_DAT_C Cable: Part of unit XP_CLK_C...
Page 602 5062 System board connectors Previous “System board” on page 5-2. Connector Pin # Signal Pin # Signal JWTB1 VS10_WB_LED RT SIDE WT Next Waste Toner Sensor VS_10_WB_PRES Cable: 10J0943 Waste S_WB_PRES_IN Toner S_WLED7 PAPER TRAY Go Back S_WLED9 NARROW MEDIA S_WLED11 FR DOOR BEACON S_WLED13...
Page 603: 550-Sheet Tray Option System Card
5062 550-sheet tray option system card Previous Next Go Back JPTS1 5-11 Connector locations...
Page 604 5062 550-sheet tray option system card Previous 550-sheet tray option system card connectors “550-sheet tray option system card” on page 5-11. Connector Pin # Signal Pin # Signal Next Jam door sensor Input Go Back +5V_Switch +5V_Switch Pick motor ENCODER Motor + Motor - +5V_Switch...
Page 605 5062 550-sheet tray option system card connectors Previous “550-sheet tray option system card” on page 5-11. Connector Pin # Signal Pin # Signal TRAY_LIGHTPIPE Next LED tray +24V Power IN Go Back Ground JPTS1 +24V Pass thru sensor +5V_Switch 5-13 Connector locations...
Page 606: 2000-Sheet High-Capacity Feeder Option System Card
5062 2000-sheet high-capacity feeder option system card Previous Next Go Back JPTS1 5-14 Service Manual...
Page 607 5062 2000-sheet high-capacity feeder option system card Previous 2000-sheet high-capacity feeder option system card connectors “2000-sheet high-capacity feeder option system card” on page 5-14. Connector Pin # Signal Pin # Signal Next Jam door sensor Input Go Back +5V_Switch +5V_Switch Pick motor ENCODER Motor +...
Page 608 5062 2000-sheet high-capacity feeder option system card connectors Previous “2000-sheet high-capacity feeder option system card” on page 5-14. Connector Pin # Signal Pin # Signal Next Paper port to printer PP_RXD PP_TXD Go Back TRAY_LIGHTPIPE LED tray +24V Power IN Ground JPTS1 +24V...
Page 609: Uicc Card
5062 UICC card Previous Next Go Back UICC card UICC card connectors with no cables attached Connector UICC card connectors Connector Connects to Speaker Display System board USB to USB port USB to card reader USB to system board 5-17 Connector locations...
Page 610: 5-Bin Mailbox System Card
5062 5-bin mailbox system card Previous Next Go Back 5-18 Service Manual...
Page 611 5062 5-bin mailbox system card Previous 5-bin mailbox system connectors with no cables attached Connector Next 5-bin mailbox system card “5-bin mailbox system card” on page 5-18. Go Back Connector Connects to HTU connector HTU connector Motor J3–Bin1 Output bin 1 sensor J4–Bin4 Solenoid 4 J5–Bottom...
Page 612: Finisher/Stacker System Card
5062 Finisher/Stacker system card Previous Next Go Back HTU system card 5-20 Service Manual...
Page 613: Preventive Maintenance
Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply • 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 Individual maintenance part expected life Description Part number...
Page 614: Redrive Parts Packet
5062 Redrive parts packet Previous Using the 739A grease that came with the redrive assembly, lubricate the four posts (A). Next Go Back Install the gears. Using the 744 grease, lubricate the teeth (B) of the gears as shown. Service Manual...
Page 615: Fuser Drive Assembly
5062 Fuser drive assembly Previous Using the 739A grease that came with the fuser drive assembly, lubricate the post (A). Next Go Back Install the gear. Using the 744 grease, lubricate the teeth (B) of the gear as shown. Preventive maintenance...
Page 616 5062 Previous Next Go Back Service Manual...
Page 617: Parts Catalog
