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Lexmark 5060-00x, Service Manual

The Lexmark 5060-00x service manual is a comprehensive guide that provides detailed instructions on how to maintain and repair your Lexmark printer. This manual can be downloaded for free from manualshive.com, ensuring you have the necessary resources to keep your printer running smoothly.

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Connector locations

5-9

 

5060-00

x

J9 LVPS

1

+3.3 V dc

2

+5  V  dc

3

+5  V  dc

4

+24  V  dc

5

+24  V  dc

6

Ground

7

Ground

8

Ground

9

Ground

10

Ground

J10 Fuser

1

EXIT SENSOR IN

2

FUSER CAM1 IN

3

FUSER CAM2 IN

4

OILER ENC A IN

5

OILER ENC B IN

6

HR THERM IN

7

BR  THERM  IN

8

Ground

9

+5 V dc switched

10

ZERO Xing IN

11

HR HEAT ON OUT

12

BR HEAT ON OUT

J11 Bin Full

1

+5 V dc switched

2

BIN FULL IN

3

Ground

J12 BOR (Lift) Motor

1

LIFT PHA OUT -

2

LIFT PHA OUT +

See 

“Engine board” on page 5-7

Connector

Pin no.

Signal

Summary of Contents for 5060-00x

Page 1: ...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 coun...

Page 2: ...e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase...

Page 3: ...Acoustics 1 5 Environment 1 5 Print speed and performance print speed 1 6 Media specifications 1 7 Acronyms 1 13 Diagnostic information 2 1 Start 2 1 POR power on reset sequence 2 2 Symptom tables 2...

Page 4: ...Error code 2 61 155 Error code 2 62 156 Error code 2 62 157 Error code 2 63 158 Error code 2 64 159 Error code 2 64 160 Error code 2 65 161 Error code 2 65 162 Error code 2 65 163 Error code 2 66 164...

Page 5: ...e no image 2 139 Entire page is mostly one color Full bleed planes in one color 2 140 Missing colors Complete or partially missing color planes 2 141 Black and white only cyan magenta and yellow are m...

Page 6: ...s Return or Stop 3 16 TOP FINE MAR ADJ 3 16 MISC TESTS 3 16 Motor Detect 3 16 Belt Tracking ITU 4th point adjustment 3 17 PRINT TESTS 3 18 Print Tests input source 3 18 Prt Quality Pgs 3 19 Prt Line L...

Page 7: ...emoval procedures 4 5 Top cover assembly removal 4 5 Rear fan cover removal 4 8 Rear cover removal 4 8 Front right handle cover assembly removal 4 9 Front left handle cover assembly removal 4 10 Front...

Page 8: ...an magenta yellow 4 64 Rear bellcrank removal black 4 66 Redrive assembly removal 4 68 Registration motor removal 4 69 RIP board removal 4 70 RIP fan removal 4 71 RIP board shield assembly removal 4 7...

Page 9: ...er size sensing 7 18 Assembly 11 Paper feed transport 7 19 Assembly 12 Multipurpose feeder MPF 7 20 Assembly 13 500 sheet integrated tray 7 22 Assembly 14 Autocompensator assembly 7 24 Assembly 15 ITU...

Page 10: ...29 Appendix B Print quality samples B 1 Print Menus Page one of two B 1 Print Menus Page two of two B 2 Print tests B 3 Print Quality Pages Title page total of five B 3 Print Quality Pages Page 1 tota...

Page 11: ...h den Kundendienst Laserbestrahlung die die Klasse I bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux...

Page 12: ...pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso...

Page 13: ...t n gon person uts tts f r laserstr lning ver Klass I niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter...

Page 14: ...xiv Service Manual 5060 00x...

Page 15: ...Laser notice xv 5060 00x...

Page 16: ...xvi Service Manual 5060 00x...

Page 17: ...nsignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le...

Page 18: ...n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y l...

Page 19: ...roducte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d a...

Page 20: ...d removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specificati...

Page 21: ...network configurations requiring Ethernet Token Ring LocalTalk serial infrared or additional parallel ports The printer has flexible paper handling It supports a wide variety of paper sizes and has a...

Page 22: ...part Each of the five bins supports approximately 100 pages of 20 lb paper Only one output option above the printer is supported Finisher offers stapling hole punching offset stacking and an addition...

Page 23: ...h Height Weight Printer Lexmark C750 n 23 8 in 604 5 mm 18 5 in 469 9 mm 20 8 in 528 3 mm 105 lb 47 7 kg Lexmark C750dn inc Duplex Opton 23 8 in 604 5 mm 18 5 in 469 9 mm 24 3 in 617 2 mm 118 lb 53 8...

Page 24: ...ll 20 in 508 mm Rear All 12 in 304 8 mm Top C750 n 42 in 1 066 8 mm 2 C750dn 34 in 863 6 mm 2 1 Allow 1 219 2 mm 48 in clearance to the right if you are adding a finisher 2 Allow clearance above the p...

Page 25: ...perature 80 1 F 26 7 C Altitude 10 000 ft 0 to 3 048 meters Atmospheric pressure 74 6 kPa Ambient operating environment Temperature 60 to 90 F 15 6 to 32 2 C Relative humidity 8 to 80 Storage and ship...

Page 26: ...letter size paper The test job consists of the character A followed by a form feed single page job The first copy time is defined as the elapsed time from hitting enter on the PC keyboard to the page...

Page 27: ...rd disk 1 Additional memory may be required for printing complex pages or full page high resolution images in 1200 image quality at rated speeds Media specifications Media type DRAM memory Lexmark C75...

Page 28: ...7 Folio 8 5 in x 13 in 216 mm x 330 mm 4 x x x x x x x 5 6 7 Legal 8 5 in x 14 in 216 mm x 256 mm x x x x x x x x 5 6 7 Executive 7 25 in x 10 5 in 184 mm x 267 mm x x x x x x x x 6 7 Universal1 5 5...

Page 29: ...page is formatted for 8 5 x 14 in 215 9 x 355 6 mm unless the size is specified in the software application 4 Statement and Folio are supported as standard size through software only Tray size sensing...

Page 30: ...s Pressure sensitive area c 140 to 175 g m2 Paper base grain long 20 to 36 lb bond 75 to 135 g m2 Multipurpose feeder Paper b f Xerographic or business paper 16 to 19 9 lb bond 60 to 74 9 g m2 grain l...

Page 31: ...on whether your vinyl label converter has passed Lexmark s criteria Refer to the Card Stock and Label Guide for more details i Lexmark transparency numbers 12A5940 and 12A5941 are supported from the...

Page 32: ...ive humidity and is not supported in duplex c Pressure sensitive area must enter the printer first d 100 cotton content maximum weight is 24 lb bond 28 lb envelopes are limited to 25 cotton content e...

Page 33: ...d Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply M Magenta MPF Multipurpose Feeder MROM Masked Read Only Memory MS Microswitch NVRAM Nonvolatil...

Page 34: ...1 14 Service Manual 5060 00x...

Page 35: ...repair a printer see the following topics POR power on reset sequence on page 2 2 Symptom table base printer on page 2 3 Symptom table 500 sheet drawer option on page 2 4 Symptom table HCIT 2000 shee...

Page 36: ...ont panel LED blinks 19 Redrive exit roller turns 20 Any cartridge errors are posted such as a defective cartridge Lexmark Return Program information or missing cartridge 21 Any applicable maintenance...

Page 37: ...nly If the printer is set up correctly check the black retract motor and gears for correct operation If the gears are operating correctly go to Black only retract BOR service check on page 2 117 Print...

Page 38: ...osition Go to Tray x autocompensator fails to retract stays in down position on page 2 109 Paper Low message appears when adequate paper is installed tray x Go to The printer does not detect paper low...

Page 39: ...ed into the 5 Bin mailbox bin selected 271 Paper Jam Check Bin 1 message on page 2 106 Paper Jam 271 Check Bin 1 message appears Go to Paper does not feed into the 5 Bin mailbox bin selected 271 Paper...

Page 40: ...does not fix the problem replace the engine board See Engine board removal on page 4 29 910 Trans Sensor Tray 1 Transparency Sensor Error replace Tray 1 autocompensator assembly See Autocompensator pi...

Page 41: ...problem replace the engine board See Engine board removal on page 4 29 940 TMC Error Cyan Cyan toner metering cycle TMC switch failure go to 940 Error code on page 2 93 941 TMC Error Magenta Magenta t...

Page 42: ...check the following If installed check network card for correct installation If correctly installed replace the network card If a network card is not installed replace the RIP board 976 Standard Netw...

Page 43: ...equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Note device can be one of the following Duplex option Tray x where x 1...

Page 44: ...go to Printhead diagnostics on page 3 1 Note Do not adjust or replace any printhead before performing the checks in Printhead diagnostics on page 3 1 109 Printhead Error Black printhead lost Hsync Che...

Page 45: ...embly J2 J3 and J4 on the RIP board Go to RIP board on page 5 14 If the cables are connected correctly to the RIP board and to the printhead assembly go to Printhead diagnostics on page 3 1 Note Do no...

Page 46: ...s on page 3 1 120 Fuser Error Wrong fuser lamp hot roll Replace with correct lamp Go to 120 Error code on page 2 44 121 Fuser Error Wrong fuser lamp BUR Replace with correct lamp Go to 121 Error code...

Page 47: ...on page 4 69 If this does not fix the problem replace the engine board See Engine board removal on page 4 29 142 Motor DC pick motor over speed registration motor replace the registration motor assem...

Page 48: ...tor Magenta cartridge motor lost lock Go to 157 Error code on page 2 63 158 Motor Cyan cartridge motor lost lock Go to 158 Error code on page 2 64 159 Motor Yellow cartridge motor lost lock Go to 159...

Page 49: ...on page 3 1 176 Motor Mirror motor lost lock yellow Go to Printhead diagnostics on page 3 1 Note Do not adjust or replace any printhead before performing checks in Printhead diagnostics on page 3 1 1...

Page 50: ...sensor out of range process direction yellow Update the machine code Run a Line Length test page See Prt Line Len Pg on page 3 19 If the problem persists go to Printhead diagnostics on page 3 1 192 PS...

Page 51: ...he timeout period 2D 09 Paper jam detected The fuser exit sensor did not deactivate during the timeout period 2D 0A Paper jam detected A paper jam detected in the Duplex Option 2D 0B Paper jam detecte...

Page 52: ...on 2D 2D Duplex input motor error detected the engine detected a PWM error 2D 2E Duplex input motor error detected the engine detected a motor encoder error 2D 2F Duplex reversing motor error detected...

Page 53: ...n Motor Encoder error detected 2D 4B Autocompensator motor encoder error detected when picking media from the MPF 2D 4C Autocompensator motor encoder error detected when picking media from Tray 1 2D 4...

Page 54: ...gram a non network printer or a non network file was used to program a network printer P109 Package size error An update file was used to program the printer but the package did not fit within the spa...

Page 55: ...es Collation Separator Sheets Separator Source Hole Punch Offset Pages Staple Job Staple Prime Src Multipage Print Multipage Order Multipage View Multipage Border Color Menu Color Correction Manual Co...

Page 56: ...lgorithm that produces brighter more saturated colors May be selected for all incoming color formats sRGB Display Applies color correction to produce output that approximates the colors displayed on a...

Page 57: ...manually relinearize the color tables adjusting for variations in output that occur as a result of environmental conditions Color Samples To assist in selecting colors used by certain applications Def...

Page 58: ...ob statistics stored on the hard disk or to clear all statistics on the disk Print Prints all statistics available for the most recent print jobs Clear Deletes all accumulated job statistics from the...

Page 59: ...fuser Open the right door to access the jam area If sheets have been accumulated to be stapled or offset when the jam occurred the printer alternately flashes the primary and secondary messages to ind...

Page 60: ...nted after the jam will not be stapled 24x Paper Jam Clear Paper Path Leave Job in Finisher Primary Media is jammed around Tray x Tray x 2 through 4 and applies to both a 500 Tray and HCIT tray Try op...

