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Preventive maintenance

6-1

5061

6. Preventive maintenance

This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help
prevent problems and maintain optimum performance.

Safety inspection guide

The purpose of this inspection guide is to aid you in identifying unsafe conditions.

If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you
correct the hazard.

Check the following items:

•

Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply

•

Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover

•

Possible safety exposure from any non-Lexmark attachments

Scheduled maintenance

The operator panel displays 80 Fuser Maintenance and 83 ITU Maintenance for scheduled maintenance.

80 Fuser Maintenance is displayed at 120,000 copies for C78x models, and at 200,000 copies for C77x models
indicating the fuser assembly needs to be replaced to maintain the print quality and reliability of the printer. The
parts are available as a maintenance kit with the following part numbers:

83 ITU Maintenance is displayed at each 120,000 copies when the ITU Assembly needs to be replaced to
maintain the print quality and reliability of the printer. There are two assemblies, ITU assembly and Second
Transfer Roll, in a maintenance kit. Both should be replaced at the same time. The parts are available as a
maintenance kits:

After replacing the kit, the fuser maintenance count must be reset to zero to clear the maintenance message.

84 Oiler Nearly Exhausted is displayed at each 100,000 copies when the Web Oiler Assembly is nearly
exhausted. Go to

“Web Oiler Assembly” on page 7-9

for part number.

Standard fusers

Description

Part number

Models 1xx/3xx
(C77x)

Models 2xx/4xx
(C78x)

Maintenance kit 115 V fuser

40X1859

40X1831

Maintenance kit 220 V fuser

40X1860

40X1832

Maintenance kit 100 V fuser

40X1861

40X1833

ITU Maintenance kits

Description

Part number

ITU Maintenance kit for 1xx and 3xx models

40X0342

ITU Maintenance kit for 2xx and 4xx models

40X0343

«
...
367
368
369
370
371
...
»

Summary of Contents for C77X

Page 1: ...061 Table of Contents Start Diagnostics Safety and Notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or o...

Page 2: ...ication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not i...

Page 3: ...ase printer 2 3 Symptom table 500 sheet drawer option 2 4 Symptom table HCIT 2000 sheet option 2 5 Symptom table output expander option 2 5 Symptom table 5 bin mailbox option 2 5 Symptom table StapleS...

Page 4: ...2 56 927 03 error code service check 2 57 930 09 error code service check 2 57 940 xx error code service check 2 58 941 xx error code service check 2 60 942 xx error code service check 2 62 943 xx er...

Page 5: ...enus and messages 2 119 Understanding the printer operator panel 2 119 Operator panel buttons 2 119 Menu map 2 121 Selected menus 2 122 Quality Menu 2 122 Utilities Menu 2 124 User attendance messages...

Page 6: ...3 26 Serial Number 3 27 Engine Setting x 3 27 Model Name 3 27 Configuration ID 3 27 Reset Color Calibration 3 28 Edge to Edge 3 28 Cal Ref Adj 3 28 EP SETUP 3 28 EP Defaults 3 28 Fuser Temp 3 28 DC C...

Page 7: ...panel bezel removal 4 7 Lens removal 4 9 Front cover rear pivot cover removal 4 10 Front cover or front cover backplate assembly removal 4 11 Redrive cap removal 4 12 Top cover assembly removal 4 13...

Page 8: ...r removal 4 84 Rib housing removal 4 85 RIP fan removal 4 87 S2 narrow media transparency multipurpose feeder cable removal 4 88 S2 narrow media transparency multipurpose feeder sensors removal 4 89 S...

Page 9: ...13 500 Sheet integrated tray 7 20 Assembly 14 Autocompensator assembly 7 21 Assembly 15 ITU assembly 7 22 Assembly 16 ITU drive assembly 7 23 Assembly 17 ITU loading 7 24 Assembly 18 Waste toner 7 26...

Page 10: ...ty Pages Page 2 total of five B 3 Print Quality Pages Page 3 total of five B 4 Print Quality Pages Page 4 total of five B 5 Registration and alignment B 6 Quick Test Page B 6 Printhead mechanical alig...

Page 11: ...r bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse I bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimant...

Page 12: ...t 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 hu...

Page 13: ...aessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA...

Page 14: ...0825 1 Els productes l ser de classe I no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud...