5062 7. Parts catalog Previous How to use this parts catalog Next Asm- Part Units/ Units/ Description Removal procedure index number mach Go Back • Asm-index: Identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 and item number 1 in the table.
Page 618: Assembly 1: Top, Right, And Front Covers
5062 Assembly 1: Top, right, and front covers Previous Next Go Back Service Manual...
Page 619 5062 Assembly 1: Top, right, and front covers Previous Units/ Units/ Index Description Removal procedure mach 1—1 40X7109 Printhead access cover “Printhead access cover removal” on page 4-19 Next 40X7127 Printhead assembly “Printhead removal, installation, and alignment” on page 4-123 40X7117 Speaker “Speaker removal”...
Page 620: Assembly 2: Left And Rear Covers
5062 Assembly 2: Left and rear covers Previous Next Go Back Service Manual...
Page 621 5062 Assembly 2: Left and rear covers Previous Units/ Units/ Index Description Removal procedure mach 2—1 40X7151 MPF sensor plate assembly “MPF sensor plate assembly removal” on page 4-108 Next 40X7122 Left cover assembly with LVPS power “Left cover removal” on page 4-11 switch cable 40X7178 MPF pick tire roll assembly, including...
Page 622: Assembly 3: Front
5062 Assembly 3: Front Previous Next Go Back Service Manual...
Page 623 5062 Assembly 3: Front Previous Units/ Units/ Index Description Removal procedure mach 3—1 40X7145 ITU contact block assembly “ITU block assembly removal” on page 4-80 Next 40X7130 Cartridge blower assembly “Cartridge blower assembly removal” on page 4-39 40X7141 Cartridge rail assembly, including “Cartridge rail removal”...
Page 624: Assembly 3.1: Front (Continued)
5062 Assembly 3.1: Front (continued) Previous Next Go Back Service Manual...
Page 625 5062 Assembly 3.1: Front (continued) Previous Units/ Units/ Index Description Removal procedure mach 3.1—1 40X7142 Cartridge memory block with sensor “Cartridge memory block removal” on page 4-44 Next 40X7160 Paper pick mechanism assembly “Paper pick mechanism assembly removal” on page 4-120 40X6104 Pick tire roll assembly “Pick rolls removal”...
Page 626: Assembly 4: Left
5062 Assembly 4: Left Previous Next Go Back 7-10 Service Manual...
Page 627 5062 Assembly 4: Left Previous Units/ Units/ Index Description Removal procedure mach 4—1 40X7133 Redrive parts packet, including “Redrive gears removal” on page 4-134 Next • Gear thrust washer (2) • Gear—Idler 50T (2) • Gear—64T 22T Compound • Gear—36T 18T Compound Go Back 40X7166 ITU autoconnect cable...
Page 628: Assembly 4.1: Left (Continued)
5062 Assembly 4.1: Left (continued) Previous Next Go Back 7-12 Service Manual...
Page 629 5062 Assembly 4.1: Left (continued) Previous Units/ Units/ Index Description Removal procedure mach 4.1—1 40X7100 Fuser assembly, 115 V “Fuser assembly removal” on page 4-63 Next 40X7101 Fuser assembly, 220 V 40X7102 Fuser assembly, 100 V 40X7153 Left access door pistons parts packet, “Left access door piston removal”...
Page 630: Assembly 5: Rear
5062 Assembly 5: Rear Previous Next Go Back 7-14 Service Manual...
Page 631 5062 Assembly 5: Rear Previous Units/ Units/ Index Description Removal procedure mach 5—1 40X0269 Bolivia, Peru (8’ ST) Next 40X0270 Japan (8’ ST) 40X0271 UK, Ireland (8' ST) 40X0273 Chile, Uruguay (8’ ST) Go Back 40X0275 Israel (8’ ST) 40X0288 Argentina (8’...
Page 632: Assembly 6: Optional 550-Sheet Tray
5062 Assembly 6: Optional 550-sheet tray Previous Next Go Back 7-16 Service Manual...
Page 633 5062 Assembly 6: Optional 550-sheet tray Previous Units/ Units/ Index Description Removal procedure 6—1 40X6967 550-sheet tray option Next 40X6102 550-sheet drawer assembly “550-sheet drawer assembly removal” on page 4-166 40X6099 550-sheet media tray assembly “550-sheet media tray assembly removal” on page 4-166 Go Back 7-17 Parts catalog...