Page 61: ...Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 272 Paper Jam Clear Paper Path Leave Job in Finisher Primary Media is jammed in output bin...

Page 62: ...s displayed if the accumulated sheets are removed the printer will not reprint these sheets Also if the print job is completed the portion of the job printed after the jam will not be stapled 202 Pape...

Page 63: ...If sheets have been accumulated to be stapled when the jam is detected the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during...

Page 64: ...the jam will not be stapled 282 Staple Jam Check Stapler 283 Staple Jam Check Stapler Remove Job from Finisher These messages are displayed when the stapler device detects a paper jam 282 Staple Jam i...

Page 65: ...when Performing Self Test displays 4 Select Calibrate Trays 5 Select Tray x from the menu 6 The display prompts load paper if necessary 7 Load paper 8 Press Go Calibrating Tray x is displayed 9 Repea...

Page 66: ...on removed If the problem continues turn the printer off and back on If the message continues to be displayed turn the printer off remove the option and call for service Close Door This message is dis...

Page 67: ...staples The Staples Empty warning appears on the status line and Load Staples may immediately appears Load Staples This message is displayed when the Staples Empty Alarm is activated and there are no...

Page 68: ...reinstallation of the option to print a page which has been formatted by an install Tray x interpreter prior to removal of the option or Cancel Job Bin x x 1 2 or 3 Tray x x 2 3 4 or 5 Duplex The fol...

Page 69: ...etects a media mismatch feeding from the MPF Primary Message Incorrect media detected Secondary Message type Bond Cardstock Colored Labels Envelopes Letterhead Plain Preprinted Transparency or Glossy...

Page 70: ...job or Press Menu or Menu to access the Busy Waiting Menu The following functions are available using the Busy Waiting Menu Cancel Job Reset Printer Reset Active Bin Check Supply Levels Note Menu Loc...

Page 71: ...cannot be accessed 38 Memory Full This message is displayed when the printer is processing an incoming job and there is not enough memory available to continue processing the job The following actions...

Page 72: ...Par ENA Connection Lost This message is displayed when the printer detects during POST that the connection to an ENA has been lost Once a connection is initially established a printer setting is modif...

Page 73: ...parallel port is discarded Press Menu to access the Busy Waiting Menu The following functions may be available Reset Printer Reset Active Bin Check Supply Levels Note Menu Lockout does NOT prevent ac...

Page 74: ...en the printer detects a defective disk This error may occur at power on or during disk format and write operations Press Go to clear the message The disk is marked as defective and normal printer ope...

Page 75: ...message is displayed when the waste container is nearly full Press Go Nearly Full appears in the Supplies Menu 84 Replace Oiler This message is displayed when the web oiler is exhausted or missing Re...

Page 76: ...on a solid flat surface Is the printer setting on a solid flat surface Go to step 3 Go to step 4 3 Inform the customer that the printer must be setting on a solid flat surface or install the printer o...

Page 77: ...8 Remove the ITU and check the ITU belt position If the belt has shifted front to rear it should be replaced The belt must not shift more than 4 mm in either direction Check by making the measurements...

Page 78: ...the engine board Is the cable correctly installed Go to step 13 Install the cable correctly 13 Make sure the ITU autoconnect connector in the printer is seated correctly in the connector plate Is the...

Page 79: ...oval on page 4 31 Step Action and questions Yes No 1 Is the correct fuser assembly installed in the printer Go to step 2 Install the correct fuser assembly See Fuser assembly removal on page 4 31 2 Is...

Page 80: ...38 3 Engine board See Engine board removal on page 4 29 124 Error code Hot fuser The printer detects a problem with the fuser running over temperature or the hot roll fuser lamp has been on too long A...

Page 81: ...er on and measure the voltage on connector J10 12 on the engine board The voltage should measure approximately 0 13 V dc to 0 64 V dc as the hot roll lamp turns on and off Is the voltage correct Repla...

Page 82: ...or See Engine board on page 5 7 The voltage should measure approximately 3 3 V dc Is the voltage correct Replace the fuser assembly See Fuser assembly removal on page 4 31 Replace the LVPS See Low vol...

Page 83: ...the fuser assembly from the printer and measure the voltage on connector J10 7 on the engine board The voltage should measure approximately 3 3 V dc Is the voltage correct Go to step 2 Replace the en...

Page 84: ...Use caution when handling the lamp as it is easily broken Check continuity of the lamp Is there continuity Replace the fuser assembly See Fuser assembly removal on page 4 31 Replace the lamp 5 Reinsta...

Page 85: ...Install the lamp correctly 4 Carefully remove the lamp from the fuser assembly being careful to only handle the lamp by the ceramic end pieces and not by the glass envelope Warning Use caution when ha...

Page 86: ...ity of the hot roll lamp by measuring between pins 1 and 2 on the AC fuser connector on the fuser assembly Is there continuity Go to step 5 Go to step 3 3 Make sure the hot roll lamp is installed corr...

Page 87: ...age on connector J10 12 on the engine board The voltage should measure approximately 0 13 V dc to 0 64 V dc as the backup roll lamp turns on and off Is the voltage correct Replace the fuser assembly S...

Page 88: ...Engine board removal on page 4 29 7 Measure the voltage on pin 7 of the fuser DC control connector The voltage should measure approximately 3 3 V dc Is the voltage correct Replace the fuser assembly S...

Page 89: ...observe the backup roll lamp to see if it turns on and off You may have to observe the lamp for a few minutes to see if it turns on and off Does the lamp turn on and off Go to step 2 Replace the LVPS...

Page 90: ...he printer Measure the voltage at the DC fuser control connector pins 2 and 9 The voltage should measure approximately 5 V dc Is the voltage correct Replace the fuser assembly See Fuser assembly remov...

Page 91: ...the ITU drive motor cable Do you measure continuity Go to step 4 Replace the ITU drive motor cable 4 ITU drive motor voltage check measure the voltage on connector J64 on the engine board The voltages...

Page 92: ...ng FRUs in the order shown 1 Fuser drive assembly removal on page 4 33 2 Engine board removal on page 4 29 Step Actions and questions Yes No 1 Check the black cartridge drive motor cable connection to...

Page 93: ...idge drive motor card Is the cable installed correctly Go to step 3 Install the cable correctly 3 Check continuity of the magenta cartridge drive motor cable Is there continuity Go to step 4 Replace t...

Page 94: ...able connection to J47 on the engine board Is the cable installed correctly Go to step 2 Install the cable correctly 2 Check the yellow cartridge drive motor cable connection to the yellow cartridge d...

Page 95: ...ity of the ITU drive motor cable Do you measure continuity Go to step 4 Replace the ITU drive motor cable 4 ITU drive motor voltage check measure the voltage on connector J64 on the engine board The v...

Page 96: ...e 4 33 2 Engine board See Engine board removal on page 4 29 Replace the fuser drive assembly See Fuser drive assembly removal on page 4 33 Replace the fuser top duct See Fuser top duct removal on page...

Page 97: ...the engine board Is the cable installed correctly Go to step 2 Install the cable correctly 2 Check the magenta cartridge drive motor cable connection to the magenta cartridge drive motor card Is the c...

Page 98: ...motor card Is the cable installed correctly Go go step 3 Install the cable correctly 3 Check continuity of the cyan cartridge drive motor cable Is there continuity Go to step 4 Replace the cyan cartri...

Page 99: ...or Detect on page 3 16 Is error code 160 still shown Call your next level support Problem solved Step Action and questions Yes No 1 Fuser drive motor assembly error code 161 indicates that an incorrec...

Page 100: ...at an incorrect motor is detected Replace the magenta cartridge drive assembly See Cartridge drive assembly removal on page 4 26 Perform the Motor Detect on page 3 16 Does the printer display error co...

Page 101: ...eak in time on page 2 69 Step Action and questions Yes No 1 Is sensor flag obstructed by paper debris out of position or broken Clear obstruction and reinstall or replace flag Go to step 2 2 Perform t...

Page 102: ...o step 3 3 Check for obstructions in the paper path Is the paper path obstructed Clear the obstruction Go to step 4 4 Is the inner deflector out of position Correct the deflector position Go to step 5...

Page 103: ...r jammed at the second transfer roll Clear the jam Call your next level of support Step Action and questions Yes No 1 Does media feed correctly from Tray 1 Go to step 2 Go to 200 Paper jam Tray 1 on p...

Page 104: ...eet option or envelope option on page 2 69 3 Check tray 1 pass thru for damage or obstruction Is the pass thru obstructed or damaged Clear the obstruction Repair or replace the duplex option Step Acti...

Page 105: ...step 5 Perform the following in order 1 Reseat the connector J10 on the engine board 2 Replace the fuser See Fuser assembly removal on page 4 31 3 Replace the LVPS See Low voltage power supply LVPS r...

Page 106: ...torn belts excessive toner buildup or damage to the transport assembly especially to the transport drive gear Are there broken or damaged parts in the vacuum transport assembly Replace the vacuum tra...

Page 107: ...ly Go to step 4 Replace the fuser See Fuser assembly removal on page 4 31 4 Reinstall the fuser and perform the BASE SENSOR TEST on page 3 29 for the fuser exit sensor Note Use a spring hook to actuat...

Page 108: ...l to check if the jam occurred at duplex entry edge guide Did the jam occur at the duplex entry edge guide Replace the duplex option Go to step 9 9 If the duplex option is in use check the actuator bu...

Page 109: ...ons Yes No 1 Check of mechanical drive components Check the output expander drive belt to make sure it is installed on the drive pulley and belt idler pulley Check the belt tension spring to make sure...

Page 110: ...oor and check that the diverter operates freely Does the diverter operate freely Go to step 5 Replace the fuser assembly See Fuser assembly removal on page 4 31 5 Close the redrive door and check that...

Page 111: ...lex system board Are the cables correctly connected Repair or replace the duplex option Correctly connect the cables Paper jam code Tray identification Problem related to the following option or tray...

Page 112: ...on by running the Tray x sensor test from the Diagnostics Menu See Sensor Test on page 3 24 Does the pass thru sensor operate correctly Check for any obstructions that might catch the media and create...

Page 113: ...e tray Does the paper feed from the paper tray Go to step 14 Go to step 4 4 Using the standalone feeding operation test observe the registration motor the registration motor is the motor at the top of...

Page 114: ...he system board Is the cable connected correctly Go to step 13 Install the cable correctly 13 Is the registration home sensor operating correctly Replace the following FRUs in the order shown 1 HCIT s...

Page 115: ...Diagnostic information 2 81 5060 00x Printer configuration diagrams for 24x paper jams...

Page 116: ...ht The leading edge of the media should be sitting on the friction buckler Is the media correctly loaded Go to step 5 Properly load the media 5 Open the MPF to the horizontal position and check the pa...

Page 117: ...step 2 2 Make sure that the MPF sensor cable from the engine board is correctly installed at J70 on the engine board Is the cable correctly installed Go to step 3 Install the cable correctly 3 Check...

Page 118: ...es approximately 0 V dc Is the voltage correct Replace the control board Replace the sensor assembly XNF Near Full Upper part of sensor assembly F Full Lower part of sensor assembly P Pass Thru Sensor...

Page 119: ...J5 on the control board Is the sensor connected correctly Go to step 3 Reseat the cable 3 Bottom pass thru sensor voltage check 1 disconnect the pass thru sensor cable and check the voltage at J5 3 o...

Page 120: ...pass thru sensor flag check the top sensor flag for correct operation binding broken parts or interference from the sensor cable Are there any problem with the sensor flag Repair as necessary Go to st...

Page 121: ...accumulator motor or sensor failure 09 Tray elevation motor timeout error Stuck or failed paper level sensor motor failure 13 Paper not detected at inverter timing sensor within timeout Jam near input...

Page 122: ...rn the printer off Raise and lower the lever above the ITU handle Do not remove the ITU assembly itself Make sure the level is pressed firmly in place Turn the printer on Does the 900 error display Go...

Page 123: ...ntact you next level of support 900 Error Code displayed when the machine is connected to a network while still in Setup Required Mode 5 Restore factory defaults from the Configuration Menu Warning Wh...