Page 15: ...Notices and safety information xv 5061...

Page 16: ...xvi Service Manual 5061...

Page 17: ...ignes 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 p...

Page 18: ...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 la...

Page 19: ...ducte 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 aqu...

Page 20: ...Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to preve...

Page 21: ...ON A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unpl...

Page 22: ...xxii Service Manual 5061...

Page 23: ...thernet 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 standard multipurpose feeder that...

Page 24: ...to offer five output destinations in one option Each of the five bins supports approximately 100 pages of 20 lb 75 g m2 paper Only one output option above the printer is supported StapleSmart Finisher...

Page 25: ...able settings to balance print darkness and toner savings The higher the setting the darker the print The toner darkness default setting is 4 Color level 4 and level 5 are the same The toner darkness...

Page 26: ...in 604 5 mm 2 181 lb 82 3 kg Options 500 sheet drawer 5 in 127 mm 23 8 in 604 5 mm 18 5 in 469 9 mm 13 5 lb 6 1 kg 500 sheet tray 3 8 in 96 5 mm 15 6 in 396 2 mm 15 5 in 386 1 mm 2 6 lb 1 2 kg Duplex...

Page 27: ...c extreme Operating clearances Printing states Lexmark C77x n Lexmark C77xdn Lexmark C78x n Lexmark C78xdn Printing average power W Base model 500 500 675 675 All options 540 540 675 675 Idle average...

Page 28: ...Pa Ambient operating environment Temperature 60 to 90 F 15 6 to 32 2 C Relative humidity 8 to 80 Storage and shipping packaged printer with or without print cartridge Temperature 40 to 110 F 40 to 43...

Page 29: ...irst copy time is defined as the elapsed time from pressing Enter on the keyboard to the page exiting to the output bin All tests pick paper from the primary input tray and the page exits into the pri...

Page 30: ...ts may occur if an attempt is made to operate the printer with memory other than SDRAM DIMM memory with the stated specifications Flash Memory Options available are 32MB and 64MB Expansion Memory slot...

Page 31: ...or only one with a 2000 sheet drawer 1 2000 Sheet drawer1 maximum of one Envelope drawer maximum of 3 or only one with a 2000 sheet drawer Outdoor media drawer Banner tray Maximum additional drawers M...

Page 32: ...a duplex unit must be a 500 sheet drawer Media sizes and support Legend 3 supported with size sensing supported without size sensing 8 unsupported Media size Dimensions 500 sheet trays Multi purpose...

Page 33: ...8 3 8 8 8 8 8 10 Envelope 104 8 x 241 3 mm 4 12 x 9 5 in 8 8 8 3 8 8 8 8 8 DL Envelope 110 x 220 mm 4 33 x 8 66 in 8 8 8 3 8 8 8 8 8 C5 Envelope 162 x 229 mm 6 38 x 9 01 in 8 8 8 3 8 8 8 8 8 B5 Envelo...

Page 34: ...onal high capacity feeder Optional duplex Optional envelope drawer Optional banner tray Optional 5 bin mailbox Optional Finisher Standard Offset Staple Paper 3 3 3 3 8 8 3 3 3 3 Card stock 3 3 8 3 8 8...

Page 35: ...lb Not recommended Not supported Tag 203 g m2 125 lb 203 g m2 125 lb Not supported Not supported Cover 216 g m2 80 lb 216 g m2 80 lb Not supported Not supported Transparencies8 Laser printer 161 to 1...

Page 36: ...g m2 47 lb bond grain short is recommended 2 Paper weighing less than 75 g m2 20 lb bond is limited to simplex printing only at less than 60 relative humidity 3 Pressure sensitive area must enter the...

Page 37: ...rd stock maximum grain short 1 Index Bristol 199 g m2 110 lb Not supported 199 g m2 110 lb 199 g m2 110 lb Not supported Tag 203 g m2 125 lb Not supported 203 g m2 125 lb 203 g m2 125 lb Not supported...

Page 38: ...Staple 1 For 60 to 176 g m2 16 to 47 lb bond paper grain long fibers are recommended For papers heavier than 176 g m2 47 lb bond grain short is recommended 2 Paper weighing less than 75 g m2 20 lb bo...