Page 634: Assembly 7: Optional 550-Sheet Drawer Assembly
5062 Assembly 7: Optional 550-sheet drawer assembly Previous Next Go Back 7-18 Service Manual...
Page 635 5062 Assembly 7: Optional 550-sheet drawer assembly Previous Units/ Units/ Index Description Removal procedure 7—1 40X6100 550-sheet tray controller card “550-sheet tray controller card assembly assembly removal” on page 4-167 Next 40X6101 Anti-tip latch assembly “550-sheet tray right anti-tip latch assembly removal”...
Page 636: Assembly 8: Optional 2000-Sheet High-Capacity Feeder (Complete)
5062 Assembly 8: Optional 2000-sheet high-capacity feeder (complete) Previous Next Go Back 7-20 Service Manual...
Page 637 5062 Assembly 8: Optional 2000-sheet high-capacity feeder (complete) Previous Units/ Units/ Index Description Removal procedure 8—1 40X6968 2000-sheet high-capacity feeder media tray option Next Go Back 7-21 Parts catalog...
Page 638: Assembly 9: Optional 2000-Sheet High-Capacity Feeder
5062 Assembly 9: Optional 2000-sheet high-capacity feeder Previous Next Go Back 7-22 Service Manual...
Page 639 5062 Assembly 9: Optional 2000-sheet high-capacity feeder Previous Units/ Units/ Index Description Removal procedure 9—1 40X6275 2000-sheet high-capacity feeder pick “2000-sheet high-capacity feeder roll assembly pick roll assembly removal” on Next page 4-224 40X6119 2000-sheet high-capacity feeder pick “2000-sheet high-capacity feeder assembly pick assembly removal”...
Page 640: Assembly 10: Finisher/High-Capacity Ouput Stacker Assembly
5062 Assembly 10: Finisher/High-capacity ouput stacker assembly Previous Next Go Back 7-24 Service Manual...
Page 641 5062 Assembly 10: Finisher/High-capacity output stacker assembly Previous Asm- Part Units/ Units/ Description Removal procedure Index number mach 10—1 40X7234 Left access door assembly “Finisher or stacker left access door assembly removal” on page 4-262 Next 40X7238 Backup redrive roller “Finisher or stacker feed roller removal”...
Page 642: Assembly 10.1: Finisher/High-Capacity Output Stacker Assembly (Continued)
5062 Assembly 10.1: Finisher/High-capacity output stacker assembly Previous (continued) Next Go Back 7-26 Service Manual...
Page 643 5062 Assembly 10.1: Finisher/High-capacity output stacker assembly Previous (continued) Asm- Part Units/ Units/ Description Removal procedure Index number mach Next 10.1—1 40X7244 Rear media stack flap “Finisher or stacker media stack flap and media stack flap actuator removal” on page 4-264 40X7245 Front media stack flap “Finisher or stacker media stack...
Page 644: Assembly 11: Finisher Stapler Assembly
5062 Assembly 11: Finisher stapler assembly Previous Next Go Back 7-28 Service Manual...
Page 645 5062 Assembly 11: Finisher stapler assembly Previous Asm- Part Units/ Units/ Description Removal procedure Index number mach 11—1 40X7246 Stapler assembly “Finisher stapler unit assembly removal” on page 4-281 Next 40X5909 Sensor (media in stapler) “Finisher or stacker sensor (pass thru) removal”...
Page 646: Assembly 12: Finisher/Stacker Assembly (Complete)
5062 Assembly 12: Finisher/Stacker assembly (complete) Previous Next Go Back 7-30 Service Manual...
Page 647 5062 Assembly 12: Finisher/Stacker assembly (complete) Previous Asm- Part Units/ Units/ Description Removal procedure Index number mach 13—1 40X7230 Finisher assembly Next 40X7251 Stacker assembly Go Back 7-31 Parts catalog...
Page 648: Assembly 13: 5-Bin Mailbox Assembly (Complete)