Page 124: ...r tan See Fuser fan removal on page 4 34 Replace the engine board See Engine board removal on page 4 29 Step Actions and questions Yes No 1 Turn the power off and manually spin the fan and check that...

Page 125: ...o step 3 Install the cable correctly 3 Check for any obstruction in the fan Is there an obstruction in the fan Remove the obstruction Go to step 4 4 Disconnect the RIP fan from J53 on the engine board...

Page 126: ...orrectly Go to step 2 Install the cable correctly 2 Voltage checks disconnect J10 from the engine board assembly Go to Engine board on page 5 7 Check the voltage at J10 10 on the cable It measures app...

Page 127: ...the printer or if the cartridge is known to be defective Note Before proceeding with this service check observe the error log for repetitive occurrences of a 94x service error Step Actions and questi...

Page 128: ...played 6 Make sure the developer HVPS cable is correctly installed on the developer board assembly Is the cable correctly installed Go to step 7 Correctly connect the cable 7 Make sure the developer H...

Page 129: ...he printer or if the cartridge is known to be defective Note Before proceeding with this service check observe the error log for repetitive occurrences of a 94x service error Step Actions and question...

Page 130: ...isplayed 6 Make sure the developer HVPS cable is correctly installed on the developer board assembly Is the cable correctly installed Go to step 7 Correctly connect the cable 7 Make sure the developer...

Page 131: ...the printer or if the cartridge is known to be defective Note Before proceeding with this service check observe the error log for repetitive occurrences of a 94x service error Step Actions and questio...

Page 132: ...rrectly Make sure all the mounting screws are tightened Recheck the printer to see if a 942 Error is still displayed 6 Make sure the developer HVPS cable is correctly installed on the developer board...

Page 133: ...h the printer or if the cartridge is known to be defective Note Before proceeding with this service check observe the error log for repetitive occurrences of a 94x service error Step Actions and quest...

Page 134: ...splayed 6 Make sure the developer HVPS cable is correctly installed on the developer board assembly Is the cable correctly installed Go to step 7 Correctly connect the cable 7 Make sure the developer...

Page 135: ...between 115 and 135 ohms Is the resistance correct Go to step 3 Replace the mechanical linkage DC motor assembly 3 DC motor check between J2 1 and between J2 2 and the case of the DC motor for shorts...

Page 136: ...sembly that has the defective parts Replace the FRUs in the following order 1 Electronic size sensing assembly 2 Autocom pensator assembly 3 Drive assembly Step Actions and questions Yes No 1 Mechanic...

Page 137: ...on the finisher system board Is the cable correctly installed Go to step 4 Install correctly 4 When 990 error is installed press and hold Return and Select to view the sub error code Scroll down with...

Page 138: ...t options as installed Go to The printer does not recognize one or more output options as installed on page 2 105 Go to step 4 4 271 Paper Jam Check Bin 1 message Go to 272 Paper jam Check Bin x on pa...

Page 139: ...system in base printer 2 Mechanical linkage tables check the 5 bin mailbox autoconnect cable and connector for any signs of damage especially the connector pins Is there any signs of damage to the cab...

Page 140: ...the resistance correct Replace the 5 bin mailbox control board assembly Replace bin x solenoid assembly 4 Mechanical linkage motor assembly check the gears clutch and other linkage parts for correct o...

Page 141: ...le connected correctly Go to step 3 Install the sensor cable correctly 3 Bin x sensor flag check the Bin x sensor flag for binding and proper operation Are there any problems with the sensor flag Repa...

Page 142: ...nnector J5 Is the cable to J5 installed correctly Go to step 4 Install the cable correctly and recheck 4 Autoconnect cables check the autoconnect from the printer or option above tray x Check for cuts...

Page 143: ...4 Install the bellcrank correctly 4 Check the following for loose broken or missing parts Boss on the side of the arm Bellcrank lift spring Tray interlock bellcrank Are any of these parts loose broken...

Page 144: ...aper level sensing flag spring Is the paper level sensing assembly installed correctly Replace the paper level sensing assembly Go to step 6 6 Make sure the paper level sensing assembly arm goes all t...

Page 145: ...size sensing assembly Install the cable correctly Step Action and questions Yes No 1 Is the tray set for the size paper loaded in the tray Go to step 2 Set the correct size 2 Are there damaged or bro...

Page 146: ...rinter is incorrect 2 AC power check wall outlet check the AC line voltage at the AC outlet Is the AC line voltage correct Go to step 3 Inform the customer that the AC line voltage is incorrect 3 AC p...

Page 147: ...s correct Go to step 3 Replace the LVPS See Low voltage power supply LVPS removal on page 4 38 3 DC voltages at RIP board turn the power off and disconnect the LVPS cable to J23 on the RIP board Turn...

Page 148: ...6 or System board network on page 5 7 Repeat this step until the original DC power problem occurs Does the DC power problem occur Check the cable and component that was last connected to system board...

Page 149: ...an you remove tray 1 from the printer Go to step 3 Go to step 2 2 Open the lower jam access door and carefully lift the autocompensator assembly until it is in its upper most position and carefully tr...

Page 150: ...correctly 4 Check the paper level sensing assembly flag for correct installation and the flag is not broken or damaged Is the paper level sensing assembly installed correctly and the flag not broken...

Page 151: ...R system Remove the print cartridges Observe the ITU belt as you manually rotate the BOR gear Does the ITU belt move up and down when the ITU is toggled Go to Entire page is mostly one color Full blee...

Page 152: ...light shield out of position Properly align the ITU light shield Go to step 2 2 Make sure the ITU assembly interlock switch actuator is not damaged or broken and actuates the switches correctly Is th...

Page 153: ...step 4 4 Front cover assembly Does the front cover close correctly Go to step 5 Install the front cover correctly or repair as necessary 5 Front cover assembly Make sure the front cover flag is not br...

Page 154: ...one of the option s that is installed beneath the printer Try to isolate which of the options is causing the problem Go to step 3 3 Make sure the duplex option is correctly installed Is the duplex opt...

Page 155: ...le in the duplex option is installed correctly in the duplex frame Is the cable installed correctly Go to step 9 Correctly install the cable If the connector is damaged replace the cable assembly 9 Ma...

Page 156: ...for the belt motor x x Error detected for the tray motor x x HCOF detects the front door is open x x x Error detected with the communications to the printer x x Error detected for the offset motor x...

Page 157: ...or any signs of damage Is the switch activating spring broken Replace the joint switch assembly Go to step 5 5 Check the joint switch for correct operation The switch can be checked by measuring conti...

Page 158: ...Autoconnect connector Pin 2 located on the top right rear of the printer The voltage measures approximately 5 V dc Is the voltage correct Go to step 7 Go to step 10 7 Check the AC line voltage between...

Page 159: ...nected correctly Go to step 5 Install the cable correctly 5 Check the continuity of the front switch as the switch is activated Do you measure continuity Go to step 6 Replace the front door switch 6 C...

Page 160: ...ges on CN5 The voltages read the following approximate values with the chad box empty Are the voltages correct Go to step 5 Replace the finisher system board 5 Check the sensor by placing the chad box...

Page 161: ...r the fuser lamps have been on too long Excessive fuser drive motor assembly noise Step Action and questions Yes No 1 Excessive noise from the fuser drive motor assembly check for correct installation...

Page 162: ...losed 5 Paper jam detected at pick sensor 6 Error detected with the tray 7 Error detected at the registration roller home position 8 Error detected at the pick roller home position sensor S1 9 Error d...

Page 163: ...iring or damage to the contacts in the connector Are there any problems with the autoconnect cables Repair or replace as necessary Go to step 6 6 HCIT autoconnect cable check the HCIT autoconnect cabl...

Page 164: ...r up and work normally when plugged into the AC outlet on the HCIT Go to step 2 Go to step 5 2 Check the system board LED Is it is on solid or blinking On solid means that the HCIT has detected the fr...

Page 165: ...stalled incorrectly 3 Check for correct installation of the paper size sensor cable to the HCIT system board at CN7 Is the cable installed correctly Go to step 4 Install the cable correctly 4 Check fo...

Page 166: ...3 19 Do any or all of the Buttons fail to operate correctly Note If all the buttons fail to operate correctly the LCD display is blank Power On Status LED is on and the printer beeps 5 times go step...

Page 167: ...11 Replace the RIP board See RIP board removal on page 4 70 11 Operator panel cable check continuity of the operator panel cable Is there continuity Replace the operator panel See Operator panel remov...

Page 168: ...h bin x is selected Paper exits half way out of the redrive Go to Output expander on page 2 75 Go to step 3 3 Remove paper Output Bin x is displayed POST is incomplete unable to clear the message Go t...

Page 169: ...ion is installed check each one to see if the printer recognizes any single option as being installed If the printer recognizes any of the output expander options then the base printer autoconnect sys...

Page 170: ...s a print quality problem first try a new cartridge to help isolate the problem An incorrect printer driver for the installed software can cause print quality problems Incorrect characters could print...

Page 171: ...t Does the problem still exist for the remaining cartridges Go to step 3 Replace the failing cartridge 3 Magenta print cartridge check enter the Diagnostics Mode Remove the magenta print cartridge and...

Page 172: ...assembly removal on page 4 37 3 Vertical streaks in a single color which are visible outside the printed are most likely caused by a cleaner problem in the print cartridge Are streaks magenta cyan or...

Page 173: ...lens may be contaminated by toner Check for any signs of contamination on the lens of the printhead Is the printhead contaminated Go to Printhead removal and adjustment on page 4 50 Call your next lev...

Page 174: ...see Printhead removal and adjustment on page 4 50 Replace the system board See System board on page 4 80 4 Change or switch the cartridge of the color that is experiencing the issue Do you continue t...

Page 175: ...ut the same plane is missing or faded on the ITU belt Go to step 4 Go to step 6 4 Turn off the printer Check the cable connections between the transfer HVPS board and the system board Do you continue...

Page 176: ...ing in the Color Menu Is the Print Mode set to Black White Change the setting to Color Go to step 2 2 Ask the user or network administrator to check if the correct color driver is installed Is the cor...

Page 177: ...cartridge contact block Make sure the PC drum contact pin is not stuck See Cartridge contact assembly pin locations on page 5 4 to identify the PC drum contact pin Go to step 4 Replace the cartridge c...

Page 178: ...o step 3 Replace any missing or damaged springs or hold downs 3 ITU Make sure that the ITU legs are properly seated onto the rail at the right side of the printer This is visible by removing the yello...

Page 179: ...the ITU assembly Replace the ITU assembly See ITU assembly removal on page 4 37 If only one color is missing or printing uneven go to step 1 Toner smears or rubs off the page with no error code displa...

Page 180: ...this location Remove the debris Go to step 2 2 Check for any signs of debris on the surface of the ITU belt near the toner patch sensor TPS which is the white egg shaped device located on the front le...

Page 181: ...to high Does this fuser setting fix the problem Problem solved Replace the fuser assembly See Fuser assembly removal on page 4 31 4 Does the transparency have a splotchy appearance Go to step 5 Repla...

Page 182: ...ansfer roll Replace the second transfer roll See Second transfer roll removal on page 4 79 Go to step 2 2 Transfer arms springs and associated hardware call your next level of support None of these pa...

Page 183: ...e 4 80 2 Engine board See Engine board removal on page 4 29 3 ITU assembly See ITU assembly removal on page 4 37 Step Action and questions Yes No 1 Check the following parts in tray 1 for broken or mi...

Page 184: ...make sure they are installed correctly and they are not damaged or broken Size sensing gear cover Size sensing gear Size sensing barrel cam Note Make sure the size sensing barrel cam is correctly inst...

Page 185: ...he printhead cables are properly seated If the printhead cables are properly seated and the error remains record the error code Continue to the next step 2 Determine how to setup the printhead diagnos...

Page 186: ...nd cyan switch as an example a Turn off the printer b Unplug the printhead cables from the RIP board in the printer and connect them to the printhead diagnostic tool c Connect the printhead diagnostic...