Page 39: ...Sulfite wood free or up to 100 cotton bonds 60 to 105 g m2 16 to 28 lb bond Not supported Not supported Not supported Not supported Media types and weights output options continued Media Type Media w...

Page 40: ...hness The degree of smoothness of paper directly affects print quality If the paper is too rough the toner does not fuse to the paper properly resulting in poor print quality If the paper is too smoot...

Page 41: ...aving a weight less than 60 g m2 16 lb Multiple part forms or documents Selecting paper Proper paper loading helps prevent jams and ensures trouble free printing To help avoid jams or poor print quali...

Page 42: ...out sacrificing fuser life Web oiler fuser life 120 000 C78x models 200 000 C77x models Web oiler life 100 000 pages Availability Order the web oiler upgrade kit Upgrade kit This kit allows you to upg...

Page 43: ...imulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply M Magenta MROM Masked Read Only Memory MS Microswitch NVRAM Nonvolatile Random Access M...

Page 44: ...1 22 Service Manual 5061...

Page 45: ...vice errors on page 2 11 User attendance messages on page 2 126 Service checks on page 2 14 for individual error messages Additional information can be found at the following locations Understanding t...

Page 46: ...as been installed The printer detects at power on when the cover is closed that a new or different ITU has been installed The printer detects at power on that the fuser temperature is below 60 C When...

Page 47: ...n page 2 116 Operator panel One or more buttons do not work Go to Operator panel LCD status LED buttons service check on page 2 90 Operator panel Display is blank printer does not sound 5 beeps but pr...

Page 48: ...rint quality Light lines or streaks appear on the printed page Go to Light lines or streaks appear on the page on page 2 105 Print quality Light print Go to Light print over the entire page on page 2...

Page 49: ...not recognize the correct media size Go to HCIT 2000 sheet option does not recognize the size paper selected on page 2 89 Paper jams in the HCIT Go to 2xx paper jams on page 2 9 Paper jams in the HCI...

Page 50: ...displayed Unable to clear or reset message POST incomplete Go to Close Finisher Top Cover displayed unable to clear or reset message POST incomplete on page 2 113 Close Finisher Side Cover displayed U...

Page 51: ...rinthead before performing checks in Printhead diagnostics on page 3 1 108 xx Printhead Error Yellow printhead error Check for the correct installation of all the cables to the system board assembly a...

Page 52: ...or code service check on page 2 22 140 xx Motor Autocompensator motor error replace the autocompensator motor See Autocompensator pick assembly removal on page 4 27 If this does not fix the problem re...

Page 53: ...er Jam Removal Door to access the jammed media If removing the jammed media does not fix the problem go to 200 07 paper jam service check on page 2 31 200 16 Paper Jam Clear Paper Path S2 sensor was m...

Page 54: ...2 35 202 xx Paper Jam Clear Paper Path Media has jammed at the fuser Open the printer right door to access the jam area If removing the jammed media does not fix the problem go to 201 xx and 202 xx pa...

Page 55: ...ing normal stapler operation such as when printing and stapling jobs Check stapler are for jam in accumulator or stapler Remove stapler cartridge to check for staple jam Press to initiate priming and...

Page 56: ...failure replace the media size sensing board See Media size sensing board removal on page 4 58 952 xx NVRAM Failure NVRAM chip failure POR the printer 953 xx NVRAM Failure NVRAM chip failure operator...

Page 57: ...the card in the specified slot 976 xx Standard Network Unrecoverable software or error in network for network card x If unable to clear the error message check the following If installed check network...

Page 58: ...Due to memory restrictions the buffer is not saved during POR This means if a printer posts a 100 02 ITU Error so the belt is tracked off and the customer or servicer turns off the printer to clear th...

Page 59: ...Go to step 5 5 Remove the ITU assembly and check that the sensor cable is seated in the handle of the ITU assembly correctly Note The sensor connector is located on the side of the ITU handle assembl...

Page 60: ...rface Is the printer setting on a solid flat surface Go to step 11 Place the printer on a solid flat surface 11 Make sure the ITU drive motor assembly cable is correctly installed to the ITU drive mot...

Page 61: ...rinter posts a 100 02 ITU Error so the belt is tracked off and the customer or servicer turns off the printer to clear the error when the printer starts up it will still not see the belt signal and wi...

