Page 1 Lexmark™ C77x, Lexmark C78x printer 5061 • 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 is a trademark of Lexmark International, Inc.
Page 3: Table Of Contents
5061 Table of contents Notices and safety information ......... . . xi Laser notice .
Page 4 5061 151.xx error code service check ........... . . 2-26 152.xx error code service check .
Page 5 5061 Low image density ............2-101 Poor color alignment .
Page 6 5061 Duplex Quick Test ............3-19 Duplex Top Margin Offset .
Page 7 5061 Paper Prompts ..............3-34 Env Prompts .
Page 8 5061 Fuser drive assembly removal ............4-46 Fuser fan removal .
Page 9 5061 Media size sensing board ............5-25 High-capacity input tray (HCIT) .
Page 10 5061 Appendix B—Print quality samples........B-1 Print tests .
Page 11: Notices And Safety Information
5061 Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Page 12 5061 Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
Page 13 5061 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. 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 14 5061 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 15 5061 Notices and safety information...
Page 16 5061 Service Manual...
Page 17: Safety Information
5061 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
Page 18 5061 Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
Page 19 5061 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 20: Preface
5061 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
Page 21: Conventions
5061 Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. There are several types of caution statements: CAUTION 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 22 5061 xxii Service Manual...
Page 23: General Information
5061 1. General information The Lexmark™ C77x, C78x (5061-xxx) is a network-capable color printer that uses electrophotographic technology to deliver high-quality images, presentation graphics, line art, and text. It prints both four-color and monochrome print jobs. The flexible design supports a variety of printing needs. For example, if you need the printer to match the color process used in a particular application, you can select RGB or CMYK color corrections.
Page 24: Options And Features
5061 Options and features Lexmark C77x and C78x printers support only Lexmark C77x and C78x paper-handling options. These options are not compatible with any other Lexmark printer. Note: The Envelope Feeder for the C772 (model 310) works only on the C772 models. The C782 (model 410) Envelope Feeder works on the C772 and the C782 (models 310 and 410).
Page 25: Toner Darkness
The toner darkness default setting is 4. Color level 4 and level 5 are the same. The toner darkness setting is available through the operator panel under the Print Quality menu or through the Lexmark PostScript driver. Setting Delta toner from default (mono)
Page 26: Printer Specifications
132 lb (including duplex unit and optional (734.1 mm) (604.5 mm) (469.9 mm) (60 kg) 500-sheet drawer) Lexmark C772, C782 maximum input trays 41.4 in. 23.8 in. 18.5 in. 179.0 lb (including duplex unit, three optional (1051.6 mm) (604.5 mm) (469.9 mm)
Page 27 Average nominal power requirements for the base printer configuration (110 volt). (Power levels are shown in watts.) Maximum current shown in amp ergs. Printing states Lexmark C77x(n) Lexmark C77xdn Lexmark C78x(n) Lexmark C78xdn Printing—average power (W) Base model All options Idle—average power...
Page 28 5061 Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296. Status (at 1 Meter average sound Lexmark Lexmark Lexmark Lexmark pressure) C770n C772n C780n C782n Printing at 4800 CQ 52 dBA 52 dBA 52 dBA...
Page 29: Power And Performance
Available printer memory • Media size and type • Resolution • Printer usage setting Processor Lexmark C77x(n), Lexmark C78x(n) Lexmark C77x Lexmark C78x Lexmark C77xdn Lexmark C78xdn Processor frequency (Mhz) Bus frequency (Mhz) Time to first print All first copy times are measured for 600 image quality, simplex printing on letter-size paper. The test job consists of the character “A”...
Page 30: Memory Configuration
256MB Maximum 640MB 768MB Available memory options Optional 128MB, 256MB and 512MB SDRAM DIMMs are available from Lexmark. The memory options are 168-pin synchronous DRAM DIMMs (dual in-line memory modules) meeting or exceeding the following specifications: • 100MHz or greater •...
Page 31: Media Specifications
5061 Media specifications Media input and output capacities The capacities listed below are based on plain paper at 75g/m Capacity (sheets) Media source or output Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark description C770n, C772n, C780n, C782n, C770dtn C772dtn...
Page 32: Media Sizes
5061 Capacity (sheets) Media source or output Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark Lexmark description C770n, C772n, C780n, C782n, C770dtn C772dtn C780dtn C782dtn C770dn, C772dn C780dn C782dn Output Standard output bin capacity Optional outputs 5-Bin mailbox (maximum of one)
Page 33 5061 Media sizes and support (continued) Legend 3 — supported with size sensing Optional finisher † — supported without size sensing 8— unsupported Media size Dimensions 215.9 x 279.4 mm † Letter (8.5 x 11 in.) 215.9 x 355.6 mm †...
Page 34 5061 Media support by type for optional features Optional Legend Finisher Optional 3 — supported Multi- Optional Optional Optional 500-sheet high Optional 8— unsupported purpose envelope banner 5-bin trays capacity duplex feeder drawer tray mailbox feeder Media Paper Card stock Transparencies Paper and Vinyl labels...
Page 35 A5 card stock, transparencies, envelopes, vinyl labels, and polyester labels. Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F). Lexmark transparency P/N12A8240 and 12A8241 are supported from the standard tray, optional 500-sheet trays, and the multipurpose feeder.
Page 36 A5 card stock, transparencies, envelopes, vinyl labels, and polyester labels. Vinyl labels are supported only when the printing environment and the media are at 20–32.2° C (68–90° F). Lexmark transparency P/N12A8240 and 12A8241 are supported from the standard tray, optional 500-sheet trays, and the multipurpose feeder.
Page 37 Refer to the Converter Listing on the Lexmark Home Page and Automated FAX system (LEXFAX™) for information on whether your vinyl label converter has passed the Lexmark criteria. Refer, also, to the Card Stock and Label Guide for more details.
Page 38 Refer to the Converter Listing on the Lexmark Home Page and Automated FAX system (LEXFAX™) for information on whether your vinyl label converter has passed the Lexmark criteria. Refer, also, to the Card Stock and Label Guide for more details.
Page 39: Media Guidelines
Refer to the Converter Listing on the Lexmark Home Page and Automated FAX system (LEXFAX™) for information on whether your vinyl label converter has passed the Lexmark criteria. Refer, also, to the Card Stock and Label Guide for more details.
Page 40: Paper Characteristics
The following paper characteristics affect print quality and reliability. It is recommended that these guidelines are followed when evaluating new paper stock. For detailed information, see the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com/publications.
Page 41: Unacceptable Paper
5061 Unacceptable paper The following papers are not recommended for use with the printer: • Chemically treated papers used to make copies without carbon paper, also known as carbonless papers, carbonless copy paper (CCP), or no carbon required (NCR) paper •...
Page 42: Web Oiler Upgrade Kit And Replacements
The web oiler works with all media types and enables the prolonged use of labels without sacrificing fuser life. • Web oiler fuser life: 120,000 (C78x models), 200,000 (C77x models), • Web oiler life: 100,000 pages •...
Page 43: Acronyms
5061 Acronyms BLDC Brushless DC Motor Black Only Retract Cyan Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT High-Capacity Input Tray HCOF High-Capacity Output Finisher HVPS...
Page 44 5061 1-22 Service Manual...
Page 45: Diagnostic Information
5061 2. Diagnostic information Start CAUTION Unplug the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. CAUTION The printer weighs 48–82 kg (105–181 lb) and requires at least three people to lift it safely.
Page 46: Por (Power-On Reset) Sequence
5061 POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed. Power the machine on. +5 V LED (Power ON) on the system board comes on. Fans turn on.
Page 47: Symptom Tables
5061 Symptom tables Symptom table—base printer Symptom Action Fuser fan fails to run or is noisy Go to “925.02 error code service check” on page 2-56. RIP fan fails to run or is noisy Go to “927.03 error code service check” on page 2-57.
Page 48: Symptom Table-500-Sheet Drawer Option
5061 Symptom Action Printer prints black only, no colors Make sure that the printer is not set up to print black only. If the printer is set up correctly, check the Black Retract (BOR) Motor and gears for correct operation. If the gears are operating correctly, replace the Retract Motor Assembly.
Page 49: Symptom Table-Hcit 2000-Sheet Option
5061 Symptom Action The tray x autocompensator fails to retract, stays in Go to “Tray x autocompensator fails to retract, down position stays in down position.” on page 2-74. Paper Low message appears when adequate paper Go to “The printer detects paper low in tray x when is installed (tray x) adequate paper is installed in the tray.”...
Page 50: Symptom Table-Staplesmart Finisher
5061 Symptom Action Bin x is full but no message displays that Bin x is full Go to “Bin x full—no message that bin x is full message” on page 2-71 Bin full message displays but paper feeds into bin. Go to “Ready—bin x full displays and paper feeds into bin x”...
Page 51: Service Error Code And Paper Jam Message Table
5061 Service error code and paper jam message table Error codes and paper jam messages Error code Action User attendance messages 1xx service errors 100.01 ITU Error ITU belt track direction problem—go to “100.01 ITU error service check” on page 2-14.
Page 52 5061 Error codes and paper jam messages (continued) Error code Action 122.06 Fuser Error Fuser failed to raise temperature quickly enough or raises temperature too quickly— go to “122.05 and 122.06 error code service check” on page 2-21. 122.07 Fuser Error Fuser timeout waiting for home sensor—go to “122.07, 122.14, and 122.15 error code service check”...
Page 53: 2Xx Paper Jams
5061 Error codes and paper jam messages (continued) Error code Action 2xx paper jams 200.03 Paper Jam S2 sensor was made at an unexpected time. This message indicates that a paper Clear Paper Path jam has occurred at or near the printer Input Sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media.
Page 54 5061 Error codes and paper jam messages (continued) Error code Action 200.72 Paper Jam Registration motor error— replace the registration motor. See “Registration motor Clear Paper Path removal” on page 4-84. If this does not fix the problem, replace the system board. See “System board removal”...
Page 55: 9Xx Service Errors
5061 Error codes and paper jam messages (continued) Error code Action 250.xx Paper Jam Paper is jammed in the MPF. Clear Paper Path If removing the jammed media does not fix the problem, go to “250.xx paper jam service check” on page 2-49.
Page 56 5061 Error codes and paper jam messages (continued) Error code Action 921.xx Registration Unrecoverable Registration Sensor Error—Replace the ITU assembly. See “ITU assembly removal” on page 4-49. 925.02 Fan Stalled Fuser fan—Go to “925.02 error code service check” on page 2-56.
Page 57 5061 Error codes and paper jam messages (continued) Error code Action 962.xx RAM Memory There is an error in the memory installed in the memory option slot 2 on the system Error board. If another memory option is available, switch the memory options to isolate the problem.
Page 58: Service Checks
5061 Error codes and paper jam messages (continued) Error code Action 990.01 <device> This error message indicates that an equipment check condition has occurred in the specified device, but the error is unable to identify the exact component failure. Go to “990.01 error service check”...
Page 59 5061 Step Actions and questions Check the ITU release lever for correct operation. The Go to step 3 Repair as ITU release lever is the black lever located on the left necessary. upper side frame above the ITU opening and can be seen by opening and lowering the MPF assembly.
Page 60 5061 Step Actions and questions Check to see if the ITU drive roll gear (A) is turning Go to step 10 Go to step 9 during POR. Observe the gear by opening the MFP door to its horizontal position. Observe the gear on the left end of the ITU drive roll.
Page 61: 100.02 Itu Error Service Check
5061 100.02 ITU error service check The ITU has an optical sensor that watches for a piece of reflective tape on the inside of the image belt. This tape is read every revolution of the belt. If a signal is not received from the belt sensor within a certain time period, the printer posts an error due to the loss of signal.
Page 62: 122.01 Error Code Service Check
5061 Step Actions and questions Check the printer is setting on a solid, flat surface. Go to step 5 Inform the customer that the Is the printer setting on a solid, flat surface? printer must be setting on a solid, flat surface.
Page 63: 122.03 Error Code Service Check
5061 122.02 error code service check Hot fuser Error code 122.02 displays whenever the printer detects a problem with the fuser running over temperature or the fuser lamps have been on too long. A problem could exist in the fuser assembly with the hot roll bearings, hot roll thermistor, or other hot roll parts.
Page 64: Error Code Service Check
5061 122.04 error code service check Cold hot roll Step Actions and questions Measure the voltage on connector J17-11 on the Go to step 2 Replace the system board. The voltage should measure system board. approximately +0.13 V dc to +0.64 V dc as the hot roll “System lamp turns off and on.
Page 65: 122.05 And 122.06 Error Code Service Check
5061 122.05 and 122.06 error code service check Error codes 122.05 and 122.-6 indicate that the fuser didn’t increase in temperature enough. Error code 122.05 may also indicate a problem in the fuser assembly with the hot roll bearings, hot roll thermistor, LVPS, or the system board.
Page 66: 122.07, 122.14, And 122.15 Error Code Service Check
5061 122.07, 122.14, and 122.15 error code service check Fuser assembly cam position is not found. Step Actions and questions Observe the fuser drive assembly gears rotate during Go to step 2 Go to step 5 POR. Do the gears rotate? Do the gears stop and the fuser drive assembly gears Replace the Go to step 3...
Page 67 5061 122.08 error code service check Step Actions and questions Replace the fuser assembly. See “Fuser assembly Replace the Problem resolved removal” on page 4-44. system board. “System Does the error remain? board removal” on page 4-90. 122.10 error code service check Cold hot roll Step Actions and questions...
Page 68 5061 122.11 error code service check Fuser hot roll is under temperature during standby Step Actions and questions Turn the printer on, and allow it to reach a Ready Go to step 2 Replace the prompt. system board. “System Note: The printer may not complete POR and continue board removal”...
Page 69: 148.Xx Error Code Service Check
5061 148.xx error code service check Step Actions and questions Connector J16 on the system board—Check for Go to step 2 Install the cable correct installation of the ITU drive motor cable from correctly. the ITU drive motor to the system board connector J16. Is the cable connected correctly? ITU drive motor—Check for continuity between pin 4 of Replace the drive...
Page 70: Error Code Service Check
5061 150.xx error code service check Black cartridge drive assembly This error indicates the black cartridge drive motor has failed to lock, has lost lock, or signature button could not be read. Step Actions and questions Check the black cartridge drive motor cable connection Go to step 2 Install the cable to J16 on the system board.
Page 71: Xx Error Code Service Check
5061 152.xx error code service check Cyan cartridge drive assembly This error indicates that the cyan cartridge drive motor has failed to lock, has lost lock, or the signature button could not be read. Step Actions and questions Check the cyan cartridge drive motor cable connection Go to step 2 Install the cable to J19 on the system board.
Page 72: 177.Xx Error Code Service Check