Page 187: ...printhead adjustments Print quality defect locator chart The print quality locator chart is copied below but the tool is a transparent sheet available with this printed book Use the tables and rulers...

Page 188: ...is correct If the distance is inaccurate the bottom registration margin setting can be adjusted to correct the discrepancy Increasing the bottom margin value stretches the image reducing it shrinks t...

Page 189: ...nal margin settings should be noted in case these changes adversely effect the print quality or registration when printing normal documents Partial Print Test This procedure is also available in color...

Page 190: ...ure that there is no damage to the cable running from the system board Developer HVPS board System board If the image is well developed on the PC drum but the same plane is missing or faded on the ITU...

Page 191: ...only displays if at least one Downloaded Emulator is installed Demo Mode Factory Defaults Energy Conserve ITU Alignment Auto Color Adj Error Log Exit Config Menu Press Select to exit CONFIG MENU and...

Page 192: ...ems The Test Pages must be printed on A4 Legal or Letter paper 1 Select Prt Quality Pgs from the CONFIG MENU 2 Press Select to print the pages Go to Print Quality Pages Title page total of five on app...

Page 193: ...as follows The following media can be sensed by Tray 1 Tray 2 Tray 3 and Tray 4 Plain Paper Glossy Paper Card Stock Labels Bond Letterhead Preprinted Colored paper Custom Type 1 Custom Type 2 Custom T...

Page 194: ...Select Panel Menus from the CONFIG MENU PPDS Emulation This only displays if the PPDS interpreter is available Select PPDS Emulation from the CONFIG MENU Download Emuls This only displays if at least...

Page 195: ...ve is on the customer does not have access to disable the Power Saver function When Energy Conserve is off Disable appears as an additional menu item in the Power Saver menu This setting only affects...

Page 196: ...tive for eight hours or more If the printer was turned off during a calibration cycle At the Ready state if one of several internal engine parameters has exceeded a given threshold If requested by the...

Page 197: ...installed INPUT TRAY TESTS OUTPUT BIN TESTS FINISHER TESTS if finisher is installed BASE SENSOR TEST DEVICE TESTS if optional flash or disk installed PRINTER SETUP EP SETUP ERROR LOG Exit Diagnostics...

Page 198: ...to adjust the To and Right margins first then adjust the Bottom and Left A positive increase in value makes the following changes to the margin locations Top margin Moves down the page Left margin Mov...

Page 199: ...aved then the default value is changed and the Alignment Test Page is printed using the new value 6 To verify that the margin values are correct you must print the Alignment Test Pages Press Go from t...

Page 200: ...or Stop TOP FINE MAR ADJ Do not change this setting without consulting your next level of support MISC TESTS Motor Detect This test initiates an Automated Motor Detection It must be performed if the...

Page 201: ...lowing is a list of failure codes Cover open Cartridges NOT removed Less than three revolutions before the test ended may never be displayed Belt tracked to front 100 revolutions when test ended belt...

Page 202: ...each character in the selected symbol set If Continuous is selected all sources printing with paper sizes prints the same page continuously until the test is stopped If continuous is selected from a...

Page 203: ...t calibration time To run the Print Line Length Page select Prt Line Len Pg from the menu No buttons are active while the Print Line Length Page is printing Press Return to exit See Print line length...

Page 204: ...pass count or fail count is reached the test is stopped the power indicator turns on solid and the final results appear If the test fails DRAM Error appears for approximately three seconds and the fai...

Page 205: ...Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select Parallel Wrap Test from the menu The power indicator blinks indicating the test is in progress The te...

Page 206: ...This test runs continuously unless canceled by pressing Return or Stop Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the te...

Page 207: ...rst The range of the adjustment is 25 to 25 The Duplex Top Margin Offset range is 20 to 20 Adjustment of this setting lets you shift up or down the position of the Top Margin Changing this parameter b...

Page 208: ...ds one sheet of media from the selected source or Continuous continues to feed from the selected source until Return or Stop is pressed 4 Press Return or Stop to exit test Sensor Test This test can be...

Page 209: ...ng this test To run the Output Bin Feed Test 1 Select Feed Test from the OUTPUT BIN TESTS menu 2 Select the output bin you want the paper to exit into All output bins installed on the printer are show...

Page 210: ...the selection is displayed you can manually actuate the sensor you want to test When the sensor is closed CL displays and when the sensor is open OP displays 4 To exit the test press Return or Stop St...

Page 211: ...es of media to the selected finisher output bin where they are stapled Note No information is printed on the fed sheets as the laser is not engaged during this test This test cannot be canceled or ter...

Page 212: ...ng is displayed and the sensors are ready to test Once the screen is displayed you can manually actuate the sensor When the sensor is closed CL is displayed when the sensor is open OP is displayed 2 T...

Page 213: ...test patterns to the bytes in the block If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select Quick Disk Test from the Device Tests menu The power indica...

Page 214: ...1 Select Flash Test from the Device Tests menu The power indicator blinks while the test is running Flash Test Test Passed is displayed if the test passes and the power indicator turns on solid Flash...

Page 215: ...her Menu until the desired value is displayed Press Select to move to the next digit The digit blinks Continue modifying each digit using this method To skip a digit and keep its current value press S...

Page 216: ...git the configuration ID is validated If the ID is invalid the invalid ID is displayed momentarily on the second line before the ID is displayed If the ID is valid then the ID is stored in NVRAM and t...

Page 217: ...messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log Menu The error log displays on three screens but only four entries display at a time To move to the...

Page 218: ...IT Control Board for the test you want to run 2 Turn the HCIT power off by moving the LVPS slide switch to the left position 3 Press and hold the Push Button Switch PBSW1 while moving the LVPS slide s...

Page 219: ...ctricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the E...

Page 220: ...left light shield to upper front cover Attach 1 121 M3 5x6mm machine LVPS to lower frame Mounting 7 Right rear cover to LVPS Attach 1 HVPS standoffs to upper frame Attach 4 232 M3x6mm Taptite metal t...

Page 221: ...Attach 1 Right front cover support to lower frame Attach 1 Front lower left cover to lower frame Attach 1 Front left handle cover asm to lower frame Attach 4 Front lower right cover to lower frame Att...

Page 222: ...to lower frame Mounting 1 Paper level sensing assembly to lower frame Mounting 3 324 M3 5x10mm Plastite thread forming Transfer HVPS RIP fan asm to RIP shield Attach 1 Front left light shield to left...

Page 223: ...weighs 47 7 kg 105 lb and requires at least two people to lift it safely Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require rem...

Page 224: ...4 Remove the operator panel bezel 5 Remove the top cover mounting screws D from the front of the printer 6 Remove the three top cover screws E type 323 on page 4 3 from the rear and the screw F from t...

Page 225: ...5060 00x 7 Remove the flag retainer G from the top cover 8 Under the top cover unclip the bin full sensor H Tilt the sensor and lower it through the top cover 9 Remove the upper option autoconnect I 1...

Page 226: ...ar cover See Rear cover removal on page 4 8 2 Remove the rear fan cover screw type 323 A and remove the rear fan cover Rear cover removal See Rear cover on page 7 5 for the part number 1 Remove the re...

Page 227: ...le cover assembly on page 7 3 for the part number 1 Open the front cover 2 Remove the light shield screw type 324 A and screw type 323 B and release tab C from the frame slot 3 Remove the light shield...

Page 228: ...y on page 7 3 for the part number 1 Open the front cover 2 Remove the front left handle cover assembly screw type 323 A and remove the assembly Front cover assembly removal See Front cover assembly on...

Page 229: ...Repair information 4 11 5060 00x 3 Remove the bezel B 4 Hold the front cover and remove the two screws type 102 C from the upper front pivot cover 5 Remove the front cover assembly B C 102...

Page 230: ...handle cover assembly See Front right handle cover assembly removal on page 4 9 3 Remove the screw A on the lower right front cover 4 Close the paper path access door and tape front jam access door B...

Page 231: ...o screws C 6 Remove the lower right door assembly Left lower cover removal 1 Remove the lower jam access door assembly See Lower jam access door assembly removal on page 4 14 2 Remove the left lower c...

Page 232: ...e Front left handle cover assembly removal on page 4 10 2 Remove the lower jam access door assembly screw type 323 A and remove the door Redrive door removal See Redrive door on page 7 16 for the part...

Page 233: ...or part number 1 Remove the paper tray 2 Remove the front left handle cover assembly See Front left handle cover assembly removal on page 4 10 3 Open the paper path access door carefully remove screw...

Page 234: ...page 4 10 3 Open the paper path access door carefully remove screw A type 323 on page 4 3 and close the door 4 Close the paper path access door and tape front jam access door B if tape is available to...

Page 235: ...4 Remove the second transfer roll See Second transfer roll removal on page 4 79 5 Remove the transfer plate Lifting and rotating the right edge of the plate up to a 45 angle will release the transfer...

Page 236: ...5060 00x 7 Remove the five screws 323 C and remove the lower left cover and the jam access door Warning Be careful not to lose the access door spring 8 Remove the pin D that holds in the MPF swing ar...

Page 237: ...Repair information 4 19 5060 00x 9 Remove the MPF swing arm assembly E E...

Page 238: ...that is located at the rear pivot point for the transfer plate F This allows the paper level assembly to drop into the cavity that the tray is inserted into Disconnect the cable from the paper level s...

Page 239: ...Repair information 4 21 5060 00x 11 Disconnect the pick motor and the transparency sensor connectors G 12 Remove four screws H holding the pick assembly in place G H DO NOT REMOVE THIS SCREW...

Page 240: ...the pick arm to fall to the bottom of the tray 14 Disconnect the spring clip J from the pick arm Be sure not to let the spring come off of the lower frame Also identify which pegs the spring clip is...

Page 241: ...on page 7 31 for the part numbers Warning Do not remove the printhead unless instructed to do so 1 Open the front cover 2 Remove the toner cartridges 3 Remove the ITU assembly See ITU assembly removal...

Page 242: ...e rail of the selected cartridge assembly yellow shown Warning When removing the black cyan or magenta cartridge rails it is necessary to remove the appropriate printhead assembly Before you can remov...

Page 243: ...that mount each cartridge drive motor and the cartridge contact assembly to the upper frame for the cartridge contact assembly you want to remove 9 Press the three cartridge contact assembly retaining...

Page 244: ...board shield assembly See RIP board shield assembly removal on page 4 71 2 Remove the engine board See Engine board removal on page 4 29 3 Remove the three cartridge drive assembly mounting screws A f...

Page 245: ...oving the yellow cyan or magenta cartridge rails remove only the large portion of the developer HVPS board 6 Remove the three mounting screws in the cartridge rail in the front A and one from the rear...

Page 246: ...t mount the developer HVPS board 3 Disconnect the HVPS to RIP board cable C the cartridge signature button cables D and the doctor blade cable E from the developer HVPS board and remove the board Inst...

Page 247: ...4 8 2 Remove the rear cover See Rear cover removal on page 4 8 3 Disconnect all cables from the engine board 4 Remove the screw 323 A holding the grounding clip B and remove the clip 5 Remove the engi...

Page 248: ...n page 4 71 2 Remove the engine board See Engine board removal on page 4 29 3 Remove the engine board shield screw type 323 A screw type 232 B and remove the shield Friction buckler removal See Fricti...

Page 249: ...Be sure the fuser assembly has cooled before you remove it See Fuser assembly 115V 500W on page 7 9 or Fuser assembly 220V 500W on page 7 9 for the part numbers 1 Open the lower right door assembly 2...

Page 250: ...removal See Fuser bottom duct on page 7 5 for the part number 1 Remove Fuser assembly removal on page 4 31 2 Remove Fuser top duct removal on page 4 34 3 Remove the redrive belt cover duct A 4 Remove...

Page 251: ...y removal See Fuser drive assembly w motor on page 7 12 for the part number 1 Remove Fuser bottom duct removal on page 4 32 2 Swing lever A and disengage VTB shaft 3 Remove the fuser drive assembly sc...