5062 Assembly 13: 5-bin mailbox assembly (complete) Previous Next Go Back 7-32 Service Manual...
Page 649 5062 Assembly 13: 5-bin mailbox assembly (complete) Previous Units/ Units/ Index Description Removal procedure mach 14—1 40X7254 5 bin mailbox total option Next Go Back 7-33 Parts catalog...
Page 650: Assembly 14: 5-Bin Mailbox Assembly (Covers)
5062 Assembly 14: 5-bin mailbox assembly (covers) Previous Next Go Back 7-34 Service Manual...
Page 651 5062 Assembly 14: 5-bin mailbox assembly (covers) Previous Units/ Units/ Index Description Removal procedure mach 14—1 40X7272 Top cover “5-bin mailbox top cover removal” on page 4-253 Next 40X7266 Output bin paper bail “5-bin mailbox output bin paper bail removal” on page 4-247 40X7267 Output bin extension cover “5-bin mailbox tray extension...
Page 652: Assembly 15: 5-Bin Mailbox Assembly (Interior)
5062 Assembly 15: 5-bin mailbox assembly (interior) Previous Next Go Back 7-36 Service Manual...
Page 653 5062 Assembly 15: 5-bin mailbox assembly (interior) Previous Units/ Units/ Index Description Removal procedure mach 15—1 40X7263 Top output bin roller “5-bin mailbox roller removal” on page 4-251 Next 40X7264 1 thru 4 output bin roller “5-bin mailbox roller removal” on page 4-251 40X5545 Output bin LED...
Page 654: Assembly 16: Htu (Complete)
5062 Assembly 16: HTU (complete) Previous Next Go Back 7-38 Service Manual...
Page 655 5062 Assembly 16: HTU (complete) Previous Units/ Units/ Index Description Removal procedure mach 16—1 40X7275 Redrive unit, total asm Next Go Back 7-39 Parts catalog...
Page 656: Assembly 17: Htu (Covers)
5062 Assembly 17: HTU (covers) Previous Next Go Back 7-40 Service Manual...
Page 657 5062 Assembly 17: HTU (covers) Previous Units/ Units/ Index Description Removal procedure mach 17—1 40X7287 HTU top right cover “HTU top right cover removal” on page 4-329 Next 40X4528 HTU access door beacon card “HTU access door paper jam beacon (with cover and cable) removal”...
Page 658: Htu (Left Interior)
5062 Assembly 18: HTU (left interior) Previous Next Go Back 7-42 Service Manual...
Page 659 5062 Assembly 18: HTU (left interior) Previous Units/ Units/ Index Description Removal procedure mach 18—1 40X7305 HTU upper redrive guide “HTU upper guide removal” on page 4-332 Next 40X7312 HTU lower redrive guide “HTU lower redrive guide removal” on page 4-297 40X7314 HTU input sensor “HTU sensor (input) removal”...
Page 660: Assembly 19: Htu (Right Interior)
5062 Assembly 19: HTU (right interior) Previous Next Go Back 7-44 Service Manual...
Page 661 5062 Assembly 19: HTU (right interior) Previous Units/ Units/ Index Description Removal procedure mach 19—1 40X7304 HTU output option with spring hook “HTU option hook removal” on page 4-300 Next • Spring torsion hook front 40X7303 HTU (engage/output option) roller “HTU engagement roller removal”...
Page 662: Assembly 20: Htu With Hole Punch (Complete)
5062 Assembly 20: HTU with hole punch (complete) Previous Next Go Back 7-46 Service Manual...
Page 663 5062 Assembly 20: HTU with hole punch (complete) Previous Units/ Units/ Index Description Removal procedures mach 20-1 40X7235 Redrive unit with hole punch, total assembly Next Go Back 7-47 Parts catalog...
Page 664: Assembly 21: Htu With Hole Punch (Covers)
5062 Assembly 21: HTU with hole punch (covers) Previous Next Go Back 7-48 Service Manual...
Page 665 5062 Assembly 21: HTU with hole punch (covers) Previous Units/ Units/ Index Description Removal procedures mach 21—1 40X7326 HTU with hole punch, top right cover “HTU top right cover removal” on page 4-329 Next 40X4528 HTU access door beacon card “HTU access door paper jam beacon (with cover and cable) removal”...