5061 177.xx error code service check This error indicates a MPF motor error. Step Actions and questions MFP motor/sensor cable—check the MPF motor/ Go to step 2 Install the cable sensor cable to JMPF1 on the system board to make correctly.
Page 73: Paper Jam Service Check
5061 200.04 paper jam service check S2 sensor late Note: See “Printer sensors” on page 5-3. Step Actions and questions Check the tray for proper edge guide setting and media Go to step 2 Properly load loading. Edge guides should be adjusted against edge media.
Page 74: 200.05 Paper Jam Service Check
5061 200.05 paper jam service check S2 or narrow media sensor did not break in time Note: See “Printer sensors” on page 5-3. Step Actions and questions Make sure the media installed in the tray meets Go to step 2 Inform the specifications.
Page 75: 200.07 Paper Jam Service Check
5061 200.07 paper jam service check S2 or narrow media sensor did not break in time. Note: See “Printer sensors” on page 5-3. Step Actions and questions Make sure the media installed in the tray meets Go to step 2 Inform the specifications.
Page 76: 200.21, 200.28, And 200.29 Paper Jam Service Check
5061 200.21, 200.28, and 200.29 paper jam service check Either the transparency sensor (200.21), the S2 sensor (200.28), or the narrow media sensor (200.29) is dislodged or damaged. Note: See “Printer sensors” on page 5-3. Step Actions and questions Check the sensor and flag. Remove the Go to step 3 paper or debris,...
Page 77: 200.93 Paper Jam Service Check
5061 Step Actions and questions Are connectors at J21 fully seated on the system Go to step 7 Reseat the board? connector on the system board. Check sensor cables. Replace the Go to step 8 cables. Are the cables cut or broken? Replace the sensor that did not pass the test.
Page 78 5061 Step Actions and questions Reinstall fuser and perform the “BASE SENSOR Go to step 5 Perform the TEST” on page 3-24. following in order: Note: Use a spring hook to actuate the flag. 1. Reseat the connector Does fuser exit sensor pass test? J17 on the system board.
Page 79: 200.96 Paper Jam Service Check
5061 200.96 paper jam service check Neither the S2 nor narrow media sensor broke in time. Note: See “Printer sensors” on page 5-3. Step Actions and questions Make sure the media installed in the tray meets Go to step 2 Inform the specifications.
Page 80 5061 Step Actions and questions Reinstall the fuser and perform the “BASE SENSOR Go to step 5 Perform the TEST” on page 3-24 for the fuser exit sensor. following in order: Note: Use a spring hook to actuate the flag. 1.
Page 81: 230.Xx Paper Jam Service Check
5061 Step Actions and questions Is a 5-bin mailbox option, StapleSmart finisher, or an Check the Contact your next output expander option in use? following: level of support. • Reseat the option on the printer. • Verify the top cover is properly seated on developer...
Page 82: 241.Xx Paper Jam Service Check
5061 Step Actions and questions Check that the diverter actuator link is not binding or Repair the Go to step 7 damaged. Examine the link for damage under the actuator link. duplex option. Is link binding or damaged? Check the duplex actuator button. See “Duplex Replace the Go to step 8...
Page 83: Xx Paper Jam Service Check
5061 Step Actions and questions Make sure the pass thru sensor is correctly connected Replace the Install the cable to the Tray x system board. FRUs in the correctly. following order: Is the sensor cable connected correctly? 1. Pass thru sensor assembly.
Page 84 5061 Step Actions and questions See if the paper is trying to feed from the tray. Go to step 8 Go to step 5 Note: You can observe the autocompensator feed rolls and the paper through the tray access door. Run the Tray x feed test from the Diagnostics menu to help diagnose a feed problem.
Page 85 5061 HCIT Use the “HCIT standalone test mode” on page 3-5 inside the HCIT to help isolate paper jams. Run the Standalone Feeding Operation Test to observe paper feeding from the tray and through the feed assembly. Use “HCIT system board LED error code table” on page 2-86 to further isolate paper jam or sensor problems.
Page 86 5061 Step Actions and questions Is the registration home sensor operating correctly? Replace the Replace the following FRUs in following FRUs in the order shown: the order shown: 1. HCIT system 1. Registration board. sensor. 2. Feed unit 2. HCIT system assembly.
Page 87: 243.Xx Paper Jam Service Check
5061 Step Actions and questions Make sure the envelopes are loaded correctly. Make Go to step 3 Load the sure the side and back restraints are located and envelopes seated properly. correctly. Are the envelopes loaded correctly? Observe if the envelopes feed from the tray. Go to step 8 Go to step 4 Note: You can observe the autocompensator pick rolls...
Page 88 5061 Step Actions and questions Make sure the media is loaded correctly. Make sure Go to step 4 Load the media the side and back restraints are located and seated correctly. properly. Is the media loaded correctly? See if the paper is trying to feed from the tray. Go to step 8 Go to step 5 Note: You can observe the autocompensator feed rolls...
Page 89 5061 HCIT Use the “HCIT standalone test mode” on page 3-5 inside the HCIT to help isolate paper jams. Run the Standalone Feeding Operation Test to observe paper feeding from the tray and through the feed assembly. Use “HCIT system board LED error code table” on page 2-86 to further isolate paper jam or sensor problems.
Page 90 5061 Step Actions and questions Is the registration home sensor operating correctly? Replace the Replace the following FRUs in following FRUs in the order shown: the order shown: 1. HCIT system 1. Registration board. sensor. 2. Feed unit 2. HCIT system assembly.
Page 91 5061 Envelope feeder Before proceeding with this service check, make sure the envelope option is installed correctly. Step Actions and questions Make sure the envelopes installed in the tray meet Inform the Go to step 2 specifications. customer of the problems with the Some guidelines that can be used in selection of envelopes that...
Page 92: 244.Xx Paper Jam Service Check
5061 244.xx paper jam service check HCIT—For the fourth installed option. Use the “HCIT standalone test mode” on page 3-5 inside the HCIT to help isolate paper jams. Run the Standalone Feeding Operation Test to observe paper feeding from the tray and through the feed assembly. Use “HCIT system board LED error code table”...
Page 93: Xx Paper Jam Service Check
5061 Step Actions and questions Is the registration home sensor operating correctly? Replace the Replace the following FRUs in following FRUs in the order shown: the order shown: 1. HCIT system 1. Registration board sensor 2. Feed unit 2. HCIT system assembly.
Page 94 5061 Step Actions and questions Open the MPF to the horizontal position, and check the Clear the Go to step 6 paper path for obstructions. obstruction. Is the paper path obstructed? Raise the pick tire off the media, and test the MPF. Go to step 8 Go to step 7 Does the pick tire turn?
Page 95: 271.Xx Paper Jam Service Check
5061 271.xx paper jam service check Output bin Note: Before proceeding with this service check, run the Output Bin x Sensor Test and check for the failing sensor. Sensor Tests: Near Full (Upper part of sensor assembly) Full (Lower part of sensor assembly) Pass Thru Sensor Step Actions and questions...
Page 96: 272.Xx Paper Jam Service Check
5061 272.xx paper jam service check 5-bin mailbox Step Actions and questions Bottom pass thru sensor flag—Make sure the flag is Fix or replace the Go to step 2 operating correctly and is not binding, broken, and flag. there is no interference from the sensor cable. Is there any problem found with the sensor flag? Bottom pass thru sensor—Make sure the sensor is Go to step 3...
Page 97: 282.98 Paper Jam Service Check
5061 282.98 paper jam service check 282.98 Staple Jam—Check Stapler displays Step Actions and questions Staple cartridge holder—Check for jammed staples in Replace the old Go to step 2 the staple cartridge holder. strip of staples with a new strip. Are there any jammed staples? Perform the Finisher Feed...
Page 98 5061 Step Actions and questions Disconnect the printer from any external connections. Go to step 4 Go to step 3 Turn the power off and remove any parallel, USB, or network connections. Turn the printer on. Does the 900 error display? Run the internal test pages.
Page 99 5061 Intermittent 900 Service RIP Error codes It is important to determine under what circumstances the error occurs. Capturing the following information aids in categorizing the nature of the intermittent error. Crash codes—With the 900 Service RIP Error displayed, press Menu ( ) and together.
Page 100 5061 925.02 error code service check Fuser fan (main fan) Step Actions and questions Turn the power off, manually spin the fan, and check Go to step 2 Replace the fuser that it rotates freely. fan. See “Fuser fan removal” on Does the fan rotate freely? page 4-47.
Page 101 5061 927.03 error code service check RIP fan Step Actions and questions Turn the power off, manually spin the fan, and check Go to step 2 Replace the RIP that it rotates freely. fan. See “RIP fan removal” on Does the fan rotate freely? page 4-87.
Page 102: 940.Xx Error Code Service Check
5061 Step Actions and questions Is 930 error still displayed? Replace the Problem resolved LVPS assembly. “LVPS assembly removal” on page 4-53. 940.xx error code service check • 940.02—cyan toner metering cycle (TMC) problem • 940.05—cyan toner metering timeout problem The TMC is where the code and electronics in the printer sense an addition of toner in the cartridge developing area.
Page 103 5061 Step Actions and questions Check the TMC pin (B) in the cyan cartridge contact Go to step 3 Replace the assembly to make sure it moves freely. cartridge contact assembly. See “Cartridge contact assembly removal” on page 4-35. Does the pin move freely? Go to the Base Sensor Test.
Page 104: Xx Error Code Service Check
5061 Step Actions and questions Check the voltage at connector J6-11 when the cyan Go to step 10 Go to step 11 TMC switch is pressed. Does the voltage measure approximately +3.3 V dc? Check the developer HVPS to system board cable for Replace the Replace the damage, broken connections, or wire and shorts...
Page 105 5061 Step Actions and questions Check the TMC pin (B) in the magenta cartridge Go to step 3 Replace the contact assembly to make sure it moves freely. cartridge contact assembly. See “Cartridge contact assembly removal” on page 4-35. Does the pin move freely? Go to the “BASE SENSOR TEST”...
Page 106: Xx Error Code Service Check
5061 Step Actions and questions Check the voltage at connector J6-6 when the Go to step 10 Go to step 11 magenta TMC switch is pressed. Does the voltage measure approximately +3.3 V dc? Check the developer HVPS to system board cable for Replace the Replace the damage, broken connections, or wire and shorts...
Page 107 5061 Step Actions and questions Check the TMC pin (B) in the yellow cartridge contact Go to step 3 Replace the assembly to make sure it moves freely. cartridge contact assembly. See “Cartridge contact assembly removal” on page 4-35. Does the pin move freely? Go to “BASE SENSOR TEST”...
Page 108: Xx Error Code Service Check
5061 Step Actions and questions Check the voltage at connector J6-16 when the yellow Go to step 10 Go to step 11 TMC switch is pressed. Does the voltage measure approximately +3.3 V dc? Check the developer HVPS to system board cable for Replace the Replace the damage, broken connections, or wire and shorts...
Page 109 5061 Step Actions and questions Check the TMC pin (B) in the black cartridge contact Go to step 3 Replace the assembly to make sure it moves freely. cartridge contact assembly. See “Cartridge contact assembly removal” on page 4-35. Does the pin move freely? Go to “BASE SENSOR TEST”...
Page 110: 956.Xx Service Error Service Check
5061 Step Actions and questions Check the voltage at connector J6-1 when the black Go to step 10 Go to step 11 TMC switch is pressed. Does the voltage measure approximately +3.3 V dc? Check the developer HVPS to system board cable for Replace the Replace the damage, broken connections, or wire and shorts...
Page 111: Error Service Check
5061 990.01 error service check This error indicates which option is causing the error. 5-Bin mailbox Step Actions and questions Mechanical linkage/DC motor assembly—Check the Go to step 2 Reseat the cable, DC motor cable connector to make sure it is installed at and recheck for J4 on the control board.
Page 112 5061 500-sheet drawer option For 990.01 Service Error—Tray x, x=Tray 2, 3, or 4, this is the tray that has a problem or needs service. Note: Verify the autoconnect housing is correctly snapped into the printer and all options and is plugged into the system board correctly.
Page 113: 5-Bin Mailbox Option Service Check
5061 Step Actions and questions Output expander control board check—Disconnect the Replace the Replace the motor cable at J4, and check the voltages at J4 on the output expander mechanical board. control board. linkage/DC motor assembly. Warning: Be careful not to short to adjacent pins on the connector.
Page 114 5061 Step Actions and questions Ready—Bin x Full message—May be able to clear Go to “Ready Go to step 5 message and will feed paper into Bin selected. bin x full message—may be able to clear message and will feed paper into bin selected.”...
Page 115 5061 Step Actions and questions Voltage check, base printer autoconnect connector— Replace the Replace the Turn the power off, and remove the output option from output option. bottom option the printer. Check the voltages on the base printer top autoconnect autoconnect connector.
Page 116 5061 Ready—bin x full displays and paper feeds into bin Step Actions and questions Bin x sensor flag—Make sure the bin x sensor flag is Replace the bin x Repair or replace not in the up position and is operating correctly. sensor.
Page 117: 500-Sheet Drawer Option Service Check
5061 500-sheet drawer option service check If the paper does not feed from the 500-sheet option, see “Autocompensator service check” on page 2-78. Whenever the 500-sheet tray is removed, use care as the autocompensator may be in its down position which could result in damage to the autocompensator assembly.
Page 118 5061 Tray autocompensator fails to retract, stays in down position. Step Actions and questions Use care when removing a tray assembly when the Go to step 2 Go to step 3 autocompensator is in its down position. Remove the tray, and manually reset the autocompensator to its uppermost position by actuating the pick arm lift bellcrank.
Page 119 5061 The printer detects paper out in tray when adequate paper is installed in the tray. Step Actions and questions Run Tray x Sensor Test from the Diagnostics Menu. Go to step 5 Go to step 2 Does the test pass for Sensor L1? Check the cable connection for the paper level sensing Go to step 3 Install the cable...
Page 120: Ac And Dc Power Service Check
5061 AC and DC power service check Before proceeding with this service check remove or disconnect any options that may be installed. Turn the machine on. If it operates correctly, reattach one option at a time until the failing option is located. Note: Set the voltage range switch to the proper power setting for the geographic area you are in.
Page 121 5061 DC power service check The machine is partially operative, a motor turns, display is on, or the Power On LED may be on or off. Step Actions and questions Does the printer beep 5 times and the operator panel Go to “Operator Go to step 2...
Page 122: Autocompensator Service Check
5061 Autocompensator service check • If the paper fails to feed from Tray 1 or 500-sheet option, go to “Step A” on page 2-78. • If the autcompensator fails to lower when Tray 1 is installed, go to “Step B” on page 2-79.
Page 123 5061 Step B Step Actions and questions Check Tray 1 for damage to the pick arm lift bellcrank Replace tray 1. Go to step 2 activation tabs on the rear of the tray. Is there any damage to the tray? Check the following parts for damaged, loose, or Repair or replace Go to step 3...
Page 124: Black Only Retract (Bor) Service Check
5061 Step D Step Actions and questions Enter the Diagnostics Mode and select INPUT TRAY Contact your next Go to step 2 TESTS, Sensor Test, and Tray 1. You can activate level of support. the paper level sensor inside the printer. The paper level sensor is a dual sensor and checks the following levels for Tray 1.
Page 125: Close Door/Hvps/Printhead Interlock Switch Service Check