Page 62: ...surements as shown The lower limit is 3 1 mm the high limit is 8 1 mm and the optimum position is 5 6 mm Has the ITU Belt shifted to the front or to the rear Replace the ITU assembly See ITU assembly...

Page 63: ...sembly See LVPS assembly removal on page 4 53 2 Turn the printer on and measure the voltage on connector J17 11 on the system board The voltage should measure approximately 0 13 V dc to 0 64 V dc as t...

Page 64: ...blem replace the fuser assembly See Fuser assembly removal on page 4 44 4 Reinstall the fuser assembly Watch to see if the lamps turn on and off as the lamp heats up Do the lamps turn on Go to step 5...

Page 65: ...correctly Is the hot roll lamp installed correctly Go to step 4 Install the lamp correctly If this does not fix the problem replace the fuser assembly See Fuser assembly removal on page 4 44 4 Reinsta...

Page 66: ...ve the fuser from the printer Measure the voltage at the DC fuser control connector on the LVPS on pin 2 and 9 on the connector The voltage should measure approximately 5 V dc Is the voltage correct R...

Page 67: ...led correctly Is the hot roll lamp installed correctly Go to step 4 Install the lamp correctly If this does not fix the problem replace the fuser assembly See Fuser assembly removal on page 4 44 4 Rei...

Page 68: ...ly from the printer Measure the voltage on connector J17 6 on the system board The voltage should measure approximately 3 3 V dc Is the voltage correct Go to step 2 Replace the system board See System...

Page 69: ...tor 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 J16 on the system board The voltages are approximate...

Page 70: ...Go to step 4 Replace the black cartridge assembly cable 4 Replace the black cartridge drive assembly Does this fix the problem Problem resolved Go to step 5 5 Replace the system board See System board...

Page 71: ...ntinuity Go to step 4 Replace the cyan cartridge assembly cable 4 Replace the cyan cartridge drive assembly Does this fix the problem Problem resolved Go to step 5 5 Replace the system board See Syste...

Page 72: ...motor removal on page 4 64 MPF motor sensor cable Replace the system board See System board removal on page 4 90 Step Actions and questions Yes No 1 Is sensor flag obstructed by paper debris out of p...

Page 73: ...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 inner deflector position Go to step 5 5 If...

Page 74: ...ng Edge guides should be adjusted against edge of media Media should be fanned and lay flat in the tray Is the media properly loaded in the tray Go to step 3 Properly load media 3 Remove the ITU and c...

Page 75: ...Edge guides should be adjusted against edge of media Media should be fanned and lay flat in the tray Is the media properly loaded in the tray Go to step 3 Properly load media 3 Remove the ITU and chec...

Page 76: ...S2 sensor 200 28 paper jam Is the sensor flag or sensor obstructed by paper debris Remove the paper or debris and go to step 2 Go to step 3 2 Replace the image transfer unit the cartridges and turn th...

Page 77: ...m board removal on page 4 90 Step Actions and questions Yes No 1 Remove fuser from printer remove oiler housing from fuser and pivot the paper guide up Is paper jammed inside the fuser Clear the jam G...

Page 78: ...t belts VTB for motion Observe the belt through the front door Are the belts on the VTB assembly turning Go to step 6 Go to Vacuum transport belt VTB removal on page 4 96 to verify correct installatio...

Page 79: ...properly loaded in the tray Go to step 3 Properly load media 3 Remove the ITU and check for the jam at the second transfer roll Is paper jammed at the second transfer roll Clear the jam Contact your n...

Page 80: ...e 4 26 6 Check for the proper operation of the redrive Are both belts in good condition and properly installed Go to step 7 Install or replace the redrive door See Redrive assembly removal on page 4 8...

Page 81: ...etween the door and the metal plate Go to step 3 Replace the lower right door assembly See Lower right door assembly removal on page 4 24 3 Are any of the following conditions true Only the back of th...

Page 82: ...t media loaded in Tray x does not meet media specifications 2 Make sure the media is loaded correctly Make sure the side and back restraints are located and seated properly Is the media loaded correct...

Page 83: ...ly Replace the option or replace the following parts in the order until the error is cleared Autocompen sator pick assembly See Auto compensa tor pick assembly removal on page 4 27 Tray x system board...