Page 252: ...4 8 2 Disconnect the fuser fan cable from connector J2 B on the engine board 3 Remove the fuser fan screws A part number 12G6529 and remove the fan Fuser top duct removal See Fuser top duct on page 7...

Page 253: ...art number 1 Remove the fuser top duct See Fuser top duct removal on page 4 34 2 Remove the paper path access door cover right mounting screw A 3 Remove the front right handle cover assembly See Front...

Page 254: ...0x Installation notes Note When you reinstall the web oiler motor assembly pull the excess cable twist install a cable tie and route the cable down into the printer Note Make sure the motor cable A is...

Page 255: ...mbly with SKC motor on page 7 27 for the part number 1 Remove the RIP board shield assembly See RIP board shield assembly removal on page 4 71 2 Remove the engine board shield See Engine board shield...

Page 256: ...gine board shield removal on page 4 30 3 Remove the ITU drive motor mounting screws B disconnect cable A and remove the assembly Low voltage power supply LVPS removal See LVPS 115V on page 7 35 or LVP...

Page 257: ...Remove the right rear cover screw type 121 A 5 Open the redrive cover and remove the screw type 121 A from the top of the LVPS and remove the LVPS from the printer Note Be sure to reinstall the groun...

Page 258: ...r MPF removal See Multipurpose Feeder MPF on page 7 21 for the part number 1 Open the MPF to the lowest position 2 Remove the MPF cable cover screw A 3 Place flatblade screwdriver in the slot B on the...

Page 259: ...mation 4 41 5060 00x 4 Disconnect the MPF switch cable from the MPF sensor C 5 Pull the MPF cable free of the enclosure and out from under the cable retainer D 6 Remove the MPF strap screw E type 412...

Page 260: ...emove waste toner container 3 Reinsert paper tray into printer If any fragments fall into the printer they should land in the paper tray and be easy to remove 4 Remove the broken pieces of old nip rel...

Page 261: ...43 5060 00x Some scarring of the post is expected but be careful not to damage the post c Remove any remnants of the handle Check the paper tray to check for debris For example see the fragment B in t...

Page 262: ...ly pry the nip relief lever B towards the rear of the machine and insert lower portion of handle so that it is trapped between the lever and the reference edge plate C 3 Holding the nip relief handle...

Page 263: ...s 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 5 Check for proper operation 6...

Page 264: ...060 00x Operator panel removal See Operator panel assembly low volt on page 7 3 or Operator panel assembly high volt on page 7 3 for the part number 1 Remove the operator panel bezel 2 Unlatch the ope...

Page 265: ...ormation 4 47 5060 00x 3 Disconnect the operator panel cable from the operator panel and remove the operator panel Outer EMC shield removal Loosen screw type 232 A and lift the outer EMC shield from t...

Page 266: ...ar fan cover removal on page 4 8 3 Remove the engine board shield See Engine board shield removal on page 4 30 4 Open the waste toner container door and slide the container out 5 Remove the paper size...

Page 267: ...the screw is fastened all the way down When replacing both the front and back rollers note the directional markings on the rollers and make sure the same narrow hub caps are facing each other Check to...

Page 268: ...a printhead is replaced you must to perform the Printhead mechanical alignment on page 4 51 and Electronic color alignment on page 4 58 The front cover must be installed and closed before any printhe...

Page 269: ...ntify the configuration of your printer The following steps are similar for both versions except you need to remove two extra screws when you have the PSD bracket You may have a PSD bracket A whether...

Page 270: ...D bracket remove the two screws A and B Note Use a small diameter Phillips screwdriver to remove screw A b Insert the printhead alignment tool placing the locating pin C in the middle hole A c Secure...

Page 271: ...the front of the printhead and secure alignment tool bracket D with screw provided Align the locating pin C in the hole in printer frame 4 Turn the thumbwheel E until the end of the thumbwheel just to...

Page 272: ...ear screw goes through the printhead spacer located at the right rear of the printer frame 6 Bias the new printhead assembly against the front and rear stops 7 Tighten the right rear printhead mountin...

Page 273: ...s 10 Select Alignment Menu select the color of the printhead that was replaced and set the Z value to zero Exit the Diagnostics Menu 11 With the printer at Ready prompt hook up a computer through the...

Page 274: ...stment procedure If not repeat steps 12 through 15 until alignment is within 5 If you are replacing the black printhead make sure on the test page that black is within 5 and also within 1 between the...

Page 275: ...ves to the next margin setting Press Go to print the Quick Test Page after adjusting the margins and saving the change Select 5 After completing the registration press Return to exit the registration...

Page 276: ...ow Examples of the alignment pages are available in Appendix B See Printhead alignment test pages magenta one of three on appendix page B 9 3 To align cyan press Menu until Cyan is displayed press Sel...

Page 277: ...horizontal lines in the target T value or Top Adjust the setting and press Go to print the page and verify the setting until the lines are even Press Select to save the value The display advances to...

Page 278: ...ust the cyan and black vertical lines until the targets overlap Adjust the setting and press Go to print the page and verify the setting until the lines are even Press Select to save the value e Chang...

Page 279: ...r of the color band and determine the value If all the color bands for cyan magenta and yellow on all six groups A through F are centered between 2 and 2 you are done If the center is located outside...

Page 280: ...all six groups A through F are centered between 2 and 2 Repeat if necessary Note The Line Length Calibration must be printed after making any changes to color alignment 11 Exit diagnostics Printhead...

Page 281: ...ng a printhead thermistor or an existing PSD sensor assembly check the Registration and Color Alignment See REGISTRATION on page 3 14 See Electronic color alignment on page 4 58 See Print line length...

Page 282: ...mbly ITU loading on page 7 29 for the part number 1 Power off the printer 2 Remove the four toner cartridges and leave the front door open 3 Remove the ITU assembly See ITU assembly removal on page 4...

Page 283: ...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 Pr...

Page 284: ...inter 2 Remove the four toner cartridges and leave the front door open 3 Remove ITU assembly removal on page 4 37 4 Check each of the rear bellcranks for cracks or breakage 5 Remove the spring 6 Remov...

Page 285: ...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...

Page 286: ...6 for the part number 1 Open the redrive door 2 Remove the redrive assembly screw type 323 A 3 Remove the drive belt B from the lower redrive pulley 4 Remove the redrive assembly Note When you reinsta...

Page 287: ...ration motor on page 7 19 for the part number 1 Remove the rear cover See Rear cover removal on page 4 8 2 Remove the transfer HVPS See Transfer HVPS board removal on page 4 80 3 Remove the registrati...

Page 288: ...SB connector screw type 232 A 4 Remove the RIP board screw type 232 B 5 Remove the parallel connector C 6 Disconnect all cables from the RIP board and remove the board Installation notes Perform the f...

Page 289: ...moval RIP board shield assembly on page 7 37 for part number 1 Remove the top cover assembly See Top cover assembly removal on page 4 5 2 Remove the rear fan cover See Rear fan cover removal on page 4...

Page 290: ...MPF door 3 Remove the ITU assembly 4 Remove the right rear cover 5 Disconnect connector J70 A to the MPF sensor from the system board 6 Remove the screws from transfer high voltage power supply C and...

Page 291: ...or hinge restraint by removing screw E and remove the MPF assembly 11 Gently pull the sensor assembly cable B through the opening between the upper and lower frame and remove the sensor assembly throu...

Page 292: ...you remove the old assembly The new sensor cable assembly is installed on the other side of the grounding clip closer to the fuser so you do not have to reinstall the new sensor cable assembly betwee...

Page 293: ...J68 connector around the ground clip B and cable channel between the upper and lower frame 4 Route the J68 cable connector through the rectangular opening D in the lower frame and out through the ope...

Page 294: ...twist left and push up gently the connector tends to follow the pathway through and out a Insert the J68 connector of the sensor cable assembly into the rectangular opening and push up b With your oth...

Page 295: ...the MPF tray assembly sensor cable through the same openings 6 Connect J68 to the engine board 7 Connect the MPF tray assembly sensor cable to the engine board at J70 8 Install the new cable tie B on...

Page 296: ...the grounding clip A closest to the fuser end of the printer 10 Install the new sensor assembly B in the lower frame 11 Verify the sensors flags are not sticking and are moving freely Service tip Use...

Page 297: ...traint 14 Install the ITU and print cartridges 15 Reconnect power to the printer 16 Run the print test to check for correct operation before replacing the right rear cover 17 Replace the right rear co...

Page 298: ...d on page 7 38 for the part number 1 Remove the rear cover See Rear cover removal on page 4 8 2 Remove the transfer HVPS board screw type 324 and 312 A 3 Disconnect the five spade terminals B from the...

Page 299: ...mber 1 Remove the S2 NMS transparency sensor assembly removal on page 4 72 2 Remove the transfer plate Lifting and rotating the right edge of the plate up to a 45 angle releases the transfer plate Rem...

Page 300: ...part number 1 Remove the transfer plate assembly See Transfer plate assembly on page 4 81 2 Remove the fuser bottom duct See Fuser bottom duct removal on page 4 32 3 Remove the two front screws A 4 L...

Page 301: ...83 5060 00x 6 Rotate release lever on gear until the gear can be removed 7 Remove screw from ground wire 8 Remove vacuum belt transfer belt unit far enough to release ground wire from restraint clips...

Page 302: ...er 1 Remove the RIP board shield assembly See RIP board shield assembly removal on page 4 71 2 Remove the VTB fan with a flatblade screwdriver Waste container door removal See Waste container door on...

Page 303: ...mode 2 Select Printer Setup 3 Select Configuration ID 4 Increase the last two digits each by four The left digit blinks indicating it is the first digit to be changed Press Select to accept the curre...

Page 304: ...0 00x 7 Unlatch the two fuser latches A 8 Remove the fuser assembly 9 Open the front cover 10 Remove the yellow print cartridge 11 Remove the front right light shield screws B and C and remove the lig...

Page 305: ...Repair information 4 87 5060 00x 12 Carefully remove the paper path access door cover right mounting screw D 13 Tape front jam access door E if tape is available to help hold the door in place...

Page 306: ...4 88 Service Manual 5060 00x 14 Remove the front right handle cover assembly screws F and remove the assembly 15 Open paper tray G F 323...

Page 307: ...5060 00x 16 Remove screw H from the top front support bracket Swing bracket to the right 17 Use the alignment pins I on the web oiler fuser motor assembly to position the assembly in holes J and inst...

Page 308: ...4 90 Service Manual 5060 00x 18 Secure the web oiler motor assembly with screws K 19 Install the web oiler card using screws L K L...

Page 309: ...web oiler card connector M Plug web oiler drive assembly cable into cable connector N Note Make sure the cables from the drive assembly are routed along the lower frame and are not in contact with the...

Page 310: ...2 Service Manual 5060 00x 22 Align tabs on the front right light shield with the slots O on the frame 23 Move the front right light shield up until alignment stud P and the screw hole Q are aligned O...

Page 311: ...rmation 4 93 5060 00x 24 Attach the new fuser web oiler fuser housing R to the new web oiler fuser 25 Insert the web oiler fuser assembly into the fuser assembly and install the fuser assembly into th...

Page 312: ...4 94 Service Manual 5060 00x...

Page 313: ...Connector locations 5 1 5060 00x 5 Connector locations Locations Printer boards...

Page 314: ...fan Pick assy motor ITU drive motor Fuser drive motor VTB fan Yellow carriage drive motor Black carriage drive motor Magenta carriage drive motor Registration drive motor BOR drive motor Cyan carriag...

Page 315: ...Connector locations 5 3 5060 00x Printer sensors...

Page 316: ...5 4 Service Manual 5060 00x Cartridge contact assembly pin locations...

Page 317: ...Connector locations 5 5 5060 00x Engine board cabling...

Page 318: ...5 6 Service Manual 5060 00x RIP board cabling...

Page 319: ...onnectors Engine board See Engine board on page 5 7 Connector Pin no Signal J2 Main Fan 1 FAN1 Stall IN 2 Ground 3 FAN1 PWM Out 4 24 V dc Left Side J3 Oiler Stepper Motor 1 Oiler PHA OUT 2 Oiler PHA O...