5061 Close door/HVPS/printhead interlock switch service check Note: There are two separate cables that contain microswitches and a cable. These cable/switches provide separate interlocks for the printhead and HVPS. One switch in the Printhead/cover open cable is mounted in the front access door support, and the other switch in the printhead/open cover cable is mounted on the ITU light shield assembly.
Page 126 5061 POR complete, printer feeds blank page This symptom is usually associated with the upper switch mounted on the front access door support. Step Actions and questions Make sure that the ITU light shield is not broken. Replace the ITU Go to step 2 light shield.
Page 127: Duplex Option Service Check
5061 Duplex option service check Before proceeding with this service check: Check for any pieces of media or obstructions in the duplex paper path that might cause a paper jam. Check for correct installation of the front duplex jam tray and right side clearance tray. Check the duplex option for any signs of loose, damaged, contaminated, or warped parts that might cause a jam.
Page 128 5061 Step Actions and questions Check the voltages on the bottom options cable Go to step 8 Replace the connector. The voltages are with the printer in standby bottom options mode. cable in the printer. Note: All voltages are approximate values. Connector pin Voltage J20-1 +5 V dc...
Page 129: Envelope Feeder Option Service Check
5061 Envelope feeder option service check Note: Except for the tray and pick tires, the envelope feeder option is a complete assembly with no other internal parts that can be replaced. If a 24x.xx paper jam is displayed, go to the appropriate service check: •...
Page 130: Hcit 2000-Sheet Option Service Check
5061 Envelopes do not feed from the tray or do not feed correctly Step Actions and questions Check the envelope feeder tray to make sure it is Go to step 2 Install the tray installed correctly. correctly. Is the tray installed correctly? Check the tray to make sure it has been set up Go to step 3 Set the tray up...
Page 131 5061 Printer does not recognize that the HCIT 2000-sheet option is installed. Step Actions and questions Is the HCIT 2000-sheet option the only paper input Go to step 5 Go to step 2 option that is not recognized? Make sure that the printer and any option above the Go to step 3 Install the options HCIT 2000-sheet option are installed correctly.
Page 132 5061 HCIT inoperative Before proceeding with this service check, make sure the 2000-sheet tray option is properly connected to AC power. The printer power cord plugs into the HCIT AC outlet, and the power cord from the HCIT plugs into the AC voltage source.
Page 133: Fuser Drive Assembly Noise Check
5061 HCIT 2000-sheet option does not recognize the size paper selected. Step Actions and questions Make sure the media loaded in the tray meets Go to step 2 Load the media specifications. properly, or inform the Is the media loaded properly and meet specifications? customer that the media does not meet...
Page 134: Operator Panel Lcd/Status Led/Buttons Service Check
5061 Operator panel LCD/status LED/buttons service check Use this service check to check both the operation of the panel buttons and to test the LCD display for correct operation. • Replace the operator panel assembly if the LCD display functions normally, but the LED does not come •...
Page 135 5061 Step Actions and questions System board—Measure the voltage at connector Replace the Go to step 8 JOPP1-2 on the “System board” on page 5-8. The operator panel voltage measures approximately +5 V dc. assembly. See “Operator panel Is the voltage correct? assembly removal”...
Page 136: Output Expander Option Service Check
5061 Output expander option service check Note: The majority of the mechanical components can be observed during operation by removing the covers. The output expander functions without the covers installed. Make sure the option is correctly installed before attempting to service the unit. Step Actions and questions The printer does not recognize one or more output...
Page 137 5061 Printer does not recognize that one or more output options as being installed. Step Actions and questions Excessive static electricity buildup—Check the output Go to step 2 1. Attach the expander control board cover to make sure the ESD ground cable if brush ground lead is firmly attached to the output not installed...
Page 138 5061 No indication that bin is full or no indication that bin is near full. Step Actions and questions Sensor cable installation—Check for correct Go to step 2 Install the cable installation of the sensor cable at J5 on the control correctly.
Page 139: Print Quality Service Check
5061 Print quality service check Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install an ITU, fuser assembly, second transfer roll, or print cartridge. Check the following before proceeding with any of the print quality service checks.
Page 140: Entire Page Is Mostly One Color-Full Bleed Planes In One Color
5061 Entire page is mostly one color—Full bleed planes in one color Some printing may appear in other colors. This applies to black, cyan, magenta, and yellow. Step Actions and questions Change or switch the cartridge of the color that is Go to step 2 Replace the experiencing the issue.
Page 141: Missing Colors-Complete Or Partially Missing Color Planes
5061 Missing colors—Complete or partially missing color planes • If a color or colors are missing, or a color is partially missing, go to “If cyan, magenta, and yellow is missing, go to “Black and white only—cyan, magenta, and yellow are missing” on page 2-98.” on page 2-97.
Page 142: Black And White Only-Cyan, Magenta, And Yellow Are Missing
5061 Step Actions and questions Cartridge contact assembly—Check the cartridge Go to step 8 Replace the contact block. Make sure the PC drum contact pin is cartridge contact not stuck. See “Cartridge contact assembly pin assembly. See locations (cyan, magenta and yellow)” on page 5-4 “Cartridge to identify the PC drum contact pin.
Page 143 5061 All colors have light print over the entire page Step Actions and questions Replace the second transfer roll. See “Second Go to step 2 Problem resolved transfer roll removal” on page 4-89. Does the light print persist? Turn the printer off. Check the cable connections Go to step 3 Problem resolved between the transfer HVPS board and the system...
Page 144: Vertical Lines Or Streaks
5061 Vertical lines or streaks Step Actions and questions Are the vertical lines or streaks visible outside the Go to step 2 Replace the printed image? cartridge. Are the vertical streaks in a single color? Go to step 3 Replace the ITU assembly.
Page 145: Low Image Density
5061 Low image density Note: If all colors have a low image density problem, set the Print Darkness to High from the user’s menu. • If only one color has a problem, go to “Step A.” • If all colors have a problem, go to “Step B.” Step A Step Actions and questions...
Page 146: Transparency Print Quality Is Poor
5061 Step Actions and questions ITU—Make sure that the ITU legs are properly seated Alignment— Reinstall the ITU. onto the rail at the right side of the printer. This is Enter the If the problem visible by removing the yellow print cartridge. Diagnostics continues, Menu.
Page 147: Negative Ghosting Or Faded Image
5061 Negative ghosting or faded image The print has a negative ghost on the page or the image is faded, particular with text. This problem may happen with any color and can be mistaken as toner smudges on the page. Step Actions and questions Check the bellcranks of the color that is having the...
Page 148: Toner Smears Or Rubs Off The Page With No Error Code Displayed
5061 Toner smears or rubs off the page with no error code displayed Note: This type of problem is associated with improper fusing or incorrect settings for media type being used. Step Actions and questions Media settings—Does the media setting match the Set the printer for Go to step 3 current media type?
Page 149: Toner Is On The Back Of The Printed Page
5061 Toner is on the back of the printed page Do the following steps before proceeding with this service check: Enter the Diagnostics Mode. Select Print Test, Tray 1, Continuous from the menu. Run at least 20 pages of text, and see if the problem remains. •...
Page 150: White Streak In Color Plane
5061 White streak in color plane A white streak appears in one particular color plane. This problem may be caused by a contaminated developer roll in the print cartridge. Step Actions and questions Check to see which color is having the problem, and go to step 2.
Page 151: User Troubleshooting For Quality
5061 User troubleshooting for quality The information in the following table may help you solve print quality problems. If these suggestions still do not correct the problem, call for service. You may have a printer part that requires adjustment or replacement. Quality troubleshooting Symptom Cause...
Page 152 5061 Quality troubleshooting (continued) Symptom Cause Solution Streaked horizontal lines The print cartridges, the Replace the print cartridge, the transfer roller, the transfer roller, image image transfer unit, or fuser as needed. transfer unit, or fuser may From the printers operator panel, print the repetitive be defective, empty, or defects guide to determine which component needs worn.
Page 153 5061 Quality troubleshooting (continued) Symptom Cause Solution Print too light • Paper settings may be • Make sure the printer paper type, paper texture, incorrect. and paper weight settings match the type of paper you are using. • The Toner Darkness setting is too light.
Page 154 • Refer to the Card Stock & Label Guide available slanted.) media size loaded in the on the Lexmark Web site at www.lexmark.com tray. for detailed specifications. • You are using paper • For more information, see “Media guidelines”...
Page 155: Second Transfer Roll Service Check
5061 Quality troubleshooting (continued) Symptom Cause Solution Blank pages The print cartridges are Replace the print cartridges. defective or empty. Solid color pages • The print cartridges are • Replace the print cartridges. defective. • Call for service. • Your printer requires servicing.
Page 156 5061 Step Actions and questions Check the continuity of the second transfer cable. Replace the Replace the FRUs in order: second transfer Is there continuity? cable. 1) Second transfer roll. See “Second transfer roll removal” on page 4-89. 2) Transfer HPVS board.
Page 157: Staplesmart Finisher Service Check
5061 StapleSmart finisher service check Note: When removing the stapler mechanism from the option, first remove the staple supply cartridge. Note: When replacing staples in the supply cartridge, discard any old staples in the cartridge, and replace with a fresh strip. Problems with static electricity buildup Make sure the brush is attached to the top cover assembly, the ground clips are installed, and the brush is grounded.
Page 158 5061 Close Finisher Side Door displayed—unable to clear or reset message (POST incomplete) Step Actions and questions Side cover door—Check the stapler access door for Replace the Replace the any signs of damage or broken parts. Make sure the stapler option. stapler access door correctly actuates the stapler side access door door switch...
Page 159 5061 Stapled sheets are not transported to the output tray Replace the stapler option. POST incomplete—Insert Stapler Cartridge displays (cartridge holder is installed and cannot clear message) When this failure occurs, the following may also occur in the order shown: •...
Page 160 5061 POST incomplete—stapler cycles several times Step Actions and questions Remove the stapler cartridge holder from the stapler Replace the Go to step 2 assembly. If the holder is jammed in the stapler broken or assembly: missing flag or spring. 1.
Page 161: Tray 1 Service Check
5061 Tray 1 service check Tray 1 does not stay seated or fit correctly in the printer, the media fails to feed correctly from tray 1, or tray 1 is difficult to install. The Tray 1 Feed Test in the Diagnostics menu can be used to help isolate problems with paper feeding from Tray 1.
Page 162: Tray 1 Media Size Sensing Service Check
5061 Tray 1 media size sensing service check The printer does not sense the size of the media installed in Tray 1. Note: If there is a problem when installing Tray 1, Tray 1 is difficult to remove or does not stay locked in position, go to “Tray 1 service check”...
Page 163: User Operator Panel, Menus, And Messages
5061 User operator panel, menus, and messages Understanding the printer operator panel The printer operator panel has a four-line, back lit, grayscale display that can show both graphics and text. The Back, Menu, and Stop buttons are located to the left of the display, the navigation buttons are located below the display, and the numeric pad is located to the right of the display.
Page 164 5061 Button Function Navigation buttons The up and down buttons are used to move up and down lists. When navigating through a list using the up or down button, the cursor moves one line at a time. Pressing the down button changes the screen to the next whole page.
Page 165: Menu Map
5061 Menu map This menu map identifies menus available to customers. The diagram shows the menu index on the operator panel, the menus, and items available under each menu. The Color Menu and Utilities Menu are detailed below. Some menu items or values are displayed only if a specific option is installed on the printer. Other menu items may only be effective for a particular printer language.
Page 166: Selected Menus
5061 Selected menus Quality Menu Use this menu selection to change settings that affect print quality and save toner. Quality menu details Menu selection Purpose Values Print Mode To determine whether Color (default) images are printed in a Black Only monochrome grayscale or in color.
Page 167 5061 Quality menu details (continued) Menu selection Purpose Values Color Balance To provide users with the Cyan -5, -4, -3, -2, -1, 0, 1, 2, 3, 4, 5 ability to make subtle color 0 is the default. Magenta adjustments to printed output by increasing or -5 is the maximum decrease Yellow...
Page 168: Utilities Menu
5061 Quality menu details (continued) Menu selection Purpose Values Manual Color To let users customize the CMYK Image US CMYK (country/region-specific RGB or CMYK color CMYK Text factory default values)—Applies a (continued) conversions applied to CMYK Graphics color conversion table to approximate each object on the printed SWOP color output.
Page 169 5061 Utilities Menu (continued) Menu selection Purpose Values Remove Held Removes confidential and Confidential Selecting a menu value only affects Jobs held jobs from the printer jobs that are resident in the printer. Held hard disk. Bookmarks, jobs on USB flash memory devices, and other types of Not Restored held jobs are not affected.
Page 170: User Attendance Messages
5061 User attendance messages Note: A secondary message only displays if the finisher option is installed. User attendance messages User primary Explanation message Activating Demo The printer is entering Demo Mode. Mode Activating Menu Wait for the message to clear. Changes Activating PPDS The PPDS emulator has been activated.
Page 171 5061 User attendance messages (continued) User primary Explanation message Delete all • Press to delete all held jobs. • Press to cancel the operation. Delete all confidential • Press to delete all confidential jobs. jobs • Press to cancel the operation. Deleting Wait for the message to clear.
Page 172 5061 User attendance messages (continued) User primary Explanation message Insert Tray <x> This message is displayed when the printer requests the user to insert tray x before it can continue printing the job. The printer needs to pick media from the missing tray or the trays below it.
Page 173 5061 User attendance messages (continued) User primary Explanation message Load <src> with • Load the input source with the correct type and size media. <Custom Type • Cancel the current job. Name> Load <src> with <Custom String> Load <src> <size> Load <src>...
Page 174 5061 User attendance messages (continued) User primary Explanation message Programming Flash Warning: Do not turn the printer off while this message is displayed. DO NOT POWER Wait for the message to clear. Programming Disk Warning: Do not turn the printer off while this message is displayed. DO NOT POWER Wait for the message to clear.