Page 84: ...ion by running the Tray x sensor test from the Diagnostics Menu See Sensor Test on page 3 20 Does the pass thru sensor operate correctly Check for any obstructions that might catch the media and creat...

Page 85: ...t to observe paper feeding from the 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 registratio...

Page 86: ...ration Test to determine where the paper jams Use the HCIT system board LED error code table on page 2 86 to help isolate problems in the feed unit assembly Are you able to determine where the failure...

Page 87: ...Check to make sure the autocompensator pick rolls are correctly installed Are the autocompensator pick rolls correctly installed Go to step 6 Install the pick rolls correctly See Pick rolls removal o...

Page 88: ...e both rolls at the same time Go to step 7 7 Check the pass thru sensor for correct operation by running the Tray x sensor test from the Diagnostics Menu See Sensor Test on page 3 20 Does the pass thr...

Page 89: ...t to observe paper feeding from the 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 registratio...

Page 90: ...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 sys...

Page 91: ...back restraints are located and seated properly Are the envelopes loaded correctly Go to step 3 Load the envelopes correctly 3 Observe if the envelopes feed from the tray Note You can observe the auto...

Page 92: ...dalone Feeding Operation Test to observe paper feeding from the 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 regist...

Page 93: ...Replace the following FRUs in the order shown 1 Registration sensor 2 HCIT system board 14 Use the Standalone Feeding Operation Test to determine where the paper jams Use the HCIT system board LED er...

Page 94: ...MPF assembly Go to step 2 10 Make sure that the MPF sensor cable from the system board is correctly installed at J10 on the system board Is the cable correctly installed Go to step 11 Install the cab...

Page 95: ...ohms and 135 ohms Is the resistance correct Go to step 3 Replace the DC motor mechanical linkage assembly 3 DC motor mechanical linkage assembly Check for continuity between J4 1 and J4 2 and the cas...

Page 96: ...control board 4 Bottom pass thru sensor voltage check 2 Check the voltage at J5 2 on the board the voltage measures approximately 0 V dc Is the voltage correct Replace the sensor assembly Replace the...

Page 97: ...ics Menu See Finisher Feed Test on page 3 23 Go to step 2 2 Staple cartridge holder Check the staple cartridge holder for any signs of damage Did you find any damage to the staple cartridge holder Rep...

Page 98: ...ves or option cards Does the 900 error persist when the printer is turned on Go to step 5 Determine which option is causing the 900 error 5 Restore factory defaults from the Configuration Menu Warning...

Page 99: ...hese can be found on Print Menus page from the Utilities menu 4 Type of connection being used to print Record the type of connection For example direct USB or parallel or network peer to peer Ethernet...

Page 100: ...check that it rotates freely Does the fan rotate freely Go to step 2 Replace the VTB fan See Vacuum transport belt VTB fan removal on page 4 98 2 Check the VTB fan cable connection to the system board...

Page 101: ...RIP fan See RIP fan removal on page 4 87 Replace the system board See System board removal on page 4 90 Step Actions and questions Yes No 1 LVPS cable check the LVPS cable to J17 on the system board...

Page 102: ...idge if there are no problems with 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 xx...

Page 103: ...cracked or broken Go to step 6 Go to step 5 5 Check the mounting of the developer HVPS Make sure the screws that mount the power supply are properly tightened down and the board is positioned and moun...

Page 104: ...measure approximately 3 3 V dc Go to step 10 Go to step 11 10 Check the developer HVPS to system board cable for damage broken connections or wire and shorts between adjacent pins Are there any signs...

Page 105: ...cked or broken Go to step 6 Go to step 5 5 Check the mounting of the developer HVPS Make sure the screws that mount the power supply are properly tightened down and the board is positioned and mounted...

Page 106: ...sure approximately 3 3 V dc Go to step 10 Go to step 11 10 Check the developer HVPS to system board cable for damage broken connections or wire and shorts between adjacent pins Are there any signs of...

Page 107: ...broken Go to step 6 Go to step 5 5 Check the mounting of the developer HVPS Make sure the screws that mount the power supply are properly tightened down and the board is positioned and mounted correct...

Page 108: ...measure approximately 3 3 V dc Go to step 10 Go to step 11 10 Check the developer HVPS to system board cable for damage broken connections or wire and shorts between adjacent pins Are there any signs...