Page 320: ...D1_OUT J7 Options Conn Stacker 1 24 V dc options 2 Ground 3 RXD1_OPTS_IN 4 Ground 5 5 V dc options 6 Ground 7 TXD1_OUT J8 Yellow Drive Motor Fuser Drive Motor 1 Y ON OUT 2 FUSER ON OUT 3 5 V dc 4 5 V...

Page 321: ...1 EXIT SENSOR IN 2 FUSER CAM1 IN 3 FUSER CAM2 IN 4 OILER ENC A IN 5 OILER ENC B IN 6 HR THERM IN 7 BR THERM IN 8 Ground 9 5 V dc switched 10 ZERO Xing IN 11 HR HEAT ON OUT 12 BR HEAT ON OUT J11 Bin Fu...

Page 322: ...V PWM OUT 13 CART METER Y IN 14 C DEV PWM OUT 15 SC Y CHIP 16 Y DEV PWM OUT 17 Ground 18 24 V dc switched J45 RIP Interface 1 I2C DATA RIP 2 I2C CLK RIP 3 NOTIFY RIP 4 Ground 5 VSYNC Y OUT 6 FPIRQ RIP...

Page 323: ...15 M LOCK IN 16 C LOCK IN J52 Waste CLNR Full 1 CLR FULL IN 2 Ground J53 RIP Fan 1 FAN3 STALL IN 2 Ground 3 FAN3 PWM OUT 4 24 V dc Right Side J64 ITU Drive Motor Black Cartridge Drive Motor 1 K ON OUT...

Page 324: ...dc switched 3 Ground 4 PPS2 IN 5 5 V dc switched 6 Ground 7 PRISM LED VOLT 8 Ground 9 PRISM SENSOR IN 10 5 V dc switched J69 Paper Out Low XPAR Media 2 1 5 V dc switched 2 PAPER OUT IN 3 PAPER LOW IN...

Page 325: ...nd 15 24 V dc switched J72 ITU Autoconnect 1 5 V dc 2 ITU DATA 3 3 3 V dc 4 TPS GAIN OUT 5 ITU TEMP 6 BELT HOLE 1 7 Ground 8 Ground 9 ITU EEPROM CLK 10 24 V dc Right Side 11 TPS LED ON OUT 12 TONER PA...

Page 326: ...NC SOS 3 Ground 4 5 V dc Hsync 5 Ground 6 mm ref freq 7 mm lock 8 mm strt en 9 Ground 10 24 V dc mir mtr J3 Printhead Yellow Connector Video 1 N C 2 N C 3 laser en 4 Ground 5 laser adj 6 Ground 7 lase...

Page 327: ...round 10 24 V dc mir mtr J6 Printhead Cyan Connector Video 1 N C 2 N C 3 laser en 4 Ground 5 laser PWR ADJ 6 Ground 7 laser PWM 8 5 V dc head 9 Ground 10 video data 11 video data J7 Printhead Magenta...

Page 328: ...data 11 video data x J9 Printhead Magenta Black Connector EOS 1 Ground 2 lexhsync eos 3 thermistor 4 5 V dc EOS card 5 Ground 6 lexhsync eos 7 thermistor 8 5 V dc EOS card J10 Printhead Black Connect...

Page 329: ...ser PWM 8 5 V dc head 9 Ground 10 video data 11 video data J12 Cover Open Switch Connector 1 5 V dc 2 Ground 3 V Cor J13 Parallel Port Connector J18 USB Port Connector 1 USB 5 V dc 2 USB D 3 USB D 4 G...

Page 330: ...c 11 3 3 V dc 12 3 3 V dc 13 5 V dc 14 5 V dc 15 5 V dc 16 24 V dc Fuser J24 Engine to RIP Connector 1 ITU Zone CLk 2 ITU Zone HB 3 RIPPRES N 4 Ground 5 HSYNCN M 6 HSYNCN K 7 HSYNCN Y 8 HSYNCN C 9 Gro...

Page 331: ...00x Transfer high voltage power supply HVPS Connector Pin no Signal CN1 HVPS Input Connector 1 24 V dc 2 24 V dc Return 3 M Txpwm 4 M Srvo out 5 Y Txpwm 6 Y Srvo out 7 C Txpwm 8 C Srvo out 9 K Txpwm 1...

Page 332: ...ansfer Cable T301 Transformer HV Terminal C Cyan 1 HV Transformer Output Terminal to Cyan Transfer Cable T401 Transformer HV Terminal Y Yellow 1 HV Transformer Output Terminal to Yellow Transfer Cable...

Page 333: ...2 Cartridge Signature Button Black 1 K CtSense 2 K TnrSense Gnd Return CN3 Cartridge Signature Button Magenta 1 M CtSense 2 M TnrSense Gnd Return CN4 Cartridge Signature Button Cyan 1 C CtSense 2 C Tn...

Page 334: ...V dc rtn 3 Ground Return 3 3 V dc rtn 4 Ground Return 3 3 V dc rtn 5 Ground Return 5 V dc rtn 6 Ground Return 5 V dc rtn 7 Ground Return 5 V dc rtn 8 Ground Return 24 V dc rtn 9 3 3 V dc Sense 10 3 3...

Page 335: ...ngine board cable LVPS to J10 fuser connector 1 EXITSENSORIN 2 BURCam1 3 N C 4 WebEncoderA 5 WebEncoderB 6 HRThermistor 7 BURThermistor 8 Ground 9 5 V dc switched 10 ZEROXINGIN 11 Heat On 1 HR 12 Heat...

Page 336: ...5 24 Service Manual 5060 00x Low voltage power supply LVPS LVPS to fuser connectors on LVPS Fuser to LVPS connectors on fuser...

Page 337: ...r Pin no Signal LVPS AC Fuser Connector 1 AC Load 1 2 AC Common 3 Ground 4 N C 5 AC Load 2x LVPS DC Fuser Control Connector 1 FusExitSen 2 BURCam1 3 N C 4 WebEncoderA 5 WebEncoderB 6 HRThermistor 7 BU...

Page 338: ...2 PRI RXD 3 PGND 4 PERON 5 SGND 6 PRI TXD CN2 LVPS 1 Poweron 2 5 V dc 3 SGND 4 PGND 5 PGND 6 PGND 7 24 V dc 8 24 V dc 9 24 V dc CN3 REG Motor 1 24 V dc 2 24 V dc 3 REG A 4 REG A 5 REG B 6 REG B 7 No...

Page 339: ...dc 5 GND 6 LEVEL 7 5 V dc 8 GND 9 EMPTY 10 5 V dc 11 GND 12 RHOME 13 5 V dc 14 GND 15 PHOME CN7 Size Sensors Near Empty 1 5 V dc 2 GND 3 SIZE 0 4 5 V dc 5 GND 6 SIZE 1 7 5 V dc 8 GND 9 SIZE 2 10 5 V d...

Page 340: ...1 24 V dc 2 24 V dc 3 24 V dc 4 24 V dc 5 Ground 6 Ground 7 Ground 8 Ground CN1 1 AC In from Relay 2 Not Used 3 Not Used 4 Not Used 5 AC In from Relay Connector Pin no Signal CN1 AC Input 1 AC In 2 N...

Page 341: ...TR 2 MTR 3 N C 4 MTR 5 MTR 6 N C 7 No Cartridge 8 Low Staple 9 Home Position 10 Unit Check 11 Ground 12 5 V dc CN3 Jogger Motor Bundle Motor 1 Jog A 2 Jog A 3 Jog B 4 Jog B 5 Bun A 6 Bun A 7 Bun B 8 B...

Page 342: ...Exit Timing Paper Surface Upper Paper Surface Lower 1 5 V dc 2 Exit Timing Sensor 3 Ground 4 5 V dc 5 Paper Surface Upper Sensor 6 Ground 7 5 V dc 8 Paper Surface Lower Sensor 9 Ground CN9 Feed 1 A 2...

Page 343: ...Drop Timing Sensor 3 Ground 4 5 V dc 5 Punch Home Sensor 6 Ground 7 5 V dc 8 Punch Timing A Sensor 9 Ground 10 5 V dc 11 Punch Timing B Sensor 12 Ground CN17 Feed 1 SOL 2 SOL CN18 Communications 1 Tx...

Page 344: ...5 32 Service Manual 5060 00x HCOF system board...

Page 345: ...d the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication specificat...

Page 346: ...in the proper lubricant in the FRU Only use the lubricant included Fuser drive assembly Before installing the new Fuser Drive Assembly 1 Apply a thin coating of Nyogel type 774 grease to the points id...

Page 347: ...the points identified A from the supplied packet 2 Rotate the motor housing B to distribute evenly ITU drive assembly 1 Apply a thin coating of Nyogel type 744 grease to the points identified A from t...

Page 348: ...fuser 12G6515 220 V web oiler fuser 12G6502 100 V web oiler fuser After replacing the kit the fuser maintenance count must be reset to zero to clear the maintenance message See Reset Fuser Cnt on page...

Page 349: ...the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP P...

Page 350: ...7 2 Service Manual 5060 00x Assembly 1 Covers...

Page 351: ...Detent spring 19 56P2218 1 Detent front access door 20 56P2219 1 Housing front access door 21 56P2217 1 Handle front access door 22 12G6357 1 Front cover assembly 23 12G6394 1 Front lower right cover...

Page 352: ...7 4 Service Manual 5060 00x Assembly 1 1 Covers...

Page 353: ...wer pivot cover 6 12G6395 1 Cover left lower 7 12G6400 1 Waste container door 8 12G6339 1 Blank TLI SN label 9 12G6390 1 Rear cover 10 12G6401 1 Rear fan cover 11 12G6383 2 Fuser latch slide 12 12G638...

Page 354: ...7 6 Service Manual 5060 00x Assembly 2 Cartridge mounting...

Page 355: ...Parts catalog 7 7 5060 00x Assembly 2 Cartridge mounting Asm Index Part number Units Description 2 1 16 Screw PP 12G6532 2 12G6535 4 Guide assembly left side 3 12G6536 4 Guide assembly right side...

Page 356: ...7 8 Service Manual 5060 00x Assembly 3 Fuser...

Page 357: ...6301 1 Fuser assembly 115V 500W 1 12G6302 1 Fuser assembly 220V 500W 2 12G6516 1 Fuser lamp 100V 500W hot roll 2 12G6337 1 Fuser lamp 115V 500W hot roll 2 12G6341 1 Fuser lamp 220V 500W hot roll 3 12G...

Page 358: ...7 10 Service Manual 5060 00x Assembly 3 1 Fuser web oiler 1 2 3...

Page 359: ...dex Part Number Units Description 3 1 1 12G6545 1 Web oiler assembly 2 12G6495 1 Fuser assembly web oiler 100V 500W 2 12G6514 1 Fuser assembly web oiler 115V 500W 2 12G6515 1 Fuser assembly web oiler...

Page 360: ...vice Manual 5060 00x Assembly 4 Fuser drive Asm Index Part Number Units Description 4 1 56P1213 1 Fuser drive assembly w motor 2 4 Screws PP 12G6309 3 56P1238 1 Fuser drive motor 4 Screws motor mounti...

Page 361: ...Parts catalog 7 13 5060 00x Assembly 5 Vacuum transport belt assembly Asm Index Part Number Units Description 5 1 12G6491 1 Jam access spring 2 12G6489 1 Vacuum transport belt assembly...

Page 362: ...7 14 Service Manual 5060 00x Assembly 6 Transfer Asm Index Part Number Units Description 6 1 12G6303 1 Second transfer roll 2 12G6488 1 Transfer plate assembly...

Page 363: ...thead assembly Do not replace more than one printhead at a time 2 12 Screw PP 12G6534 3 12 Screw PP 12G6539 4 4 PSD assembly order 7 5 thermistor card when replacing this assembly 5 56P1198 4 Thermist...