Page 175 The printer automatically clears the message in 30 seconds, and then disables the Load Emul Option download emulator on the firmware card. Download the correct download emulator version from the Lexmark Web site. 30 <color> toner Install the specified toner cartridge, and close the front cover.
Page 176 5061 User attendance messages (continued) User primary Explanation message 34 Incorrect media This message is displayed when the printer detects a media mismatch. The following actions can be taken: • Replace the media in the source with the requested media, and press to clear the message and print the job.
Page 177 5061 User attendance messages (continued) User primary Explanation message 37 Insufficient This message is displayed when insufficient printer memory is available to perform memory for Flash Flash Memory Defragment operation. Memory Defragment This message appears prior to the actual start of the deframent operation. operation Press to stop the defragment operation.
Page 178 5061 User attendance messages (continued) User primary Explanation message 50 PPDS font error This error displays when the PPDS interpreter has detected a font error. When a specific font, which is not installed, is requested based on a PPDS mode Set Font Global command, a Select Code Page command, or a comprehensive Font Selection command and the printer BEST FIT setting is off.
Page 179 5061 User attendance messages (continued) User primary Explanation message 55 Unsupported This message displays when an unsupported option is installed or when an option in slot <x> unsupported flash DIMM, such as a C750 version, is installed in a memory slot. 1.
Page 180 5061 User attendance messages (continued) User primary Explanation message 57 Configuration This message are displays when the printer has attempted to Print and Hold jobs Change from the disk and found that some or all of the jobs could not be restored. The printer firmware could not restore jobs from the disk because the configuration of the printer has changed.
Page 181 5061 User attendance messages (continued) User primary Explanation message 63 Unformatted disk • Press to clear the message and continue printing. • Format the disk. If the error message remains, the hard disk may be defective and require replacing. 82 Waste toner box Press to clear the message and continue printing.
Page 182 5061 2-138 Service Manual...
Page 183: Diagnostic Aids
5061 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Diagnostic procedures Printhead diagnostics If you get a printhead error, follow this diagnostic to find the specific failure. Remove the top cover.
Page 184 5061 Select which pair of printheads to switch based on the error code. • If the printer displays one of the codes that indicate yellow or cyan, switch the yellow with the cyan printhead cable and the yellow with the cyan mirror motor cable. •...
Page 185: Print Quality Defect Locator Chart
5061 Print quality defect locator chart The print quality locator chart is attached to the back of this book, use the tables and rulers to determine the source of repeating defects. Using the charts Measure repeating horizontal lines from the reference lines at the top to determine what may have caused the lines to form in that pattern.
Page 186: Partial Print Test
5061 Partial Print Test Diagnostic procedure for missing or faded planes Turn the printer off. Remove all cartridges and the ITU. Inspect the bellcranks. Enter the Configuration Menu. See “Configuration Menu” on page 3-31. Select Prt Quality Pgs, and press Select. Open the vacuum transport belt (VTB) jam access door, and watch the test pages pass from left to right over the VTB.
Page 187: Hcit Standalone Test Mode
5061 If the image is well developed on the PC drum, but the same plane is missing or faded on the ITU belt, the following components should be checked: • Bell cranks—Check the condition of the bell cranks. • Continuity on the bell crank circuit—Turn the printer off. Using a multimeter, check the continuity between the rear bell crank contact for the failing color and the respective cable on the transfer HVPS board.
Page 188: Accessing Service Menus
5061 Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Mode 1. Turn off the printer. The Diagnostics Mode group contains the settings and operations used while manufacturing and 2.
Page 189: Diagnostics Mode
5061 Diagnostics mode To run the printer diagnostic tests described in this chapter, put the printer in Diagnostics mode. Entering Diagnostics mode To enter the Diagnostics Mode: Turn off the printer. Press and hold Turn on the printer. Hold the buttons about 10 seconds (until the clock face appears). Diagnostic mode menus REGISTRATION “REGISTRATION”...
Page 190 5061 HARDWARE TESTS LCD Test “LCD Test” on page 3-15 Button Test “Button Test” on page 3-15 DRAM Test “DRAM Test” on page 3-16 CACHE Test “CACHE Test” on page 3-16 Parallel 1 Wrap (If installed) “Parallel Wrap Test” on page 3-17 Serial 1 Wrap (If installed) “Serial Wrap Test”...
Page 191: Exiting The Diagnostics Mode
5061 EP SETUP EP Defaults “EP Defaults” on page 3-28 Fuser Temp “Fuser Temp” on page 3-28 DC Charge Adjust “DC Charge Adjustment” on page 3-28 Dev Bias Adj “Dev Bias Adj” on page 3-28 Transfer Adjust “Transfer Adjust” on page 3-28 EVENT LOG Display Log “Display Log”...
Page 192: Registration
5061 REGISTRATION Use REGISTRATION to align the black image on the page. Use ALIGNMENT to align the individual colors. The black image should be aligned before the individual colors are aligned. To set Registration: Select REGISTRATION from the Diagnostics mode. Press to print the Quick Test Page.
Page 193: Alignment Menu
5061 Print the Quick Test Page on letter or A4 paper. Repeat for Bottom Margin, Left Margin, and Right Margin. Print a Test Page after each change to evaluate the results. To exit the Registration menu, press Back ( Quick Test “REGISTRATION”...
Page 194: Drift Sensors
5061 Press Back ( ) to exit the ALIGNMENT MENU. Drift Sensors This check is used to display the status of the thermal system used to compensate for printhead drift. To perform the test: Select ALIGNMENT from Diagnostics mode. Select Drift Sensors. The following screen is displayed when the test is selected: Drift Sensors Drift Sensors...
Page 195: Misc Tests
5061 MISC TESTS 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 the belt will move to the requested position.
Page 196: Printhead Inst
5061 Evaluate results: When the test is complete, the following screen is displayed: Test Complete Test Failed Code <pass code> Failure Code=<fail code> If the test is successful, the pass code will be a number between -250 and +250. Do not install a shim. If the test fails, then a fail code will be a number between 0 and 200 and a message indicates the cause of the failure.
Page 197: Print Quality Pgs
5061 Select either Single or Continuous from the menu. Note: If Single is selected, no buttons are active while the Print Test Page is printing. If Continuous is selected, Back ( ) or Stop ( ) can be pressed to cancel the test. The following screen is displayed while printing.
Page 198: Dram Test
5061 DRAM Test This test checks the validity of DRAM, both standard and optional. The test repeatedly writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: Select DRAM Test from HARDWARE TESTS in the Diagnostics mode.
Page 199: Parallel Wrap Test
5061 Parallel Wrap Test Use this test with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested. To run the Parallel Wrap Test: Disconnect the parallel interface cable, and install the wrap plug (P/N 1319128). Select the Parallel Wrap Test from HARDWARE TESTS in the Diagnostics mode.
Page 200: Serial Wrap Test
5061 Serial Wrap Test Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. To run the Serial Wrap Test: Disconnect the serial interface cable, and install the wrap plug. Select the appropriate Serial Wrap Test from HARDWARE TESTS in the Diagnostics mode.
Page 201: Duplex Tests
5061 DUPLEX TESTS Duplex Quick Test This test verifies if the Duplex Option Top Margin is set correctly. This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the back of the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages (Continuous) until Back ( ) or Stop ( ) is...
Page 202: Input Tray Tests
5061 INPUT TRAY TESTS Feed Test This test lets you observe the paper path as media is feeding through the printer. The upper front door, used to access the print cartridge, cannot be opened during the feed test. To observe the paper path, you must open the lower front door, used to access the paper jams on the vacuum transport belt.
Page 203: Output Bin Tests
5061 Manually actuate each sensor. The tray empty sensor can be actuated by hand, however, a sheet of paper can be used to cover the pass thru sensor. When the sensor is closed, CL displays when the sensor is open, OP appears. Press Back ( ) or Stop ( ) to exit the test.
Page 204: Sensor Test
5061 Sensor Test This test verifies if the output bin sensors are working correctly. The following output sources, if installed, are supported by this test. Standard Bin Output Expander 5-Bin Mailbox To run the Output Bin Sensor Test: Select Sensor Test from OUTPUT BIN TESTS in the Diagnostics mode. Select the bin you want to test.
Page 205: Finisher Tests
5061 FINISHER TESTS Staple Test This test verifies the operation of the staple mechanism in the finisher. To run the Staple Test: Select Staple Test from FINISHER TESTS in the Diagnostics menu. The printer feeds eight pieces of media to the finisher and accumulates all eight pieces in the finisher. After the last sheets are accumulated, the pack is stapled.
Page 206: Base Sensor Test
5061 BASE SENSOR TEST Use the Base Sensor Test to determine that the sensors located inside the printer are operating correctly. The following sensors can be checked using this test: Input—In-Line Media Clear Input—S2 Media Clear Fuser Exit Media Clear NarrowMedia Media Clear K TMC Sensor Not Closed (black) C TMC Sensor Not Closed (cyan)
Page 207: Device Tests
5061 DEVICE TESTS Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk.
Page 208: Printer Setup
5061 PRINTER SETUP Defaults This setting is used by the printer to determine whether US or non-US factory defaults should be selected. The following printer settings have different US and non-US values: Printer default values US value Non-US value Media size (paper feeding sources which do not have Letter hardware size sensing capabilities) Envelope size...
Page 209: Serial Number
5061 Viewing the permanent page count The permanent page count can only be viewed from the operator panel and cannot be changed. Select Perm Page Count from PRINTER SETUP in the Diagnostics mode. A screen similar to the following screen displays when permanent page count is selected: Perm Page Count =1234567* Press Back (...
Page 210: Reset Color Calibration
5061 Reset Color Calibration The Reset Calibration resets the TPS NVRAM values when initiated. Select Reset Calibration from PRINTER SETUP in the Diagnostics mode, and the following screen displays: PRINTER SETUP Reset Calibration Then the following screen is displayed: Resetting Calibration The printer returns to the previous screen when calibration is complete.
Page 211: Error Log
5061 ERROR LOG Display Log The event log provides a history of printer errors. The event log contains the 12 most recent errors. The most recent error appears in position 1, and the oldest error appears in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded.
Page 212: Clear Log
5061 Clear Log To clear the Event Log: Select Clear Log from EVENT LOG in the Diagnostics mode. Select Yes to clear the Event Log or No to exit the Clear Log menu. If Yes is selected, the Empty Event Log displays on the screen. Press Back ( ) or Stop ( ) to exit the Clear Log menu.
Page 213: Configuration Menu
5061 Configuration Menu The Configuration menu contains a set of menus, settings, and operations which are infrequently used by a user. Generally, the options made available in this menu are used to configure a printer for operation. Note: An asterisk (*) in the value list in the following menus indicates the default value. Entering Config Menu To enter the Configuration Menu: Turn off the printer.
Page 214: Reset Fuser Cnt
ID. The fuser maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. The counter can be used to track printer usage. When the counter reaches 120,000 for models C78x or 200,000 for models C77x, the printer posts a fuser maintenance message on the operator panel.
Page 215: Panel Menus
5061 Panel Menus Disabling Panel Menus prohibits users from modifying any setting or executing any operation available in the Ready Menu group. Select Panel Menus from the Config Menu. Select Disable or Enable. Enable is the default. PPDS Emulation This only displays if the PPDS interpreter is available. Select PPDS Emulation from the Config Menu.
Page 216: Auto Color Adjust
5061 Auto Color Adjust Automatic color adjustments periodically occur during printing, based on internal algorithms. The following situations prompt the adjustment: • If the printer detects a new or different color cartridge is installed, usually at power on or when the cover is closed.
Page 217: Jobs On Disk
5061 Jobs On Disk This setting only appears if a hard disk is installed. Jobs can be deleted from the hard disk. Settings are Delete and Do Not Delete (default). Disk Encryption This setting only appears if a hard disk is installed, the disk is not read only, and Disk Encryption is enabled. Warning: When the settings are changed, all data on the hard disk is deleted.
Page 218: Paper Jams
5061 Paper jams Identifying jams If the printer jams, the appropriate jam message will be displayed on the printer operator panel. If you select Show areas on the operator panel, you can view one or more images to help you clear the jam. See the diagram “Access doors and trays”...
Page 219: Understanding Jam Messages
5061 Understanding jam messages Note: Always clear the entire paper path when you receive any jam message. Paper jam messages Area M 5-Bin Mailbox 272.xx Paper Jam Area D Front access door Output Expander 201.xx Paper Jam 271.xx Paper Jam StapleSmart Finisher Area T1 28x.xx Paper Jam...
Page 220: Clearing The Entire Paper Path
5061 Clearing the entire paper path When a paper jam occurs, the printer stops operating and displays 2<xx>.yy Paper Jam and a message to clear certain printer areas. After you have cleared the following areas, make sure all printer covers, doors, and trays are closed, and then press to resume printing.
Page 221: Area B
5061 Area B Open the left access door until it latches open. Remove all visible media. Note: Remove any torn media from the printer. Close the door. Note: Open Tray 1, and make sure the entire media stack is pushed all the way down into the tray. Area C If you have one or more optional 500-sheet drawers: Open the 500-sheet drawer access door.
Page 222: Area D
5061 If you have an optional 2000-sheet drawer: Open the 2000-sheet drawer access door. Pull the jam down and out of the rollers. Close the door. Area D Open the front access door. Hold down the front access door. Remove jams in the rollers under the image transfer unit. Note: Any image printed will not be fused to the page.
Page 223: Area E
5061 Area E Pull the duplex tray E completely out. Look inside, and remove any paper caught in the rollers. Also, look up inside, as some jams may be above the rollers. Reinstall the duplex mechanism in the printer. Area T<x> If you cannot clear all the 500-sheet drawer jams from Area C: Carefully open trays 2 through 4 (all 500-sheet trays), and remove jams.
Page 224: Area J
5061 Area J Remove the duplex tray J. Remove any jams, and then reinstall the tray. Area K Open the lower right access door. Remove any jams, and then close the door. 3-42 Service Manual...
Page 225: Area L
5061 Area L Open the upper right access door. Remove jams from the rollers, and then close the door. Clearing mailbox, finisher, or output expander jams (Area M) Open the rear door of the 5-bin mailbox or output expander. Pull the jam straight out, and then close the door. 3-43 Diagnostic aids...
Page 226: Clearing Fuser Jams
5061 Clearing fuser jams Clear the paper path. If the jam error message persists, go to step 2. Open both the upper right and the lower right access doors (Areas K and L). CAUTION The fuser assembly may be hot. Let it cool before continuing. Pull down the latches.
Page 227: Clearing Image Transfer Unit Jams
5061 Lift up the fuser roller cover, and remove the jam. Close the fuser roller cover. Snap the housing back onto the fuser. Insert the fuser back into the printer. Slide the latches out, and then pull up to refasten them. Close the doors.