Page 666: Assembly 22: Htu With Hole Punch (Left Interior)
5062 Assembly 22: HTU with hole punch (left interior) Previous Next Go Back 7-50 Service Manual...
Page 667 5062 Assembly 22: HTU with hole punch (left interior) Previous Units/ Units/ Index Description Removal procedure mach 22—1 40X7305 HTU upper redrive guide “HTU upper guide removal” on page 4-332 Next 40X7312 HTU lower redrive guide “HTU lower redrive guide removal”...
Page 668: Assembly 23: Miscellaneous
5062 Assembly 23: Miscellaneous Previous Units/ Description Removal procedure 40X7163 Sensors parts packet, including “Waste toner sensor removal” on page 4-159 Next • Waste toner sensors (2) • Paper auto size sensor “Waste toner full sensor removal” on • Paper path sensor (not shown) page 4-162 •...
Page 669 5062 Assembly 23: Miscellaneous Previous Units/ Description Removal procedure 40X7248 Finisher/Stacker cable parts pkt Next • Standard bin LED cable • Exit tray LED cable • Full/Near sensor cable • Jam door LED cable Go Back 40X7250 Output options screws 40X7320 HTU cable parts pack •...
Page 670: Assembly 24: Internal Options
5062 Assembly 24: Internal options Previous Units/ Units/ Index Description mach 40X6919 IPDS SCS card Next 40X6874 Forms & bar code card 40X6920 PRESCRIBE card 40X4819 Serial interface adapter Go Back 40X4823 Parallel 1284-B SERI adapter 40X4826 MarkNet N8120 10/1000 card 40X4827 MarkNet N8130 10/1000 F adapter 40X5301...
Page 671: Cable And Thermistor Location Table
5062 Previous Cable and thermistor location table Using the following table, locate the part you need to replace, and then go to the listed removal to find instructions for accessing the cable or thermistor. Next Cable location table item number Description Location To access...
Page 672 5062 Cable location table Previous item number Description Location To access 40X7168 10J0927 Paper path Deflector assembly 1. Remove the lower frame cable cables cover. See “Lower frame cable • System board connector: cover removal” on page 4-16. JPP2 Next 2.
Page 673 5062 Cable location table Previous item number Description Location To access 40X7168 10J0937 Thermistor & Behind fuser “Fuser thermistor removal” redrive cable on page 4-70. (Cont.) System board connector: JFSRD1 Next 10J0939 HVPS cable Under HVPS board “High-voltage power supply (HVPS) board removal”...
Page 674 5062 Cable location table Previous item number Description Location To access 40X7170 10J0943 Waste toner Under lower frame cable cover “Waste toner cable removal” cable on page 4-160. • System board connector: JWTB1 Next 10J0950 Bin-full sensor Top cover “Top cover removal” on cable page 4-30.
Page 675: Screw And Retainer Identification Table
5062 Previous Screw and retainer identification table The following table contains screw and fastener descriptions, 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. Next Sizes are as close to actual as possible, as long as the printout is not scaled or resized.
Page 676 5062 Screw identification table (continued) Previous Screw type Location 27S2839 Taptite M3 x 6 mm System board shield to system board cage slotted hex black Next Go Back 88A0001 MACH M3X0.5-6G 550-sheet drive assembly to 550-sheet drawer 88A0121 M3.5 x 6 Machine Standoff to HVPS board Panhead 88A0212...
Page 677 5062 Screw identification table (continued) Previous Screw type Location 88A0232 Taptite M3 x 6 mm 550-sheet left anti-tip latch assembly to 550-sheet drawer MTF PAN 550-sheet right anti-tip latch assembly to 550-sheet drawer Next Cable cover to system board cage System board to cage Fax ports on system board to cage Go Back...