Page 364: ...n 8 1 56P0167 8 Anchor bracket mounting 2 12G6493 2 Upper door hinge 3 2 Screw PP 12G6533 4 56P2204 1 Redrive belt 300 T 5 12G6492 1 Redrive assembly 6 12G6355 1 Redrive door 7 12G6513 1 Lower rear do...

Page 365: ...Parts catalog 7 17 5060 00x Assembly 9 Paper feed input Asm Index Part number Units Description 9 1 12G6486 1 S2 transparency narrow media sensor assembly...

Page 366: ...Number Units Description 10 1 12G6470 1 Waste container latch spring 2 12G6469 1 Waste container latch 3 12G6467 4 Paper size sensing spring 4 12G6468 1 Paper size sensing bracket 5 1 Screw paper siz...

Page 367: ...er Units Description 11 1 56P2199 1 Nip relief handle 2 12G6483 1 Gear staging idler 3 12G6482 1 Gear staging reduction 1 4 12G6481 1 Registration plate assembly 5 12G6484 1 Gear reference plate drive...

Page 368: ...7 20 Service Manual 5060 00x Assembly 12 Multipurpose feeder MPF...

Page 369: ...57 2 MPF support bracket cover 9 12G6456 1 Sensor mount bracket 10 12G6461 1 Paper out low sensor 11 12G6448 1 MPF cable 12 12G6449 1 MPF cable cover 13 12G6458 2 MPF support bracket spring 14 12G6459...

Page 370: ...7 22 Service Manual 5060 00x Assembly 13 500 sheet integrated tray...

Page 371: ...1 500 Sheet tray assembly 2 12G6419 1 Back restraint latch 3 12G6418 1 Back restraint 4 12G6425 1 Tray bias bellcrank assembly 5 1 Screw PP 12G6533 6 12G6426 1 Tray bias spring 7 12G6568 1 Reflector...

Page 372: ...Tray interlock bellcrank 3 12G6558 1 Pick arm lift bellcrank 4 12G6427 1 Pick assembly 500 tray 5 12G6557 1 Bellcrank lift spring 6 12G6476 1 Paper level sensing assembly 7 12G6472 1 Tray interlock b...

Page 373: ...bly 15 ITU assembly Asm Index Part Number Units Description 15 1 12G6413 1 ITU light shield assembly 2 12G6503 1 Cable printhead interlock cover open 3 wire 3 12G6504 1 Cable HVPS interlock cover open...

Page 374: ...7 26 Service Manual 5060 00x Assembly 16 ITU drive assembly 2 4 1 5 3 5...

Page 375: ...Asm index Part number Units Description 16 1 56P1216 1 ITU motor drive assembly with SKC motor 2 12G6385 1 58 Gear 3 56P0568 1 ITU drive motor SKC 4 4 Screw PP 12G6309 ITU drive motor to ITU drive as...

Page 376: ...7 28 Service Manual 5060 00x Assembly 17 ITU loading...

Page 377: ...ear transfer bellcrank Front V block guide Front transfer bellcrank High voltage contact spring 7 56P1497 1 Parts packet ITU loading magenta including Magenta BOR spring Rear V block guide Rear transf...

Page 378: ...7 30 Service Manual 5060 00x Assembly 18 BOR drive assembly Asm Index Part number Units Description 18 1 12G6446 1 BOR housing assembly with motor...

Page 379: ...7 31 5060 00x Assembly 19 Cartridge contact assembly Asm Index Part number Units Description 19 1 56P0310 4 Cartridge contact assembly complete 2 12G6377 1 Rear hold down bellcrank 3 12G6376 1 Rear ho...

Page 380: ...7 32 Service Manual 5060 00x Assembly 20 Cartridge drive assembly...

Page 381: ...7 33 5060 00x Assembly 20 Cartridge drive assembly Asm Index Part Number Units Description 20 1 4 Screw PP 12G6530 2 56P1214 3 Cartridge drive assembly cyan magenta black 3 56P1215 1 Cartridge drive a...

Page 382: ...7 34 Service Manual 5060 00x Assembly 21 Electronics...

Page 383: ...razil HV Paraguay HV Uruguay HV African Countries Denmark HV Austria HV Czech HV Slovak countries HV Greece HV Hungary HV Finland HV Norway HV Sweden HV France HV Belgium HV Netherlands HV Germany HV...

Page 384: ...7 36 Service Manual 5060 00x Assembly 21 1 Electronics...

Page 385: ...port brackets 7 12G6335 1 Standoff INA RIP spacer 8 56P9910 1 SDRAM DIMM 128MB 8 12G6509 1 SDRAM DIMM 64MB 9 56P1187 1 RIP board assembly non network Model 5060 001 10 99A0426 1 Screw parallel connect...

Page 386: ...s Asm Index Part number Units Description 21 2 1 12G6327 1 Transfer HVPS board 2 1 Screw PP 12G6309 3 1 Screw PP 12G6533 4 1 Screw PP 12G6530 5 12G6541 4 Standoff high voltage power supply developer 6...

Page 387: ...g 7 39 5060 00x Assembly 21 3 Electronics Asm Index Part Number Units Description 21 3 1 12G6336 1 Engine board shield 2 12 Screw PP 12G6531 3 12G6323 1 Engine board 4 12G6387 1 Ground strap 5 14 Scre...

Page 388: ...7 40 Service Manual 5060 00x Assembly 21 4 Electronics...

Page 389: ...1 4 Electronics Asm Index Part Number Units Description 21 4 1 12G6343 1 RIP fan duct 2 2 Screws PP 12G6530 3 12G6361 1 RIP fan 4 12G6479 1 VTB fan 5 12G6490 1 VTB fan gap cover 6 12G6382 1 Fuser fan...

Page 390: ...7 42 Service Manual 5060 00x Assembly 22 Electronic cabling engine board...

Page 391: ...le LVPS to engine power attached to LVPS P N 12G6329 14 12G6350 1 Cable attached to main fan P N 12G6382 15 12G6349 1 Cable fuser and yellow cartridge motor 16 1 Cable LVPS to RIP board power attached...

Page 392: ...7 44 Service Manual 5060 00x Assembly 23 Electronic cabling RIP board...

Page 393: ...sembly 6 12G6387 1 Cable ground 7 12G6321 1 Cable operator panel 8 1 Printhead assembly yellow includes HSYNC and mirror motor cables P N 12G6322 9 12G6310 1 Cable video printhead yellow 10 12G6314 1...

Page 394: ...cription 24 1 56P1565 1 Cable assembly black terminal contact 2 56P1567 1 Cable assembly cyan terminal contact 3 56P1568 1 Cable assembly yellow terminal contact 4 56P1566 1 Cable assembly magenta ter...

Page 395: ...HVPS Asm Index Part Number Units Description 25 1 56P1502 1 Cable assembly HVPS control developer 2 56P0310 3 Cartridge contact assembly complete cyan magenta yellow 3 56P1561 1 Cartridge contact ass...

Page 396: ...7 48 Service Manual 5060 00x Assembly 26 Output expander...

Page 397: ...oard Output Expander DC motor 7 9 Screw PP 56P0169 8 56P0409 1 Cover front control board 9 99A1817 1 Tray Output Expander 10 99A1688 1 Diverter arm 11 99A1689 1 Spring clutch assembly 12 99A0482 1 Spr...

Page 398: ...7 50 Service Manual 5060 00x Assembly 26 1 Output expander...

Page 399: ...6P0410 2 Bracket attach 5 11 Screw PP 56P0169 6 56P0400 1 Cover front 7 99A0361 1 Belt 160 gear 8 99A0362 1 Arm assembly belt idler 9 99A0364 1 Spring belt tensioner 10 99A0482 1 Spring output tray 11...

Page 400: ...7 52 Service Manual 5060 00x Assembly 27 5 bin mailbox...

Page 401: ...5 Bin Mailbox pass thru 14 99A1712 5 Tray paper cap 15 56P0420 1 Bracket asm bail attach 16 99A1743 1 Kit 5 Bin Mailbox asm 17 1 Bail order 99A1743 5 Bin Mailbox asm kit 18 99A1713 5 Support paper tra...

Page 402: ...7 54 Service Manual 5060 00x Assembly 27 1 5 bin mailbox...

Page 403: ...rter actuator 7 99A1730 4 Arbor diverter actuator 8 99A1789 4 C clip 9 56P0418 1 Bracket attach front 10 99A1732 4 Solenoid diverter 11 99A1738 5 Deflector paper exit w brush 12 99A1722 4 Deflector pa...

Page 404: ...7 56 Service Manual 5060 00x Assembly 28 500 sheet drawer option...

Page 405: ...frame 7 12G6553 1 Pass thru sensor 8 12G6562 1 Hinge 9 12G6559 1 Electronics size sensing assembly with system board 10 12G6558 1 Pick arm lift bellcrank 11 12G6566 1 Paper size sensing assembly 12 12...

Page 406: ...7 58 Service Manual 5060 00x Assembly 28 1 500 sheet tray option...

Page 407: ...1 500 Sheet tray assembly 2 12G6419 1 Back restraint latch 3 12G6418 1 Back restraint 4 12G6425 1 Tray bias bellcrank assembly 5 1 Screw PP 12G6533 6 12G6426 1 Tray bias spring 7 12G6568 1 Reflector...

Page 408: ...7 60 Service Manual 5060 00x Assembly 29 Duplex option...

Page 409: ...r 11 56P0435 1 Duplex shaft mount 12 56P0479 1 Front decurl assembly 13 56P0444 1 F R backup shaft assembly 14 56P0476 3 5 mm bushing 15 56P0473 1 Brake pad 16 56P0439 1 Duplex paper guide 17 56P0454...

Page 410: ...7 62 Service Manual 5060 00x Assembly 29 1 Duplex option...

Page 411: ...0 1 Duplex card assembly 9 56P2484 1 Belt transfer 10 56P0433 1 Right jam clearance tray assembly 11 56P0458 1 Chassis ground spring 12 99A1789 1 Retainer C clip 13 56P0478 2 Aligner spring 14 99A0323...

Page 412: ...7 64 Service Manual 5060 00x Assembly 30 High capacity input tray HCIT...

Page 413: ...per AC power cord 15 56P0524 1 Paper tray guide 16 56P0547 1 Elevator lift belt 17 56P0549 1 Elevator lift 18 56P0563 3 Ring 7 elevator lift gear elevator lift 19 56P0548 1 Elevator lift gear 20 56P05...

Page 414: ...7 66 Service Manual 5060 00x Assembly 30 1 High capacity input tray HCIT...

Page 415: ...ter fixed 9 56P0504 1 Left side cover 10 56P0508 1 Upper left side jam cover 11 56P0507 1 Locating pin options front right 12 56P0506 1 Locating pin options rear left 13 56P0514 1 Options autoconnect...

Page 416: ...7 68 Service Manual 5060 00x Assembly 31 High capacity output finisher HCOF...

Page 417: ...2 56P0569 1 Rear cover 3 56P0573 1 Upper right side cover tall finisher 3 56P1286 1 Upper right side cover short finisher 4 56P0574 1 Lower tray cover 5 56P0576 1 Bottom kick cover 6 56P0575 1 Front...

Page 418: ...7 70 Service Manual 5060 00x Assembly 31 1 High capacity output finisher...

Page 419: ...levator belt 60S6M1420 16 56P0323 1 Output tray offset motor and gear assembly 17 56P0386 1 Fan assembly DC motor 18 56P0322 1 Tray paper 19 56P0326 1 Flag paper full 20 56P0331 1 Exit foam Roller dri...

Page 420: ...7 72 Service Manual 5060 00x Assembly 31 2 High capacity output finisher...

Page 421: ...6P0319 1 Accumulator w o stapler 7 56P0348 1 Drop timing sensor OS 535223 602 8 56P0349 1 Accumulator homing sensor OS 311D A5 9 56P0316 1 Staple assembly 10 56P0358 2 Accumulator slides 11 56P0317 1...

Page 422: ...Service Manual 5060 0xx Assembly 32 High capacity output finisher cables...

Page 423: ...5 system board to chad box full sensor 11 56P0369 1 Harness cable assembly E2 cable E5 to exit timing sensor 12 56P0370 1 Harness cable assembly E3 cable E5 to paper surface upper sensor paper surface...