Page 228 5061 Turn the printer off. Open the front cover assembly. Remove all the print cartridges. Pull up slightly on the cartridge handhold. Pull the cartridge straight out, and use the handle to lift it off the guides. Place the cartridges on a clean, flat surface out of direct light. 3-46 Service Manual...
Page 229 5061 Release the latches to open the multipurpose feeder (area A) all the way. Remove the image transfer unit. Raise the lever to unlock the image transfer unit. Pull down on the handle. 3-47 Diagnostic aids...
Page 230 5061 Slide the image transfer unit out, and place it on a clean, flat surface. Warning: Do not touch the transfer belt. Touching the belt will damage the image transfer unit. Look inside the printer. Remove all torn paper or other jams. Insert the image transfer unit back into the printer.
Page 231 5061 Rotate the handle up, and push gently to lock the unit in place. Lower the lever to lock the image transfer unit into place. 3-49 Diagnostic aids...
Page 232: If You Still Need Help
5061 Return the multipurpose feeder to its working position. Reinstall all the print cartridges. Close the printer door. Turn the printer on. The printer returns to a Ready state. If you still need help Turn the printer off and then back on. 3-50 Service Manual...
Page 233: Repair Information
5061 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...
Page 234: Screw Identification Table
5061 Screw identification table The following table contains screw types, locations, and quantities necessary to service the printer. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly. Reference Screw type Location...
Page 235 5061 Reference Screw type Location Purpose number M3x6 mm Taptite Ground cable to right front cover support Attach Metal Thread and upper frame. Forming Blank INA covers to system card shield Mounting Rear V-block plate to upper frame Mounting Transfer HVPS to card shield Attach Media size card to support plate Attach...
Page 236 5061 Reference Screw type Location Purpose number M3.5x8 mm Left lower cover to lower frame Attach Plastite Thread Left upper cover asm to lower frame Attach Forming Left upper cover asm to upper frame Attach (continued) Left lower pivot to lower frame Attach Left upper pivot lower frame Attach...
Page 237 5061 Reference Screw type Location Purpose number M3.5x10 mm Transfer HVPS/RIP fan asm to RIP shield Attach Plastite Thread Front left light shield to left upper cover Attach Forming asm and top cover Front right light shield to right front cover Attach support and top cover Cartridge drive assemblies to upper frame...
Page 238: Removal Procedures
5061 Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. CAUTION The C77x weighs approximately 48–82 kg (105–181 lb) and requires at least three people to lift it safely.
Page 239: Operator Panel Bezel Removal
5061 Operator panel bezel removal “Operator panel bezel with overlays—1xx only”, “Operator panel bezel with overlays—2xx only”, “Operator panel bezel with overlays—3xx only”, or “Operator panel bezel with overlays—4xx only” on page 7-3 for the part number. Open the front cover assembly. Remove the two small screws (A).
Page 240 5061 Lift the bezel out and then straight up. Note: Be careful not to swing the bezel out too far and break off the clips. Note: Set the lens (B) aside. It is not part of the bezel FRU. Service Manual...
Page 241: Lens Removal
5061 Lens removal “Clear LCD lens” on page 7-3 for the part number. Remove the bezel. See “Operator panel bezel removal” on page 4-7. Remove the lens (A). Repair information...
Page 242: Front Cover Rear Pivot Cover Removal
5061 Front cover rear pivot cover removal “Front cover rear pivot cover” on page 7-3 for the part number. Remove the bezel. See “Operator panel bezel removal” on page 4-7. Remove the four screws (A). Remove the front cover rear pivot cover. 4-10 Service Manual...
Page 243: Front Cover Or Front Cover Backplate Assembly Removal
5061 Front cover or front cover backplate assembly removal The front cover does not include the front cover backplate assembly and operator panel. To remove the front cover, remove the front cover backplate and operator panel and reinstall on the new front cover. “Front cover”...
Page 244: Redrive Cap Removal
5061 Unplug the two cables (B) from the operator panel assembly. Remove the front cover. Remove the operator panel. See “Operator panel assembly removal” on page 4-68. Note: Set aside the operator panel assembly and front cover backplate assembly for reinstallation. The operator panel is not part of the front cover FRU.
Page 245: Top Cover Assembly Removal
5061 Top cover assembly removal “Top cover assembly Also order cable tie parts packet (P/N 40X1648)” on page 7-3 for the part number. Remove the redrive cap. See “Redrive cap removal” on page 4-12. Remove the front right light shield screw. See “Front right light shield removal”...
Page 246 5061 Remove the top cover mounting screws (C) from the front of the printer. Remove four screws (D) holding the outer system board shield. Remove the shield. 4-14 Service Manual...
Page 247 5061 Disconnect the cable from J2 (E) on the system board. Lift the top cover, and clip and remove the cable tie (F). Pull the cable through the inner system board shield. Remove the autoconnect cable (G) from the cable retainer (H). Remove the top cover.
Page 248 5061 Installation notes Note: Replace all cable ties. Warnings: • Be sure the cables are in the cable retainer (A). • Be sure the cables are not pinched by the top cover ribs against the indicated surfaces (B) of the printer frame.
Page 249: Front Lower Left Cover Removal
5061 Front lower left cover removal “Front lower left cover” on page 7-3 for the part numbers. Remove the paper tray. Open the front cover assembly. Open the paper path access door, carefully remove screw (A) type “323” on page 4-3 and screw (B), and close the door.
Page 250: Paper Path Access Door Removal
5061 Tape front jam access door (C), to help hold the door in place. The spring loaded door is difficult to reassemble. Avoid disassembly of the door, unless you need to replace the paper path access door. Remove the screw (D) in the front left handle cover assembly. Remove the front lower left cover with the paper path door attached.
Page 251: Front Left Handle Cover Assembly Removal
5061 Front left handle cover assembly removal “Front left handle cover assembly” on page 7-3 for the part number. Remove the front lower left cover. See “Front lower left cover removal” on page 4-17. Remove the three front left handle cover assembly screws (A) type “323”...
Page 252 5061 Close the paper path access door, and tape front jam access door (B), if tape is available, to help hold the door in place. The spring loaded latch is difficult to reassemble. Avoid unlatching the left side if you just need access to the right screw.
Page 253: Front Right Handle Cover Assembly Removal
5061 Front right handle cover assembly removal “Front right handle cover assembly” on page 7-3 for the part number. Open the front cover assembly. Remove the toner cartridges. Remove the four front right handle cover assembly screws (A) type “323” on page 4-3 and the screw (B) from the front lower right cover.
Page 254: Rear Cover Removal
5061 Rear cover removal “Rear cover” on page 7-5 for the part number. Remove the outer system board shield. See “Outer system board shield removal” on page 4-69. Press the releases (A) to open the MPF all the way. Loosen the screw (B). Remove the screw (C).
Page 255 5061 Remove 13 rear cover screws (D) and (E). Remove tabs (F) from slots. Remove the rear cover. 4-23 Repair information...
Page 256: Lower Right Door Assembly Removal
5061 Lower right door assembly removal “Lower right door assembly” on page 7-3 for the part number. Open the lower right door assembly. Remove the front lower right cover. See “Front lower right cover removal” on page 4-19. Loosen the two screws (A). Remove the lower right door assembly.
Page 257: Lower Jam Access Door Assembly Removal
5061 Lower jam access door assembly removal “Lower jam access door assembly” on page 7-5 for the part number. Remove the paper path access door cover. See “Paper path access door removal” on page 4-18. Remove the front left handle cover assembly. See “Front left handle cover assembly removal”...
Page 258: Redrive Door Removal
5061 Redrive door removal “Redrive door assembly” on page 7-14 for the part number. Open the redrive door. Loosen the redrive door upper hinge screw (A) type “324” on page 4-5. Lift the redrive door from the hinge (B), and remove the redrive door. 4-26 Service Manual...
Page 259: Autocompensator Pick Assembly Removal
5061 Autocompensator pick assembly removal “Pick assembly 500-tray” on page 7-21 for the part number. Remove the transfer plate assembly. See “Transfer plate assembly removal” on page 4-95. Cut the cable tie (A) and remove the black mylar piece. Remove the front lower left cover. See “Front lower left cover removal”...
Page 260 5061 Remove the paper level sensor. Remove the three screws (C). Two screws are located under the back VTB belt. The third screw is located at the rear pivot point for the transfer plate. This allows the paper level assembly to drop into the integrated paper drawer. Disconnect the cable from the connector (D) on the paper level sensor.
Page 261 5061 Disconnect the pick motor connector (E). Remove three screws (F) holding the pick assembly in place. 4-29 Repair information...
Page 262 5061 Push the bellcrank (G) in to allow the pick arm to fall to the bottom of the tray. Disconnect the spring clip (H) from the pick arm. Be sure not to let the spring come off of the lower frame. Also identify which pegs the spring clip is sitting on.
Page 263 5061 Leaving the pick arm down, lift the pick assembly and slide it toward the back of the printer, and drop it through the holes located next to the brackets. Installation notes: Put the new pick assembly into the printer. •...
Page 264 5061 Lift the pick assembly to insert the brackets up through the appropriate openings. Once the pick assembly brackets are through their openings, slide the assembly toward the front of the machine until the half moon on the bracket is against the locator pin (B). Reattach the spring clip to the pick arm.
Page 265 5061 Position the mylar piece, and replace the cable tie. Note: When you place the mylar piece, make sure you place it back under the metal bar (C) under the inner deflector. Make sure that the blue cable running under the mylar piece is retained by the cable tie. 4-33 Repair information...
Page 266: Bor Drive Assembly Removal
5061 BOR drive assembly removal “Lift/BOR assembly” on page 7-27 for the part numbers. Open the front cover assembly. Remove the yellow toner cartridge. Remove the front right light shield cover. See “Front right light shield removal” on page 4-42. Remove the BOR housing assembly screw (A) type “323”...
Page 267: Cartridge Contact Assembly Removal
5061 Cartridge contact assembly removal “Cartridge contact assembly, complete Also order cable tie parts packet (P/N 40X1648)” on page 7-28 for the part numbers. Warning: Do not remove the printheads. Open the front cover assembly. Remove the toner cartridges. Remove the ITU assembly. See “ITU assembly removal”...
Page 268 5061 Press the cartridge contact assembly (yellow shown) retaining tabs (B), and remove the assembly. Remove the screw (C) from the front of the printhead. 4-36 Service Manual...
Page 269 5061 Remove the screws (D) for the contact assembly you are removing. Installation note: Be sure to replace all the cable ties. 4-37 Repair information...
Page 270: Cartridge Drive Assembly Removal
5061 Cartridge drive assembly removal Note: Drive assemblies must be removed in the following order until the desired assembly can be removed: Black Magenta Cyan Yellow “Cartridge drive assembly (one drive assembly per package) Also order cable tie parts packet (P/N 40X1648).”...
Page 271: Developer Hvps Board Removal
5061 Developer HVPS board removal “Developer HVPS board—1xx/3xx only Also order cable tie parts packet (P/N 40X1648)” on page 7-34 for the part numbers. Remove inner system board shield. See “Inner system board shield removal” on page 4-48. Lift the plastic shield. Remove all connectors from the HVPS developer board.
Page 272: Friction Buckler And Buckler Housing Removal
5061 Friction buckler and buckler housing removal “Friction buckler and buckler housing” on page 7-19 for the part number. Open the MPF, and press the releases (A) to open the MPF to the lowest position. Remove the MPF cable cover screw (B). Release the MPF latch (C), and lower the MFP door down.
Page 273 5061 Use needlenose pliers to remove the buckler housing (D). Installation notes: Before installation, insert the friction buckler into the buckler housing. The tab (E) on the side should be aligned with the notch (F) in the buckler housing. 4-41 Repair information...
Page 274: Front Right Light Shield Removal
5061 The end of the buckler housing that goes into the printer first has tabs flush with the edge. Place the housing between the two sets of slots in the printer, and then slide the housing into position. Front right light shield removal “Front right light shield”...
Page 275 5061 Unlatch the alignment stud (C). Remove the front right light shield. 4-43 Repair information...
Page 276: Fuser Assembly Removal
5061 Fuser assembly removal CAUTION Be sure the fuser assembly has cooled before you remove it. “Fuser assembly” on page 7-7 for the part numbers. Turn the printer off. Note: The printer shouldbe powered down prior to removal and/or replacement of the fuser. Open the lower right door assembly and redrive door.
Page 277 5061 Unlatch the two fuser latches (A). Remove the fuser assembly. Installation note: Reset the Reset Fuser counter in the Configuration Menu. Enter the Configuration Menu (Turn off the printer, turn on the printer while holding , release the buttons after about 10 seconds or when the clock face appears.) Select Reset Fuser Cnt in the Config Menu to view the page count.
Page 278: Fuser Bottom Duct Removal
5061 Fuser bottom duct removal “Fuser bottom duct” on page 7-5 for the part number. Remove the fuser assembly. See “Fuser assembly removal” on page 4-44. Remove the fuser top duct. See “Fuser top duct removal” on page 4-47. Remove the redrive belt cover duct (A). Remove fuser left duct (B).
Page 279: Fuser Fan Removal
5061 Fuser fan removal “Fuser fan assembly” on page 7-35 for part number. Remove rear cover. See “Rear cover removal” on page 4-22. Disconnect the fuser fan cable from connector JM1 (A) on the system board. Remove the fuser fan screws (B), and remove the fan. Fuser top duct removal “Fuser top duct”...
Page 280: Inner System Board Shield Removal
5061 Inner system board shield removal “System board inner shield assembly” on page 7-33 for part number. Remove the top cover assembly. See “Top cover assembly removal” on page 4-13. Remove the rear cover. See “Rear cover removal” on page 4-22.
Page 281: Itu Assembly Removal
5061 ITU assembly removal “ITU assembly—1xx/3xx only” on page 7-22 for the part number. Open the front cover assembly. Remove the toner cartridges. Open the MPF, and press the releases (A) to open the MPF to the lowest position. 4-49 Repair information...
Page 282 5061 Raise the ITU release lever (B). Slide the ITU assembly from the printer. 4-50 Service Manual...
Page 283 5061 Lift the second transfer roll right end (closest to front). Slide the left side to the side to disengage from the gear, and allow clearance to remove the roll. Installation notes: Replace the second transfer roll. Be sure to replace the ITU assembly in the slots (C) indicated by arrows. Rear edge Front edge 4-51...
Page 284: Itu Drive Assembly Removal
5061 ITU drive assembly removal “ITU drive assembly Also order cable tie parts packet (P/N 40X1648).” on page 7-23 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-49. Remove the black cartridge drive assembly. See the removal for the “Cartridge drive assembly removal”...
Page 285: Lvps Assembly Removal
5061 LVPS assembly removal “LVPS assembly” on page 7-31 for the part number. Note: Set the voltage range switch to the proper power setting for the geographic area you are in. Remove the fuser drive assembly. See “Fuser drive assembly removal” on page 4-46.
Page 286 5061 Remove the screw (C) type “121” on page 4-2 from the top of the LVPS, and remove the LVPS from the printer. 4-54 Service Manual...
Page 287: Media Size Sensing Assembly Removal