Page 678 5062 Screw identification table (continued) Previous Screw type Location 88A0323 Plastite 550-sheet top metal cover to 550-sheet drawer M3.5 x 8 mm PAN 550-sheet bottom cover to 550-sheet drawer Next 550-sheet option deflector to 550-sheet drawer 550-sheet drive assembly to 550-sheet drawer ACM bias spring to lower frame Go Back Auto-connect harness to frame...
Page 679 5062 Screw identification table (continued) Previous Screw type Location 88A0329 M3.5 x 30 mm Paper path staging assembly to frame Next Go Back 88A0412 PL ROLN 550-sheet pick tire to 550-sheet pick arm assembly 2.9 x 5.2 mm Pick tires to Tray 1 paper pick mechanism 88A0414 SEMS PL ROLN 2000-sheet jam clearance top cover to 2000-sheet drawer...
Page 680 5062 Screw identification table (continued) Previous Screw type Location 1126830 E-clip M5 Bellcrank daturn, front and rear MPF pivot shaft Next MPF pulley Spur 17T Helicai gear Go Back 1126831 E-clip M6 MPF redrive gear 7-64 Service Manual...
Page 681: Appendix A-Print Samples
5062 Appendix A—Print samples Previous 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 682: Print Quality Pages-Page 1 (Total Of Five)
5062 Print Quality Pages—Page 1 (total of five) Previous Next Go Back Service Manual...
Page 683: Print Quality Pages-Page 2 (Total Of Five)
5062 Print Quality Pages—Page 2 (total of five) Previous Next Go Back Appendix A—Print samples...
Page 684: Print Quality Pages-Page 3 (Total Of Five)
5062 Print Quality Pages—Page 3 (total of five) Previous Next Go Back Service Manual...
Page 685: Print Quality Pages-Page 4 (Total Of Five)
5062 Print Quality Pages—Page 4 (total of five) Previous Next Go Back Appendix A—Print samples...
Page 686: Registration And Alignment
5062 Previous Registration and alignment Quick Test Page From the Diagnostics menu, select: REGISTRATION > Quick Test. Next Go Back Service Manual...
Page 687: Printhead Mechanical Alignment Test Page
5062 Printhead mechanical alignment test page Previous From the Diagnostics menu, select MISC TESTS > Printhead Inst. Next Go Back Appendix A—Print samples...
Page 688: Printhead Electronic Alignment Test Page-Magenta (One Of Two)
5062 Printhead electronic alignment test page—Magenta (one of two) Previous From the Diagnostics menu, select Alignment Menu > [select a color] > Quick Test. Next Go Back Service Manual...
Page 689: Printhead Electronic Alignment Test Page-Magenta (Two Of Two)
5062 Printhead electronic alignment test page—Magenta (two of two) Previous Next Go Back Appendix A—Print samples...
Page 690: Printhead Linearity Test Page
5062 Printhead linearity test page Previous From the Diagnostics menu, select Alignment Menu > [select a color] > Linearity > Quick Test] Next Go Back A-10 Service Manual...
Page 691: Index
5062 Index Previous Numerics cartridge rail 4-47 Next removal 2-20 2xx paper jam codes – cartridge rails 2-53 2-59 3x–8x attendance messages – parts catalog 2000-sheet high capacity feeder input option 3-28 Color Adjustment Go Back 2-66 diagnostics 3-29 Color Alignment 500-sheet tray input option 3-27 Color Trapping...
Page 692 5062 3-28 entering Download Emuls Previous 3-24 3-14 EP SETUP DRAM Test 3-24 3-12 DC Charge Adjustment Drift Sensors 3-24 Dev Bias Adj DUAL DIODE ADJUST 3-24 EP Defaults duplex assembly 3-24 4-53 Fuser Temp removal Next 3-24 3-16 OP Point Boost Duplex Quick Test 3-24 3-16...
Page 693 Lexmark confidential until announced 5062 7-12 parts catalog fuser drive assembly Previous 3-24 Fuser Temp redrive parts packet Fuser/MPF/autocomp parts packet lubrication specifications 7-10 parts catalog LVPS 7-14 parts catalog LVPS exit duct guidelines, media Next 7-14 parts catalog 4-89...