Page 424: ...d NS 56P9926 1 Lexmark Optra Forms software NS 56P9927 1 Lexmark Forms Director software NS 56P9928 1 Lexmark Forms 4MB flash DIMM NS 56P9929 1 Lexmark Forms 8MB flash DIMM NS 56P9930 1 Lexmark Forms...

Page 425: ...1 Screw type 484 PP 12G6534 NS 1 Screw 500 sheet tray PP 12G6538 NS 1 Screw type 124 PP 12G6539 NS 1 Screw type 121 PP 12G6540 NS 7370235 1 Kit relocation package assembly printer NS 7370563 1 Kit re...

Page 426: ...7 78 Service Manual 5060 00x...

Page 427: ...how to setup the printhead diagnostic tool a If the printhead diagnostic tool is not configured as in the illustration below reconfigure it to match b Select which pair of printheads to switch based...

Page 428: ...nd cyan switch as an example a Turn off the printer b Unplug the printhead cables from the RIP board in the printer and connect them to the printhead diagnostic tool c Connect the printhead diagnostic...

Page 429: ...thead or the printhead cables are defective See the table below for printhead codes For example the printer originally displays the printhead error code 108 yellow After switching the signals using th...

Page 430: ...ust to perform the Printhead mechanical alignment on appendix page A 5 and Electronic color alignment on appendix page A 12 The front cover must be installed and closed before any printhead alignment...

Page 431: ...dentify the configuration of your printer The following steps are similar for both versions except you need to remove two extra screws when you have the PSD bracket You may have a PSD bracket A whethe...

Page 432: ...D bracket remove the two screws A and B Note Use a small diameter Phillips screwdriver to remove screw A b Insert the printhead alignment tool placing the locating pin C in the middle hole A c Secure...

Page 433: ...the front of the printhead and secure alignment tool bracket D with screw provided Note Align the locating pin C in the hole in printer frame 4 Turn the thumbwheel E until the end of the thumbwheel ju...

Page 434: ...ear screw goes through the printhead spacer located at the right rear of the printer frame 6 Bias the new printhead assembly against the front and rear stops 7 Tighten the right rear printhead mountin...

Page 435: ...color of the printhead that was replaced and set the Z value to zero Exit the Diagnostics Menu 11 With the printer at Ready prompt hook up a computer through the USB network or parallel connection and...

Page 436: ...through 15 until alignment is within 5 If you are replacing the black printhead make sure on the test page that black is within 5 and also within 1 between the front and rear side For example if the...

Page 437: ...moves to the next margin setting Press Go to print the Quick Test Page after adjusting the margins and saving the change Select 5 After completing the registration press Return to exit the registratio...

Page 438: ...an over the Black Repeat for each of the colors Cyan Magenta and Yellow 3 To align Cyan press Menu until Cyan is displayed press Select Four alignment settings are displayed Menu changes the values Se...

Page 439: ...to the next value b To adjust Z or theta value Press Go to print the Cyan Alignment Page Use the rightmost target in the first row to adjust the Cyan and Black horizontal lines Adjust the setting and...

Page 440: ...value e Change each of the settings Top Left Right and Theta for Cyan When the targets are aligned press Go to print the final page 5 After aligning the Cyan targets press Return Repeat the process t...

Page 441: ...d 2 range return to the Alignment menu See Electronic color alignment on page 12 7 Select the appropriate color 8 Change value of the respective setting by the calculated value For example if T 5 and...

Page 442: ...over the VTB There is a delay between the first and second page 7 Once the pages are printed examine the pages for to confirm the color plane is not printing Note The third page is particularly impor...

Page 443: ...amage to the cable running from the system board Developer HVPS board System board If the image is well developed on the PC drum but the same plane is missing or faded on the ITU belt the following co...

Page 444: ...y fragments fall into the printer they should land in the paper tray and be easy to remove 4 Remove the broken pieces of old nip relief handle a Pull up the upper piece of handle to raise the nip reli...

Page 445: ...Appendix A Service tips A 19 5060 00x c Remove any remnants of the handle Check the paper tray to check for debris For example see the fragment B in the following picture...

Page 446: ...te the new nip relief handle into place to connect it to the nip relief link A 2 Using a screwdriver gently pry the nip relief lever B towards the rear of the machine and insert lower portion of handl...

Page 447: ...allowing the handle to press into place onto the post using moderate force 4 Once the handle snaps onto the post press the upper portion of the handle to the right and rotate the handle into its home...

Page 448: ...can be made to correctly align the finisher with the printer There are two adjustment casters on the left the side closest to the printer and two on the right underneath the platform cover Note The sh...

Page 449: ...Appendix A Service tips A 23 5060 00x Tall finisher Printer Optional duplex unit One additional 500 sheet drawer Optional 2000 sheet drawer Finisher...

Page 450: ...ve a short or tall finisher Short finisher 1 Attach caster brakes A to the two back legs of the printer caster base 2 Screw the caster brakes onto the legs of the caster base 3 Adjust the leveling fee...

Page 451: ...er as needed so the pin D on the printer properly aligns with the hole in the finisher the pin should freely slide into the hole Short finisher 1 Insert the Allen wrench E into either caster bolt F 2...

Page 452: ...wise raises the finisher Step 3 Align the bumper pads Adjust the two casters on the right side under the platform cover to raise or lower the finisher as needed so the two bumper pads on the finisher...

Page 453: ...bolt Step 4 Adjust the tilt If necessary adjust the tilt of the finisher so that the front is flush with the front of the printer This can usually be done by adjusting the two front casters those clo...

Page 454: ...2 The finisher s height is correct The pin should align with the hole in the finisher and the finisher should easily dock to the printer without interference or binding with the pin Step 2 Align the p...

Page 455: ...receive the sheet and prompts a 230 Paper Jam message Replace the rubber deflector button with the compression spring deflector button 1 The FRU kit contains a spring and button that should be assembl...

Page 456: ...A 30 Service Manual 5060 00x...

Page 457: ...y 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 pri...

Page 458: ...B 2 Service Manual 5060 00x Print Menus Page two of two...

Page 459: ...Appendix B Print quality samples B 3 5060 00x Print tests Print Quality Pages Title page total of five...

Page 460: ...B 4 Service Manual 5060 00x Print Quality Pages Page 1 total of five...

Page 461: ...Appendix B Print quality samples B 5 5060 00x Print Quality Pages Page 2 total of five...

Page 462: ...B 6 Service Manual 5060 00x Print Quality Pages Page 3 total of five...

Page 463: ...Appendix B Print quality samples B 7 5060 00x Print Quality Pages Page 4 total of five...

Page 464: ...B 8 Service Manual 5060 00x Registration Quick Test...

Page 465: ...Appendix B Print quality samples B 9 5060 00x Alignment test pages Printhead alignment test pages magenta one of three...

Page 466: ...B 10 Service Manual 5060 00x Printhead alignment test page yellow two of three...

Page 467: ...Appendix B Print quality samples B 11 5060 00x Printhead alignment test page cyan three of three...

Page 468: ...B 12 Service Manual 5060 00x Print Line Len page...

Page 469: ...endix 8 1 attendance messages 2 28 Auto Color Adjust 3 12 autocompensator assembly parts catalog 7 24 removal 4 17 service check 2 114 automated motor detection 3 16 B Base Sensor Test 3 29 Belt Track...

Page 470: ...3 20 Drift Sensor Check 3 16 ducts fuser bottom duct 4 32 fuser top duct 4 34 duplex option deflector button replacement 8 29 error codes 2 8 2 9 parts catalog 7 60 7 62 relocation packaging 7 77 serv...

Page 471: ...installation narrow media sensor assembly 4 75 redrive assembly 4 68 S2 NMS transparency sensor assembly 4 75 web oiler motor assembly 4 36 installations transparency sensor assembly 4 75 ITU Alignme...

Page 472: ...ight print 2 142 light print all colors 2 142 low image density 2 143 missing colors 2 141 negative ghost image 2 144 one color has light print 2 143 poor color alignment 2 144 residual image 2 145 se...

Page 473: ...rs 5 14 installation notes 4 70 locations 5 1 removal 4 70 ROM Test 3 21 S S2 NMS transparency sensor assembly 4 72 safety information v xvii safety inspection guide 6 1 scheduled maintenance 6 4 scre...

Page 474: ...24 input tray sensor test 500 sheet trays 3 24 LCD test 3 19 quick disk test 3 29 thermistor card locations 5 1 parts catalog 7 15 tips 8 1 toner metering cycle TMC locations 5 4 service check 2 93 2...

Page 475: ...G6315 Cable thermistor magenta and black 7 45 12G6316 Cable HVPS control developer 7 43 12G6317 Cable HVPS control transfer 7 43 12G6318 Cable engine RIP communications 7 43 12G6319 Cable options stac...

Page 476: ...Machine pad 7 3 7 57 12G6382 Cable attached to main fan 7 43 12G6382 Fuser fan 7 41 12G6383 Fuser latch slide 7 5 12G6384 Fuser latch slide spring 7 5 12G6385 58 Gear 7 27 12G6386 Duplex actuator arm...

Page 477: ...t 7 21 12G6457 MPD support bracket cover 7 21 12G6458 MPF support bracket spring 7 21 12G6459 MPF support bracket 7 21 12G6460 Door hinge restraint 7 21 12G6461 Paper out low sensor 7 21 12G6461 Senso...

Page 478: ...4 12G6514 Fuser assembly web oiler 115V 500W 7 11 12G6515 220 V web oiler fuser 1 4 6 4 12G6515 220 V web oiler upgrade kit 1 4 12G6515 Fuser assembly web oiler 220V 500W 7 11 12G6516 Fuser lamp 100V...

Page 479: ...a HV Lesotho HV Botswana HV 7 35 1339524 Power cord set Chile HV 7 35 1339525 Power cord set Denmark HV 7 35 1339544 Power cord set Argentina HV 7 35 43H5544 Power cord set PRC 7 35 56P0161 RS 232 C s...

Page 480: ...sensor OS 535223 602 7 73 56P0349 Accumulator homing sensor OS 311D A5 7 73 56P0350 Paper surface sensor EE SX460 P1 CHN 7 71 56P0351 Cover open switch 7 73 56P0352 Printer docking switch SS 5FL 3T 1...

Page 481: ...0434 Right side front tray guide 7 61 56P0435 Duplex shaft mount 7 61 56P0436 Upper rib assembly 7 63 56P0437 Duplex output sensor 7 63 56P0439 Duplex paper guide 7 61 56P0441 Duplex shaft assembly 7...

Page 482: ...e sensors cable 7 65 56P0512 Cable elevator motor 7 67 56P0513 Elevator motor assembly 7 65 56P0514 Options autoconnect cable assembly 7 67 56P0515 Magnetic latch 7 67 56P0516 Sensor photo interrupter...

Page 483: ...e assembly cyan magenta black 7 33 56P1215 Cartridge drive assembly yellow 7 33 56P1216 Cable waste toner full attached to ITU drive assembly 7 43 56P1216 ITU motor drive assembly with SKC motor 7 27...

Page 484: ...Forms 4MB flash DIMM 7 76 56P9929 Lexmark Forms 8MB flash DIMM 7 76 56P9930 Lexmark Forms 16MBMB flash DIMM 7 76 56P9932 Lexmark Forms 64MB flash DIMM 7 76 56P9934 MarkNet Token Ring Print Server 7 76...

Page 485: ...top asm paper tray 7 53 99A1688 Diverter arm 7 49 99A1689 Spring clutch assembly 7 49 99A1708 Cover right side 7 53 99A1710 Cover wire 7 53 99A1712 Tray paper cap 7 53 99A1713 Support paper tray 7 53...

Page 486: ...r drive 7 53 99A1787 Deflector 7 55 99A1788 Retainer R ring 7 55 99A1789 C clip 7 55 99A1789 Retainer C clip 7 63 99A1817 Tray Output Expander 7 49 99A2432 Blank parallel shield use with network RIP b...

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