5061 Media size sensing assembly removal “Media size sensing” on page 7-16 for part numbers associated with this assembly. Enter Diagnostics mode. Power up the printer in Diagnostics mode (holding about 10 seconds or until the clock face appears). Print the Quick Test Page, if possible. Retain this sheet to verify the installation. Select REGISTRATION.
Page 288 5061 Remove screw (C) from the media size sensing assembly. Gently twist and remove the media size sensing assembly. As shown, the assembly touches at the spring (D), the fingers (E), the bottom (F), and the right side (G). This also occurs when replacing the assembly.
Page 289 5061 Replacing the media size sensing assembly Installation note: Be sure to replace all cable ties. Press on the back of the media size sensing assembly fingers (H). Move the assembly down to the bottom of the aligning hole. Be careful with the exposed fingers. Do not allow them to press against the black plastic frame.
Page 290: Media Size Sensing Board Removal
5061 Media size sensing board removal “Media size sensing board assembly Also order cable tie parts packet (P/N 40X1648)” on page 7-16 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-22. Disconnect the cables (A). Remove the media size sensing board screws (B).
Page 291: Multipurpose Feeder (Mpf) Removal
5061 Multipurpose feeder (MPF) removal “Multipurpose feeder (MPF)” on page 7-19 for the part numbers. Open the MPF, and press the releases (A) to open the MPF to the lowest position. Remove the MPF cable cover screw (B). 4-59 Repair information...
Page 292 5061 Remove the three screws (C) that secure the MPF inner cover. Press the latches (D) to release the MPF switch cable from the MPF sensor, and disconnect the cable. Remove the cable from the cable retainer (E). 4-60 Service Manual...
Page 293 5061 Release the MPF latch (F), and remove the MPF. 4-61 Repair information...
Page 294: Multipurpose Feeder (Mpf) Autocompensator Or Side Restraints Removal
5061 Multipurpose feeder (MPF) autocompensator or side restraints removal “MPF autocompensator pick assembly” “MPF side restraint” on page 7-19 for the part numbers. Remove the MPF. See “Multipurpose feeder (MPF) removal” on page 4-59. Remove the c-clip (A). Remove the gear (B). 4-62 Service Manual...
Page 295 5061 Unhook the autocompensator spring (C). Rotate the shaft up and out of the MPF assembly. 4-63 Repair information...
Page 296: Multipurpose Feeder (Mpf) Motor Removal
5061 Multipurpose feeder (MPF) motor removal “MPF drive assembly” on page 7-19 for the part number. Remove the MPF. See “Multipurpose feeder (MPF) removal” on page 4-59. Remove the MPF autocompensators 1 and 2. See “Multipurpose feeder (MPF) autocompensator or side restraints removal”...
Page 297: Nip Relief Handle Removal
5061 Nip relief handle removal “Nip relief handle Also order cable tie parts packet (P/N 40X1648)” on page 7-17 for the part number. Remove the left lower cover to access the nip relief handle. See “Left lower cover removal” on page 4-24.
Page 298: Installation Notes
5061 Installation notes Rotate the new nip relief handle into place to connect it to the nip relief link (A). Using a screwdriver, gently pry the nip relief lever (B) toward the rear of the printer, and insert lower portion of the handle so that it is between the nip relief lever and the reference edge plate (C).
Page 299 5061 Once the handle snaps onto the post, press the upper portion of the handle to the right, and rotate the handle into its home position. This seats the nip relief lever into the correct position. Check for proper operation. Install the waste toner container.
Page 300: Operator Panel Assembly Removal
5061 Operator panel assembly removal “Operator panel assembly” on page 7-3 for the part number. Remove the front cover and front cover backplate assembly. See “Front cover or front cover backplate assembly removal” on page 4-11. Remove the four screws (A) attaching the operator panel to the front cover. Remove the operator panel assembly.
Page 301: Outer System Board Shield Removal
5061 Outer system board shield removal “System board outer shield” on page 7-33 for the part number. Remove four screws (A). Remove outer system board shield. 4-69 Repair information...
Page 302: Pick Rolls Removal
5061 Pick rolls removal “Pick roll tires (2 per pack)” on page 7-53 for the part number. Note: Replace both rolls at the same time. Front roll Remove the paper tray. Wipe any toner or debris from the bottom pan to avoid contaminating the pick rolls. Open the lower jam access door assembly for access.
Page 303 5061 • When replacing the front roll, the dots (A) on the outside of the tire should be facing the front of the printer. Rear roll Reach around and depress the latch (A) on the end of the shaft, and remove the roll. Installation note for the rear roll: •...
Page 304 5061 • Once the pick arm assembly is lowered, the spring is disengaged. To properly position the pick arm assembly and re-engage the spring: Reach through the lower jam access door opening, and lift and hold the pick assembly in the proper position.
Page 305: Printhead Removal And Adjustments
5061 Printhead removal and adjustments See Printhead assembly on page 7-13 for the part number. Warnings: • Whenever a printhead is replaced, it is necessary to perform the ““Mechanical alignment”. Then, if a black printhead is replaced, perform the “Black printhead electronic alignment” on page 4-78 and the “Color printhead electronic alignment”...
Page 306 5061 Determine which printhead to remove. Align the printhead alignment assembly locating pin (A) with the hole in the printer frame and the attachment screw (B) with the screw hole (shown without the printhead for clarity). The adjustment thumbscrew (C) should be facing the closest mounting beam. 4-74 Service Manual...
Page 307 5061 Install one printhead alignment assembly (D) in the front and the other (E) in the rear of the selected printhead. Screw the printhead alignment assembly to the printer frame. Finger tighten the adjustment screw until the end of the screw is pressing firmly against the mounting beam.
Page 308 5061 Remove the three printhead mounting screws (H), and remove the printhead. Lift the old printhead out, leaving the printhead alignment assemblies in place. Note: Untwist the printhead motor cables before placing the printhead assembly into the printer. Install the new printhead assembly, reconnect the printhead motor cable into the system board, and reconnect the color keyed printhead cable into the top of the printhead.
Page 309 5061 With one hand, bias the new printhead against the front and rear adjustment screws of the printhead alignment assembly. Note: Using a consistent force on the front and back of the printhead is important and will reduce the number of interations. While maintaining bias pressure, tighten the right rear printhead mounting screw.
Page 310: Black Printhead Electronic Alignment
5061 Repeat steps 13 through 16 as necessary until the line is within 1 and -1 on both ends. Remove both printhead alignment assemblies from the printer. Warning: Leaving the printhead alignment assemblies in the printer can cause damage to the printer. Press Back ( ) to return to the main Diagnostic Menu.
Page 311: Color Printhead Electronic Alignment
5061 Color printhead electronic alignment After replacing a color printhead: Select Alignment from the Diagnostics Menu. Select the color of printhead you are replacing. Select Quick Test. Test pages are printed. Adjust the Step 1 settings, based on the Test pages. •...
Page 312: Rear Bellcrank Removal (Cyan, Magenta, Yellow)
5061 Rear bellcrank removal (cyan, magenta, yellow) page 7-25 for the part numbers for the parts packet, including the rear transfer bellcranks, for yellow, cyan, and magenta. Power off the printer. Remove the four toner cartridges, and leave the front door open. Remove the ITU assembly.
Page 313 5061 Rotate the contact end of the bellcrank down (B) and remove. Be careful not to lose the contact spring (C). Installation note Replace the bellcranks by reversing the order of removal. Note: Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu. 4-81 Repair information...
Page 314: Rear Bellcrank (Black) Removal
5061 Rear bellcrank (black) removal page 7-25 for the part number for the parts packet, including the rear transfer bellcranks, for black. Power off the printer. Remove the four toner cartridges, and leave the front door open. Remove the ITU assembly. See “ITU assembly removal”...
Page 315: Redrive Assembly Removal
5061 Rotate the contact end of the bellcrank down (C) and remove. Be careful not to lose the spring (D). Installation note Replace the bellcranks by using reverse order of removal. Note: Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu. Redrive assembly removal “Redrive assembly”...
Page 316: Registration Motor Removal
5061 Remove the drive belt (B) from the lower redrive pulley. Remove the redrive assembly. Note: When you reinstall the redrive assembly be sure to align the notch in the redrive assembly with tab (C). Registration motor removal page 7-17 for the part number for the registration motor assembly kit.
Page 317: Rib Housing Removal
5061 Rib housing removal “Rib housing” on page 7-19 for the part number. Open the MPF, and press the releases (A) to open the MPF to the lowest position. Remove the MPF cable cover screw (B). Release the MPF latch (C), and lower the MFP door down. Support the tray to relieve pressure on the MPF switch cable.
Page 318 5061 Use needlenose pliers to remove the rib housing (D) that requires replacement. Installation note: The end of the rib housing that goes into the printer first has tabs flush with the edge. Place the housing between the two sets of slots in the printer, and then slide the housing into position. 4-86 Service Manual...
Page 319: Rip Fan Removal
5061 RIP fan removal “RIP fan, 92 mm” on page 7-35 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-22. Disconnect the rip fan cable from the system board at connector J3. Remove the front rip fan screw (A). Remove the two rip fan rear screws (B).
Page 320: S2/Narrow Media/Transparency/Multipurpose Feeder Cable Removal
5061 S2/narrow media/transparency/multipurpose feeder cable removal “S2/XPAR/NMS/MPF cable assembly (with sensors)” on page 7-37 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-22. Open the MPF, and press the releases (A) to open the MPF to the lowest position. Remove the J10 connector cable to allow space.
Page 321: S2/Narrow Media/Transparency/Multipurpose Feeder Sensors Removal
5061 S2/narrow media/transparency/multipurpose feeder sensors removal The individual sensors are not available separately from the cable. If you need to replace a single sensor, remove it from the S2/narrow media/transparency/multipurpose feeder cable and replace that one. See “S2/XPAR/NMS/MPF cable assembly (with sensors)” on page 7-37 for the part number.
Page 322: System Board Removal
5061 System board removal “System board, network—1xx/3xx only Also order cable tie parts packet (P/N 40X1648)” on page 7-33 for the part numbers. Note: For a color image of the cabling, see “System board cabling reference” on page 5-6. Warning: When replacing any one of the following components: •...
Page 323 5061 Clip the cable ties (C). Remove the system board. Note: When reinstalling the system board, verify the input and output option cables are fully connected. Replace all cable ties. To verify the input sources are recognized: On the operator panel, at the Ready prompt, select Paper Menu. Select Paper Source.
Page 324: Transfer Hvps Board Removal
5061 Transfer HVPS board removal “Transfer HVPS board” on page 7-34 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-22. Remove screw (A) and the two screws (B) on the bottom of the transfer HVPS. 4-92 Service Manual...
Page 325 5061 Remove all connectors (C). Remove the transfer HVPS board. 4-93 Repair information...
Page 326 5061 Installation notes • To identify the color coded cable bands to the connectors, see “Transfer high voltage power supply (HVPS)” on page 5-20. • When installing the transfer HVPS board, route the cable to the HVPS input connector at CN1 (C) over the cable to the yellow transfer contact (D), under the cable to the magenta transfer contact (E), and attached to the cable tie (F).
Page 327: Transfer Plate Assembly Removal
5061 Transfer plate assembly removal “Transfer plate assembly” on page 7-12 for the part number. Remove the ITU assembly. See “ITU assembly removal” on page 4-49. Remove tray 1. Lifting and rotate the right edge of the transfer plate up to a 45° angle to release the transfer plate. Remove the grounding strap (A) attached to the bottom of the transfer plate.
Page 328: Vacuum Transport Belt (Vtb) Removal
5061 Vacuum transport belt (VTB) removal “Vacuum transport belt assembly” on page 7-11 for the part number. Remove the transfer plate assembly. See “Transfer plate assembly removal” on page 4-95. Remove the fuser bottom duct. See “Fuser bottom duct removal” on page 4-46.
Page 329 5061 Rotate release lever on gear until the gear can be removed. Remove screw from ground wire. Remove vacuum belt transfer belt unit far enough to release ground wire from restraint clips, and remove completely. 4-97 Repair information...
Page 330: Vacuum Transport Belt (Vtb) Fan Removal
5061 Vacuum transport belt (VTB) fan removal “VTB fan, 60 mm” on page 7-35 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-22. Disconnect VTB fan from the system board. Remove VTB fan with a flatblade screwdriver. Waste container door removal “Waste container door”...
Page 331: Waste Container Latch Removal
5061 Waste container latch removal “Waste container latch Also order cable tie parts packet (P/N 40X1648)” on page 7-26 for the part number. Remove the media size sensing assembly. See “Media size sensing assembly removal” on page 4-55. Use a flatblade screwdriver to release the waste container latch from the media size sensing assembly. 4-99 Repair information...
Page 332: Web Oiler Fuser Assembly And Card Removal And Replacement
5061 Web oiler fuser assembly and card removal and replacement “Fuser assembly” on page 7-7 for the part number. Turn the printer off. Open the fuser access cover. Unlatch the two fuser latches (A). Remove the fuser assembly. CAUTION The fuser may be hot. To avoid a burn injury, allow the fuser to cool to room temperature before removing.
Page 333 5061 Remove screw (B) from the top front support bracket. Swing bracket to the right. Remove the two screws (C) securing the web oiler motor assembly. 4-101 Repair information...
Page 334 5061 Remove the web oiler fuser motor assembly. Note: To reinstall the web oiler fuser motor assembly, use the alignment pins (D) to position the assembly in holes (E). Remove the four screws (F) securing the card. 4-102 Service Manual...
Page 335 5061 Installation notes: Use the alignment pins (A) on the web oiler fuser motor assembly to position the assembly in holes (B), and install the assembly. Secure the web oiler motor assembly with screws (C). Install the web oiler card using screws. Plug web oiler cable (D) into web oiler card connector.
Page 336 5061 Plug web oiler drive assembly cable into cable connector (E). Reinstall paper path access door. Align tabs on the front right light shield with the slots (F) on the frame. 4-104 Service Manual...
Page 337 5061 Move the front right light shield up until alignment stud (G) and the screw hole (H) are aligned. Attach the new web oiler fuser housing (J) to new web oiler fuser. Insert the web oiler fuser assembly into the fuser assembly, and install the fuser assembly into the printer. 4-105 Repair information...
Page 338 5061 4-106 Service Manual...
Page 339: Connector Locations
5061 5. Connector locations Locations Printer boards Connector locations...
Page 340: Printer Motors
5061 Printer motors Service Manual...
Page 341: Printer Sensors
5061 Printer sensors Connector locations...
Page 342: Cartridge Contact Assembly Pin Locations (Cyan, Magenta And Yellow)
5061 Cartridge contact assembly pin locations (cyan, magenta and yellow) Service Manual...
Page 343: Cartridge Contact Assembly Pin Locations (Black)
5061 Cartridge contact assembly pin locations (black) Connector locations...
Page 344: System Board Cabling Reference
5061 System board cabling reference Refer to the System board wiring diagrams for additional details. Service Manual...
Page 345: Connectors
5061 Connectors System board Connector locations...
Page 346: System Board