Page 694 5062 3-28 MPF wear strips PPDS Emulation Previous 4-109 removal preventive maintenance multipurpose feeder assembly print quality 2-31 parts catalog background 2-33 multipurpose feeder cover blank page 4-17 2-34 removal blurred or fuzzy print Next 2-34 characters have jagged or uneven edges 2-35 colors not properly aligned OP panel bezel...
Page 695 Lexmark confidential until announced 5062 4-135 4-24 removal right cover Previous 4-137 redrive parts packet sensors (D1, D2, fuser bubble) lubrication sensors (input, S1, narrow media, near narrow media) 7-10 4-138 parts catalog 3-10 4-139 REGISTRATION speaker 4-140 removals staging deflector assembly...
Page 696 5062 4-242 4-295 front cover locking lever Previous 4-244 4-297 media bin full actuator locking lever card 4-245 4-297 option cable lower redrive guide 4-246 4-300 output bin deflector option hook 4-247 4-302 output bin paper bail option roller 4-248 4-310 output bin sensors outer front cover removal...
Page 697 Lexmark confidential until announced 5062 3-23 4-139 Reset Calibration removal Previous right cover specifications parts catalog acoustics 4-24 removal dimensions electrical environment ii-xxi safety information Next memory configuration safety inspection guide operating clearance 7-59 screw and retainer identification table paper and media...
Page 698 5062 waste toner cover Previous 4-34 removal waste toner full sensor 4-162 removal waste toner gears 7-14 parts catalog Next waste toner left cover parts catalog waste toner sensor 4-159 removal Go Back waste toner tray bracket parts catalog 4-163 removal Service Manual...
Page 699: Part Number Index
5062 Part number index Previous Description Page 40X0269 Power cord—Bolivia, Peru - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Next 40X0270...
Page 700 5062 40X5970 Simplified Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-54 Previous 40X5971...
Page 701 5062 40X7124 Bin-full flag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous 40X7125 Waste toner left cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 702 5062 40X7233 Top cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 Previous 40X7234...
Page 703 5062 40X7302 HTU controller card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43 7-51 Previous...
Page 704 5062 Previous Next Go Back I-14 Service Manual...
Page 705 Cartridge Memory Lexmark C79X(5062) Blocks Printhead Wiring Diagram Fuser Redrive Fuser Bin Full Main Fan Sensor Output Option Cartridge Blower JBLW1 JPK1 JPY1 JCMKM1 JPH1 JPH2 JOOPT1 JMM1 JFSRD1 JTCVR1 JPC1 JFSR1 JCMCY1 JYF1 JRDR1 EP Drive JPM1 Assembly Fuser Drive...

Lexmark C792 series Service Manual

Notices and Safety Information

Laser Notice

Safety Information

Preface

Navigation Buttons

Change History

Conventions

General Information

Models

Maintenance Approach

Printer Configurations

Options and Features

Printer Specifications

Tools Required for Service

Acronyms

Diagnostic Information

Troubleshooting Map

Paper Jams

Output Option Paper Jams

Print Quality

User Messages

Service Errors

Symptoms

Service Checks

Diagnostic Aids

Understanding the Operator Panel and Menus

Accessing Service Menus

Diagnostics Menu

Configuration Menu

Theory of Operation

Printhead Verification

Repair Information

Handling ESD-Sensitive Parts

Removal Procedures

Base Printer Cover Removals

Base Printer Removals

Quick Links

Related Manuals for Lexmark C792 series

Summary of Contents for Lexmark C792 series