5061 System board “System board” on page 5-7. Connector Pin no. Signal Printer TXD Top options connector bin full Ground Ground Printer RXD +24V_OPTIONS (through fuse F11) Ground +5V_OPTIONS (through fuse F9) +5V_BIN_FULL (switched) Ground BIN_FULL_IN LIFT_OUT- (+24 V dc in standby) BOR lift motor LIFT_OUT+ (+24 V dc in standby) VBUS...
Page 347 5061 “System board” on page 5-7. Connector Pin no. Signal J6 (continued) +24V_SWITCHED Developer HVPS ITU/TPS autoconnect ITU_I2C_DATA +3.3 V dc (Through fuse F13) TPS_GAIN_OUT ITU_TEMP BELT_HOLE 1 N/C Ground Ground ITU_I2C_CLK +24V_SWITCHED TPS_LED_ON_OUT TONER_PATCH_OUT BELT_HOLE 2 +5V_SWITCHED Ground S2/narrow media/prism/MPF sensor +5V dc S2 (switched) NARROW_MEDIA_IN PAPERPATH_S2_IN...
Page 348 5061 “System board” on page 5-7. Connector Pin no. Signal Option DRAM Socket ITU_TX_ENA_OUT (active low) Transfer HVPS ITU_TX_CUR_PWM_OUT ITU_SERVO_IN ITU_TX_PWM_OUT CMY_TX_ENA_OUT (active low) K_SERVO_IN K_TX_PWM_OUT C_SERVO_IN C_TX_PWM_OUT M_SERVO_IN Y_TX_PWM_OUT Y_SERVO_IN M_TX_PWM_OUT Ground +24V_SWITCHED +24V To Cover Open Switch Cover open switch +24V dc Switched (+24V dc switched) Y_ON_OUT...
Page 349 5061 “System board” on page 5-7. Connector Pin no. Signal K_ON_OUT ITU/black BLDC motors ITU_ON_OUT +5V dc (Through fuse F8) +5V dc (Through fuse F8) K_DIR_OUT ITU_DIR_OUT +24V_K_AND_ITU (Through fuse F4) +24V_K_AND_ITU (Through fuse F4) Ground Ground K_CLK_OUT ITU_CLK_OUT K_HALL_IN ITU_HALL_IN EXIT_SENSOR_IN Fuser interface...
Page 350 5061 “System board” on page 5-7. Connector Pin no. Signal +3.3 V dc Low voltage power supply +3.3 V dc +5 V dc +5 V dc +24V dc +24V dc +24V dc +3.3 V dc Sense Ground Ground Ground Ground Ground Ground Ground...
Page 351 5061 “System board” on page 5-7. Connector Pin no. Signal Printer TXD Bottom options connector Ground Waste toner full Ground Media size Printer RXD +24V_OPTIONS (Through fuse F11) Ground +5V_OPTIONS (Through fuse F9) Staging Encoder ITU_CLNR_FULL Ground WASTE_BTL_PRES TRAY_SIZE_3 Ground TRAY_SIZE_2 TRAY_SIZE_1 Ground...
Page 352 5061 “System board” on page 5-7. Connector Pin no. Signal JCY1 C_DATA+ Yellow and cyan video to printheads Ground C_DATA- Y_THERMISTOR Ground Y_LENA +5 V dc (through fuse F12 and safety switches at J10) Ground C_LPWM Y_LADJ Ground Ground C_LADJ Y_LPWM Ground +5 V dc (through fuse F12 and safety switches at...
Page 353 5061 “System board” on page 5-7. Connector Pin no. Signal JMK1 K_DATA+ Printhead—black/magenta video Ground K_DATA- M_THERMISTOR Ground M_LENA +5 V dc (through fuse F12 and safety switches at J10) Ground K_LPWM M_LADJ Ground Ground K_LADJ M_LPWM Ground +5 V dc (through fuse F12 and safety switches at J10) K_LENA Ground...
Page 354 5061 “System board” on page 5-7. Connector Pin no. Signal JMMK1 FUSE24V Printhead—black mirror motor Ground Ground +5 V dc (through fuse F12) K_MMSTART K_HSYN-SOS K_MMLOCK Ground K_MMREF JMMM1 FUSE24V Printhead—magenta mirror motor Ground Ground V_V5FUSE M_MMSTART M_HSYN-S0S M_MMLOCK Ground M_MMREF JMPF1 +5 V dc...
Page 355 5061 “System board” on page 5-7. Connector Pin no. Signal FAN3_STALL_IN RIP fan Ground FAN3_CNTRL- +24V_LEFTSIDE JTRAY1 +5 V dc Paper level (switched) Autocomp motor +5V_SWITCHED PAPER_OUT_IN AUTOCOMP_ENC PAPER_LOW_IN Ground Ground Ground AUTOCOMP_OUT1 (+24 V dc in standby) AUTOCOMP_OUT2 (+24 V dc in standby) JUSB1 Ground USB port...
Page 356: Autoconnect-Top
5061 Autoconnect—top Connector Pin no Color Signal CN1 Autoconnect—top White +24 V dc Black Ground Yellow Printer RXD Black Ground +5 V dc Black Ground Blue Printer TXD 5-18 Service Manual...
Page 357: Autoconnect-Bottom
5061 Autoconnect—bottom Connector Pin no Signal Signal CN1 Autoconnect—bottom White +24 V dc Black Ground Yellow Printer RXD Black Ground Brown STAGING_ENCODER +5 V dc Black Ground Blue Printer TXD 5-19 Connector locations...
Page 358: Transfer High Voltage Power Supply (Hvps)
5061 Transfer high voltage power supply (HVPS) 5-20 Service Manual...
Page 359 5061 Connector Pin no Signal CN1 HVPS Input Connector +24 V dc Switched +24 V dc Return M-Txpwm M-Srvo out Y-Txpwm Y-Srvo out C-Txpwm C-Srvo out K-Txpwm K-Srvo out KCYM-Txenable ITU-Txpwm ITU-Srvo out ITU-Txcurpwm TUI-Txenable T102 Transformer HV Terminal I HV Transformer output to 2nd Transfer Roll Cable (ITU) T201 Transformer HV Terminal K...
Page 360: Developer High Voltage Power Supply (Hvps) Board
5061 Developer high voltage power supply (HVPS) board Connector Pin no Signal CN1 Developer HVPS Input +24 V dc Return +24 V dc Y-Ctsense Y-Devpwm Y-TnrSense C-Devpwm C-CtSense M-Devpwm C-TnrSense CYM-Acenable M-CtSense CYM-Chgpwm M-TnrSense K-Chgpwm K-CtSense K-Devpwm K-TnrSense K-Acenable CB Terminal Cleaner Bias Terminal (not used) 5-22 Service Manual...
Page 361: Low Voltage Power Supply (Lvps)
5061 Low voltage power supply (LVPS) LVPS cable connectors to system board Connector Signal Main power to +3.3 V dc system board +3.3 V dc (J35) +5 V dc +5 V dc +24 V dc +24 V dc +24 V dc +3.3 V dc Sense Ground Ground...
Page 362: Lvps Fuser Connectors
5061 LVPS fuser connectors Connector Pin no. Signal LVPS AC Fuser Connector AC Load #1 AC Common Ground AC Load #2x LVPS DC Fuser Control Connector FusExitSen BURCam1 WebEncoderA WebEncoderB HRThermistor BURThermistor Return—Analog Ground +5 V dc switched 5-24 Service Manual...
Page 363: Media Size Sensing Board
5061 Media size sensing board Connector Signal +3.3V dc EPROM Data Ground EPROM Clock J3-1 (Waste BTL Full) Ground Waste BTL PRESENT (SW4) Tray Size 1 (SW3) Ground Tray Size 2 (SW2) Tray Size 3 (SW1) J2-1 (Waste BTL Full) Ground 5-25 Connector locations...
Page 364: High-Capacity Input Tray (Hcit)
5061 High-capacity input tray (HCIT) HCIT 2000-sheet board Connector Signal CN1 I/F Send PRI RXD PGND PERON SGND PRI TXD CN2 LVPS Poweron +5 V dc SGND PGND PGND PGND +24 V dc +24 V dc +24 V dc CN3 REG Motor +24 V dc +24 V dc REG A...
Page 365 5061 Connector Signal CN6 Sensors +5 V dc Side Door/Level/ Empty/ Registration SIDE Home/Pick Home +5 V dc LEVEL +5 V dc EMPTY +5 V dc RHOME +5 V dc PHOME CN7 Size +5 V dc Sensors/Near Empty SIZE 0 +5 V dc SIZE 1 +5 V dc...
Page 366: Staplesmart Finisher
5061 StapleSmart finisher Connector Signal Staple card assembly J1A Bottom +24 V dc autoconnect Ground +5 V in J1B Bottom rtxdin autoconnect Ground prtrxd Ground Ground J2 Feed motor fdmtr1 fdmtr2 Ground Ground tachft 5Vptt J3 Stepper motor stpmtr- stpmtr- stpmtr+ stpmtr+ crtprsnt-...
Page 367 5061 Connector Signal Staple card assembly (continued) J7 Right side Ground sensor board Bottom Ground J8 Solenoid Sol2- +24 V dc J9 Bin empty Ground sensor bnempty- 5Vsnsr2 J10 Left side Ground sensor board full+ NRFull+ Ground J12 Pass thru Ground sensor psthruint...
Page 368 5061 5-30 Service Manual...
Page 369: Preventive Maintenance
The operator panel displays 80 Fuser Maintenance and 83 ITU Maintenance for scheduled maintenance. 80 Fuser Maintenance is displayed at 120,000 copies for C78x models, and at 200,000 copies for C77x models indicating the fuser assembly needs to be replaced to maintain the print quality and reliability of the printer. The...
Page 370: Lubrication Specifications
5061 Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure. Some unauthorized lubricants may chemically attack polycarbonate parts. Use IBM no. 10 oil, P/N 1280443 (Approved equivalents: Mobil DTE27, Shell Tellus 100, Fuchs Renolin MR30), IBM no.
Page 371: Cartridge Drive Assembly
5061 Cartridge drive assembly Apply a thin coating of Nyogel type 744 grease to the points identified (A) from the supplied packet. Rotate the motor housing (B) to distribute evenly. ITU drive assembly Apply a thin coating of Nyogel type 744 grease to the points identified (A) from the supplied packet. Note: Do not lubricate Gear 58 (C).
Page 372 5061 Service Manual...
Page 373: Parts Catalog
• NA: (Not available) in the parts description column indicates the part is shown for identification purposes only and is not available as a FRU. The Lexmark C77x (506x-4xx) laser printer is available in four models: Machine Abbreviation used in...
Page 374: Assembly 1: Covers
5061 Assembly 1: Covers Service Manual...
Page 375 5061 Assembly 1: Covers Asm- Part Units/ Units/ Description Index number mach 1–1 40X1628 Top cover assembly Also order cable tie parts packet (P/N 40X1648) 40X1631 250 output flag and retainer 40X1637 Top autoconnect and output bin sensor—1xx/3xx only 40X1777 Top autoconnect and output bin sensor—2xx/4xx 40X1638 Redrive cap cover assembly...
Page 376 5061 Assembly 1.1: Covers BACK FRONT Service Manual...
Page 377 5061 Assembly 1.1: Covers Asm- Part Units/ Units/ Description Index number mach 1.1–1 40X1657 Left upper cover assembly Screw type 323, parts packet, (40X1633) 40X1653 Left upper pivot cover 40X1787 Jam access door spring 40X1658 Lower jam access door assembly 40X1655 Left lower pivot cover 40X1768...
Page 378: Assembly 2: Cartridge Mounting
5061 Assembly 2: Cartridge mounting Asm- Part Units/ Units/ Description Index number mach 2–1 40X1663 Guide assembly, left side 40X1664 Guide assembly, right side Screw type 102, parts packet (40X1639) Service Manual...
Page 379: Assembly 3: Fuser Assembly
5061 Assembly 3: Fuser assembly Asm- Part Units/ Units/ Description Index number mach 3–1 40X1666 Fuser assembly, 220 V 500W—1xx/3xx 40X1832 Fuser assembly, 220 V 500W—2xx/4xx 40X1651 Fuser assembly, 115 V 500W—1xx/3xx 40X1831 Fuser assembly, 115 V 500W—2xx/4xx 40X1667 Fuser assembly, 100 V 500W (Japan)—1xx/3xx 40X1833 Fuser assembly, 100 V 500W (Japan)—2xx/4xx Parts catalog...
Page 380 5061 Assembly 3.1: Fuser (web oiler) Service Manual...
Page 381 5061 Assembly 3.1: Fuser (web oiler) Asm- Part Units/ Units/ Description Index number mach 3.1–1 40X1674 Web oiler assembly 40X1670 Web oiler driver board assembly 40X1669 Web oiler index drive assembly Parts catalog...
Page 382: Assembly 4: Fuser Drive
5061 Assembly 4: Fuser drive Asm- Part Units/ Units/ Description Index number mach 4–1 Screws type 323, parts packet (40X1633) 40X1661 Fuser drive assembly 7-10 Service Manual...
Page 383: Assembly 5: Vacuum Transport Belt (Vtb) Assembly
5061 Assembly 5: Vacuum transport belt (VTB) assembly Asm- Part Units/ Units/ Description Index number mach 5–1 40X1660 Jam access spring 40X1677 Vacuum transport belt assembly 7-11 Parts catalog...
Page 384: Assembly 6: Transfer
5061 Assembly 6: Transfer Asm- Part Units/ Units/ Description Index number mach 6–1 40X1678 Second transfer roll 40X1679 Transfer plate assembly 7-12 Service Manual...
Page 385: Assembly 7: Printheads
5061 Assembly 7: Printheads Asm- Part Units/ Units/ Description Index number mach 40X1778 Printhead assembly (do not replace more than one printhead at a time) Also order cable tie parts packet (P/N 40X1648) Screw type 484, parts packet (40X1632) 7-13 Parts catalog...
Page 386: Assembly 8: Paper Feed Output (Redrive)
5061 Assembly 8: Paper feed output (redrive) Asm- Part Units/ Units/ Description Index number mach 8–1 40X1686 Bracket mounting anchor (2 per package) 40X1685 Upper door hinge Screw type 312/322/412/423, parts packet, (40X1691) 40X1689 Redrive belt 300 T 40X1684 Redrive assembly 40X1690 Redrive door assembly 40X1687...
Page 387: Assembly 9: Paper Feed Input
5061 Assembly 9: Paper feed input Asm- Part Units/ Units/ Description Index number mach 9–1 40X1692 S2/XPAR/NMS/MPF cable assembly (with sensors) 7-15 Parts catalog...
Page 388: Assembly 10: Media Size Sensing
5061 Assembly 10: Media size sensing Asm- Part Units/ Units/ Description Index number mach 10–1 40X1700 System board shield support with clips Also order cable tie parts packet (P/N 40X1648) 40X1698 Media size sensing bracket Also order cable tie parts packet (P/N 40X1648) 40X1697 Media size sensing spring Also order cable tie parts packet (P/N 40X1648)
Page 389: Assembly 11: Paper Feed Transport
5061 Assembly 11: Paper feed transport Asm- Part Units/ Units/ Description Index number mach 11–1 40X1701 Nip relief handle Also order cable tie parts packet (P/N 40X1648) 40X1702 Registration motor assembly kit, including: (also order cable tie parts packet, P/N 40X1648) - Staging motor assembly - Gear, reference plate - Gear, staging idler...
Page 390: Assembly 12: Multipurpose Feeder (Mpf)
5061 Assembly 12: Multipurpose feeder (MPF) 7-18 Service Manual...
Page 391 5061 Assembly 12: Multipurpose feeder (MPF) Asm- Part Units/ Units/ Description Index number mach 12–1 40X1714 MPF door assembly—1xx/3xx 40X1841 MPF door assembly—2xx/4xx 40X1711 MPF door cover 40X1853 MPF drive assembly 40X1708 Door hinge restraint Screw type 312/322/412/423, parts packet, 40X1691 40X1710 MPF gear cover 40X1673...
Page 392: Assembly 13: 500-Sheet Integrated Tray
5061 Assembly 13: 500-Sheet integrated tray Asm- Part Units/ Units/ Description Index number mach 13–1 40X1728 500-Sheet tray assembly 40X1720 Back restraint latch 40X1719 Back restraint 40X1723 Tray bias bellcrank assembly Screw type 312/322/412/423, parts packet, 40X1691 40X1725 Tray bias spring 40X1722 Wear strip 40X1885...
Page 393: Assembly 14: Autocompensator Assembly
5061 Assembly 14: Autocompensator assembly Asm- Part Units/ Units/ Description Index number mach 14–1 40X1730 Tray interlock bellcrank 40X1741 Pick arm lift bellcrank 40X1724 Pick assembly 500-tray 40X1734 Bellcrank lift spring 40X1732 Paper level sensing assembly 40X1731 Tray interlock bracket 40X1729 Sensor, paper out/low Screw type 312/322/412/423, parts packet, 40X1691 (pick roll mounting)
Page 394: Assembly 15: Itu Assembly
5061 Assembly 15: ITU assembly Asm- Part Units/ Units/ Description Index number mach 15-1 40X1739 ITU light shield assembly 40X0342 ITU assembly—1xx/3xx only 40X0343 ITU assembly—2xx/4xx only 40X1678 Second transfer roll 40X1737 ITU coupler retract lever 7-22 Service Manual...
Page 395: Assembly 16: Itu Drive Assembly
5061 Assembly 16: ITU drive assembly Asm- Part Units/ Units/ Description Index number mach 40X1823 ITU drive assembly Also order cable tie parts packet (P/N 40X1648). 40X1742 #58 gear Also order cable tie parts packet (P/N 40X1648) Screw type 323, parts packet, 40X1633 (ITU drive assembly lower frame) 7-23 Parts catalog...
Page 396: Assembly 17: Itu Loading
5061 Assembly 17: ITU loading 7-24 Service Manual...
Page 397 5061 Assembly 17: ITU loading Asm- Part Units/ Units/ Description Index number mach 17–1 40X1761 Yellow terminal contact assembly 40X1744 Contact spring terminal Screw type 312/322/412/423, parts packet, 40X1691 40X1743 Cartridge support roller 40X1749 Parts packet, ITU loading—yellow, including - Yellow BOR spring - Rear block guide - Rear transfer bellcrank - Front V block guide...
Page 398: Assembly 18: Waste Toner
5061 Assembly 18: Waste toner Asm- Part Units/ Units/ Description Index number mach 18–1 40X1756 Waste toner container 40X1755 Waste container latch spring Also order cable tie parts packet (P/N 40X1648) 40X1754 Waste container latch Also order cable tie parts packet (P/N 40X1648) 7-26 Service Manual...
Page 399: Assembly 19: Bor Drive Assembly
5061 Assembly 19: BOR drive assembly Asm- Part Units/ Units/ Description Index number mach 19–1 40X1758 Lift/BOR assembly 7-27 Parts catalog...
Page 400: Assembly 20: Cartridge Contact Assembly
5061 Assembly 20: Cartridge contact assembly Asm- Part Units/ Units/ Description Index number mach 20–1 40X1762 Cartridge contact assembly, complete Also order cable tie parts packet (P/N 40X1648) 40X1636 Rear hold down spring Also order cable tie parts packet (P/N 40X1648) 40X1760 Rear hold down bellcrank Also order cable tie parts packet (P/N 40X1648)
Page 401: Assembly 21: Cartridge Drive Assembly
5061 Assembly 21: Cartridge drive assembly Asm- Part Units/ Units/ Description Index number mach 40X1824 Cartridge drive assembly (one drive assembly per package) Also order cable tie parts packet (P/N 40X1648). Screw type 324, parts packet, 40X1635 7-29 Parts catalog...
Page 402: Assembly 22: Electronics
5061 Assembly 22: Electronics 7-30 Service Manual...
Page 403 5061 Assembly 22: Electronics Asm- Part Units/ Units/ Description Index number mach 22–1 40X0269 Power cord set, 8 ft (straight)—U.S., Asia Pacific (English), Canada, Colombia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Taiwan, Venezuela, Virgin Islands 40X1767 Power cord set, 8 ft (straight)—African countries—Bluemark, Austria,...
Page 404 5061 Assembly 22.1: Electronics 7-32 Service Manual...
Page 405 5061 Assembly 22.1: Electronics Asm- Part Units/ Units/ Description Index number mach 22.1–1 40X1782 System board outer shield 40X1786 Cable clip 40X1783 System board inner shield assembly Also order cable tie parts packet (P/N 40X1648) 40X1785 Ground cable 40X1700 System board shield support with clips Screw type 232, parts packet, 40X1676 40X1775 System board, network—1xx/3xx only...
Page 406 5061 Assembly 22.2: Electronics Asm- Part Units/ Units/ Description Index number mach 22.2–1 40X1793 Transfer HVPS board Screw type 323, parts packet, 40X1633 (TFR HVPS board to frame) Screw type 324, parts packet, 40X1635 (TFR HVPS board to frame) 40X1794 Standoff, high voltage power supply—developer board Screw type 121, parts packet, 40X1780 40X1795...
Page 407 5061 Assembly 22.3: Electronics Asm- Part Units/ Units/ Description Index number mach 22.3–1 40X1800 VTB fan, 60 mm 40X1796 VTB fan gap cover 40X1798 Fuser fan assembly Screws, parts packet, 40X1797 (fuser fan mounting) 40X1799 RIP fan, 92 mm 40X1662 RIP fan duct Screw type 324, parts packet, 40X1635 7-35...
Page 408: Assembly 23: Electronics-Cabling Interconnections 1
5061 Assembly 23: Electronics—cabling interconnections 1 7-36 Service Manual...
Page 409 5061 Assembly 23: Electronics—cabling interconnections 1 Asm- Part Units/ Units/ Description Index number mach 23–1 40X1637 Top autoconnect and output bin sensor—1xx/3xx only 40X1777 Top autoconnect and output bin sensor—2xx/4xx 40X1799 RIP fan, 92 mm 40X1758 Lift/BOR assembly 40X1807 Oiler motor driver cable 40X1801 Operator panel cable 40X1769...
Page 410: Assembly 24: Electronics-Cabling Interconnections 2
5061 Assembly 24: Electronics—cabling interconnections 2 7-38 Service Manual...
Page 411 5061 Assembly 24: Electronics—cabling interconnections 2 Asm- Part Units/ Units/ Description Index number mach 24–1 40X1753 Black terminal contact assembly 40X1759 Cyan terminal contact assembly 40X1761 Yellow terminal contact assembly 40X1757 Magenta terminal contact assembly 40X1812 Second transfer voltage cable assembly 40X1809 HVPS control cable—transfer 7-39...
Page 412: Assembly 25: Electronics-Cabling Interconnections 3
5061 Assembly 25: Electronics—cabling interconnections 3 Asm- Part Units/ Units/ Description Index number mach 25–1 40X1810 HVPS control cable—developer 40X1762 Cartridge contact assembly, complete 7-40 Service Manual...
Page 413: Assembly 26: Electronics-Cabling Interconnections 4
5061 Assembly 26: Electronics—cabling interconnections 4 Asm- Part Units/ Units/ Description Index number mach 26–1 40X1811 Options bottom/media size sensing cable assembly 40X1823 ITU drive assembly 7-41 Parts catalog...
Page 414: Assembly 27: Output Expander
5061 Assembly 27: Output expander 7-42 Service Manual...
Page 415 5061 Assembly 27: Output expander Asm- Part Units/ Units/ Description Index number option 27–1 40X1980 Output expander, complete 40X1997 ESD brush cover 40X1996 Right cover 40X1988 Deflector gate (also order 40X2000) Also called upper redrive deflecter. 40X2000 Upper diverter spring 40X2007 Exit shaft assembly, also order parts packet 40X2011 40X1999...
Page 416 5061 Assembly 27.1: Output expander 7-44 Service Manual...
Page 417 5061 Assembly 27.1: Output expander Asm- Part Units/ Units/ Description Index number option 27.1–1 40X1994 Right jam access door assembly 40X2006 Lower shaft assembly, also order parts packet 40X2011 40X2004 Drive pulley 40X1983 Rear attach bracket Screw, parts packet, 40X1813 40X1985 Front cover 40X2002...
Page 418: Assembly 28: 5-Bin Mailbox
5061 Assembly 28: 5-Bin mailbox 7-46 Service Manual...
Page 419 5061 Assembly 28: 5-Bin mailbox Asm- Part Units/ Units/ Description Index number option 28–1 40X2020 5-Bin mailbox, complete 40X2157 Access door rear latch 40X2049 Rear access door roller assembly 40X2024 Access door front latch 40X2032 Front door cover 40X4268 Front door assembly 40X2044 Left frame assembly w/clutch assembly 40X2056...
Page 420 5061 Assembly 28.1: 5-Bin mailbox 7-48 Service Manual...
Page 421 5061 Assembly 28.1: 5-Bin mailbox Asm- Part Units/ Units/ Description Index number option 28.1–1 40X2065 Diverter spring 40X2039 Right side frame assembly Screw type 323, parts packet, 40X1633 40X2057 Diverter actuator cam 40X2060 Diverter actuator spring 40X2058 Diverter actuator latch 40X2059 Diverter actuator arbor 40X2069...
Page 422: Assembly 29: 500-Sheet Drawer Option
5061 Assembly 29: 500-Sheet drawer option 7-50 Service Manual...
Page 423 5061 Assembly 29: 500-Sheet drawer option Asm- Part Units/ Units/ Description Index number option 29–1 40X1880 500-Sheet drawer option, complete 40X1728 500-Sheet tray assembly 40X1720 Back restraint latch 40X1719 Back restraint 40X1723 Tray bias bellcrank assembly Screw type 312/322/412/423, parts packet, 40X1691 40X1725 Tray bias spring 40X1722...
Page 424 5061 Assembly 29.1: 500-Sheet drawer option 7-52 Service Manual...
Page 425 5061 Assembly 29.1: 500-Sheet drawer option Asm- Part Units/ Units/ Description Index number option 29.1–1 40X1901 Drive assembly, 500 option 2 Screw type 323, parts packet, 40X1633 40X1910 500-Sheet option tray pick assembly 40X1898 Paper level sensing assembly 40X1938 Autoconnect cable assembly 40X1648 Cable tie (6 in a pack) Note: To secure cables to the inner system board shield)
Page 426: Assembly 30: Duplex Option
5061 Assembly 30: Duplex option 7-54 Service Manual...
Page 427 5061 Assembly 30: Duplex option Asm- Part Units/ Units/ Description Index number option 30–1 40X1920 Duplex option, complete 40X1961 Back cover 40X1965 Redrive bearing 40X1930 Duplex entry shaft assembly Screw type 312/322/412/423, parts packet, 40X1691 40X1923 Right side front tray guide 40X1956 Deflector actuator assembly 40X1957...
Page 428 5061 Assembly 30.1: Duplex option 7-56 Service Manual...
Page 429 5061 Assembly 30.1: Duplex option Asm- Part Units/ Units/ Description Index number option 30.1–1 40X1934 Duplex support plate 40X1938 Autoconnect cable assembly 40X1939 DC forward/reverse motor assembly 40X1940 DC duplex feed motor Screw type 323, parts packet, 40X1633 40X1648 Cable tie (6 in pack) 40X1937 Back support 40X1922...
Page 430: Assembly 31: High-Capacity Input Tray (Hcit)
5061 Assembly 31: High-capacity input tray (HCIT) 7-58 Service Manual...
Page 431 5061 Assembly 31: HCIT Asm- Part Units/ Units/ Description Index number option 31–1 40X2137 Paper size sensor box assembly 40X2111 Flag, paper size F 40X2112 Flag, paper size C 40X2110 Flag, paper size R 40X2113 Spring, paper size flag 40X2108 Sensor, photo interrupter 40X2103 Paper size sensors cable...
Page 432 5061 Assembly 31.1: High-capacity input tray (HCIT) 7-60 Service Manual...
Page 433 5061 Assembly 31.1: HCIT Asm- Part Units/ Units/ Description Index number option 31.1–1 40X2145 Rear cover 40X2143 Right side cover 40X2092 Caster, movable Screw type 312/322/412/423, parts packet, 40X1691 40X2094 F adjuster 40X2141 Front cover 40X2142 Cover, main CA 40X2093 Caster, fixed 40X2144 Left side cover...
Page 434: Assembly 32: Staplesmart Finishe
5061 Assembly 32: StapleSmart finishe Asm- Part Units/ Units/ Description Index number option 32—1 40X2159 Redrive cap cover 40X2150 Complete option 40X2155 Jam access door 40X2156 Front door latch 40X2157 Access door rear latch 40X2152 Front assembly cover 40X2153 Stapler access cover 40X3274 Stapler access door switch assembly 40X3277...
Page 435 5061 Assembly 32.1: StapleSmart finisher Asm- Part Units/ Units/ Description Index number option 32.1—1 40X3278 Stapler assembly 7-63 Parts catalog...
Page 436 5061 Assembly 32.2: StapleSmart finisher Asm- Part Units/ Units/ Description Index number option 32.2—1 40X3279 Switch assembly, safety cover open 99A0104 Spring, upper diverter 7-64 Service Manual...
Page 437 5061 Assembly 32.3: StapleSmart finisher Asm- Part Units/ Units/ Description Index number option 32.3—1 99A2480 StapleSmart wheels maintenance kit 7-65 Parts catalog...
Page 438: Assembly 33: Envelope Option
5061 Assembly 33: Envelope option 7-66 Service Manual...
Page 439 5061 Assembly 33: Envelope option Asm- Part Units/ Units/ Description Index number option 33–1 40X1842 Envelope option, complete 40X1843 Envelope tray assembly 40X2080 Envelope feeder pick tire 7-67 Parts catalog...
Page 440: Assembly 34: Outdoor Media Tray Option
5061 Assembly 34: Outdoor media tray option Asm- Part Units/ Units/ Description Index number option 35–1 40X2083 Outdoor media drawer assembly 40X2084 Outdoor media tray assembly 7-68 Service Manual...
Page 441: Assembly 35: Banner Option
5061 Assembly 35: Banner option Asm- Part Units/ Units/ Description Index number option 36–1 40X2086 Paper support bail 40X2088 Banner option screw 40X2087 Wire bail 7-69 Parts catalog...
Page 442: Assembly 36: Options
5061 Assembly 36: Options 7-70 Service Manual...
Page 443 40X4743 IPDS/SCS card assembly—2xx/4xx only 40X3521 Bar code card assembly—1xx/3xx only 40X4741 Bar code card assembly—2xx/4xx only 40X3523 Lexmark Forms card assembly—1xx/3xx only 40X4742 Lexmark Forms card assembly—2xx/4xx only 40X3524 PrintCryption™ card assembly—1xx/3xx only 40X4744 PrintCryption card assembly—2xx/4xx only 40X4754 PRESCRIBE card assembly—2xx/4xx only...
Page 444 5061 7-72 Service Manual...
Page 445: Appendix A-Service Tips
5061 Appendix A—Service tips Identifying the printheads Warning: Do not loosen or remove all printheads at the same time. If all printheads are loosened or removed, your reference to readjust will be lost. Notes: • Whenever a printhead is removed, it is necessary to perform the “Mechanical alignment”...
Page 446: Redrive Belt Routing
5061 Redrive belt routing If the redrive belt has been removed, use the diagram and information to properly route the belt. The idler gear roller in these photos is only visible because the printer has been disassembled to the frame. The gear will have to be located by feel to ensure proper installation.
Page 447: Duplex Option Deflector Button Replacement
5061 Duplex option deflector button replacement 230 Paper Jam—duplex deflector fails During a duplex job, the duplex option fails to actuate the deflector in the fuser, and the paper is diverted away from the duplex. The duplex option does not receive the sheet and prompts a 230 Paper Jam message. Replace the rubber deflector button with the enclosed compression spring deflector button.
Page 448 5061 Place the new button into the cam. Verify the new button moves freely by pressing the button firmly down and watching it snap back. Note: Leave the button in the up position. Service Manual...
Page 449: Appendix B-Print Quality Samples
5061 Appendix B—Print quality samples The following pages represent some of the pages available in various menus. While they are as close as possible to what you will see, variations in printing may result from individual user printer settings, media, and printer alignment.
Page 450: Print Quality Pages-Page 1 (Total Of Five
5061 Print Quality Pages—Page 1 (total of five) Service Manual...
Page 451: Print Quality Pages-Page 2 (Total Of Five
5061 Print Quality Pages—Page 2 (total of five) Appendix B—Print quality samples...
Page 452: Print Quality Pages-Page 3 (Total Of Five
5061 Print Quality Pages—Page 3 (total of five) Service Manual...
Page 453: Print Quality Pages-Page 4 (Total Of Five
5061 Print Quality Pages—Page 4 (total of five) Appendix B—Print quality samples...
Page 454: Registration And Alignment
5061 Registration and alignment Quick Test Page In Diagnostic Menu, select REGISTRATION and select Quick Test. Service Manual...
Page 455: Printhead Mechanical Alignment Test Page
5061 Printhead mechanical alignment test page In Diagnostics Menu, select MISC TESTS and select Printhead Inst. Appendix B—Print quality samples...
Page 456: Printhead Electronic Alignment Test Page-Magenta (One Of Two
5061 Printhead electronic alignment test page—Magenta (one of two) In Diagnostic Menu, select ALIGNMENT, select a color, and select Quick Test. Service Manual...
Page 457: Printhead Electronic Alignment Test Page-Magenta (Two Of Two
5061 Printhead electronic alignment test page—Magenta (two of two) Appendix B—Print quality samples...
Page 458 5061 B-10 Service Manual...
Page 459: Index
5061 Index 2-80 Numerics service checks 3-15 Button Test 1xx service errors buttons error code table – accessing service menus 2-14 2-28 error-specific service checks – 3-15 Button Test 2xx paper jams 2-119 operator panel 2-11 description – 2000-sheet input tray option diagnostics cabling 7-58...
Page 460 5061 3-23 connector locations Staple Test 5-22 3-15 developer HVPS board HARDWARE TESTS 5-24 3-15 fuser connectors Button Test 5-26 3-16 HCIT 2000-sheet board CACHE Test 5-20 3-16 HVPS DRAM Test 5-20 3-15 HVPS board LCD Test 5-23 3-17 LVPS Parallel Wrap Test 5-25 3-18...
Page 461 5061 2-124 3-35 Enhance Fine Lines Jobs On Disk 3-34 Env Prompts HCIT standalone test mode 2-125 envelope feeder option Hex Trace 7-66 parts catalog high-capacity input tray (HCIT) 2-85 5-26 service checks connections 2-41 2-45 error codes paper jam 7-58 7-60 1xx service errors...
Page 462 5061 1-17 7-50 7-52 recommended types 500-sheet drawer option 1-10 1-11 7-20 sizes supported 500-sheet integrated tray 1-19 7-46 7-48 unacceptable 5-bin mailbox 1-13 1-15 7-21 weight autocompensator assembly 7-69 memory banner tray 7-27 available memory options BOR drive assembly 7-28 configuration cartridge contact assembly...
Page 463 5061 3-15 4-19 print quality test pages front left handle cover assembly 2-103 4-17 residual image front lower left cover 2-95 4-19 service check front lower right cover 2-104 4-21 smudged or distorted images front right handle cover assembly 2-105 4-24 toner is on the back of the printed page left lower cover...
Page 464 5061 2-122 RGB Brightness environment 2-122 RGB Contrast media 2-122 RGB Saturation memory configuration 4-85 rib housing, removal memory options RIP fan operating clearance location performance 4-87 removal power and electrical 2-57 service check time to first print 3-23 Stapler Test StapleSmart finisher 4-88 S2 sensor cable, removal...
Page 465 5061 7-26 waste container latch 7-26 waste toner container, parts catalog web oiler fuser location 4-100 removal 1-20 upgrade kit Index...
Page 466 5061 Service Manual...
Page 467: Part Number Index
5061 Part number index Description Page 40X0070 Pick roll tires (2 per pack) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 40X0269 Power cord set—U.S., Asia Pacific (English), Canada, Colombia, Costa Rica, Dominican Republic, Ecuador,...
Page 468 5061 40X1621 Front lower right cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X1622 Right rear cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X1623...
Page 469 5061 40X1686 Bracket mounting anchor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14 40X1687 Lower right door latch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 470 5061 40X1754 Waste container latch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-26 40X1755 Waste container latch spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 471 5061 40X1828 Printhead assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 40X1831 Fuser assembly, 115 V 500W—2xx/4xx - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 472 5061 40X1944 Pass thru spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55 40X1946 Bellcrank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 473 5061 40X2015 Frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45 40X2020 5-Bin mailbox, complete - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 474 5061 40X2099 Locating pin, options rear left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 40X2100 Locating pin, options front right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 475 Lexmark Forms card assembly—1xx/3xx...
Page 476 5061 I-18 Service Manual...
Page 477 Reference Reference C77x, C78x Repeating Defect Locator Components NOTE Nip Shock : Do not use the side rulers to assess repeating defects if the left and right calibration lines do not measure 110 mm respectively. When printing this document, make sure ‘Fit to page’ is not selected.

This manual is also suitable for:

C77x

Lexmark C78x Service Manual

Notices and Safety Information

Laser Notice

Safety Information

Preface

Change History

Conventions

General Information

Models

Tools Required for Service

Options and Features

Printer Specifications

Power and Performance

Media Specifications

Web Oiler Upgrade Kit and Replacements

Acronyms

Diagnostic Information

Start

POR (Power-On Reset) Sequence

Symptom Tables

Service Error Code and Paper Jam Message Table

Service Checks

User Operator Panel, Menus, and Messages

Diagnostic Aids

Diagnostic Procedures

Accessing Service Menus

Diagnostics Mode

Configuration Menu

Paper Jams

Repair Information

Handling ESD-Sensitive Parts

Screw Identification Table

Removal Procedures

Quick Links

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Summary of Contents for Lexmark C78x