Page 109: ...roken Go to step 6 Go to step 5 5 Check the mounting of the developer HVPS Make sure the screws that mount the power supply are properly tightened down and the board is positioned and mounted correctl...

Page 110: ...rd Turn on the printer Does the error continue Replace the system board See System board removal on page 4 90 Go to step 2 2 Replace each option board one at a time making sure the boards are properly...

Page 111: ...tween 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 Is...

Page 112: ...d Replace the assembly 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 Y...

Page 113: ...cable at J4 and check the voltages at J4 on the board Warning Be careful not to short to adjacent pins on the connector The voltages measure approximately Are the voltages correct Replace the output e...

Page 114: ...the bin selected 272 xx Paper Jam check bin 1 message on page 2 72 Go to step 8 8 990 Service Error Go to 950 xx Error Code service check Contact your next level of support Step Actions and questions...

Page 115: ...nnected 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 Repair or...

Page 116: ...ecto gater or deflector cover broken or binding shaft assemblies or broken gear teeth Are parts broken loose binding or missing Replace parts or repairs necessary Go to step 2 2 Bin x solenoid Check t...

Page 117: ...20 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 pinched wiring or damage t...

Page 118: ...ly 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 or missing Repair or replace a...

Page 119: ...flag bellcrank Paper level sensing flag Paper 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 pa...

Page 120: ...and questions Yes No 1 Main AC power Make sure the printer is receiving main AC power Is the printer receiving AC power Go to step 2 Inform the customer that AC power to the printer is incorrect 2 AC...

Page 121: ...stem board except JOPP1 J18 and J20 See System board on page 5 7 Does the printer power up and display a message Go to step 4 Replace the system board See System board removal on page 4 90 4 Turn off...

Page 122: ...olls by opening the lower jam access door assembly Do the pick rolls turn Go to step 2 Go to step 3 2 Check the autocompensator pick rolls for contamination or damage to the rolls Is there any excessi...

Page 123: ...from the printer Go to step 3 Go to step 2 2 Open the lower jam access door carefully lift the autocompensator assembly until it is in its uppermost position and carefully try to remove tray 1 Can you...

Page 124: ...stallation and that the flag is not broken or damaged Is the paper level sensing assembly installed correctly and the flag not broken or damaged Go to step 5 Install correctly or replace the flag if d...

Page 125: ...ates the switches correctly Is the actuator damaged or broken Replace the ITU assembly See ITU assembly removal on page 4 49 Go to step 3 3 Front cover assembly Does the front cover assembly close cor...

Page 126: ...correctly or repair as necessary 5 Front cover assembly Make sure the front cover flag is not broken or damaged and actuates the switches correctly Is the flag broken or damaged Replace the front cove...

Page 127: ...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 op...

Page 128: ...ption 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 Make sure the upper...

Page 129: ...elope feeder installed correctly Go to step 4 Install the printer or options correctly and recheck performance 4 Check for the correct installation of the lower options autoconnect cable for the syste...

Page 130: ...pes being used Has the tray been set up correctly Go to step 3 Set the tray up correctly 3 Check the tray for any signs of broken or damaged parts Are there any signs of damage to the tray or parts in...

Page 131: ...board and check the voltages on connector J20 on the system board Note All voltages are approximate values Are the voltages correct Go to step 5 Replace the system board 5 Autoconnect cables Check th...

Page 132: ...n solid or blinking On solid means that the HCIT has detected the front door or side door open Blinking means that the system is operating Is the LED on solid or blinking If the LED is on solid check...

Page 133: ...ng media size sensor flag spring Is a sensor flag spring broken loose or missing Reconnect the spring if it is loose Replace the spring if broken or missing Go to step 5 5 Check the media size sensor...

Page 134: ...tons 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 B Replace the operator panel a...

Page 135: ...rd removal on page 4 90 11 Operator panel cable Check continuity of the operator panel cable Is there continuity Replace the operator panel assembly See Operator panel assembly removal on page 4 68 Go...

Page 136: ...standard bin even though bin x is selected Paper exits half way out of the redrive Go to 271 xx paper jam service check on page 2 51 Go to step 3 3 Remove paper Output Bin x is displayed POST is inco...

Page 137: ...rol board to make sure they are attached securely and correctly Are the cables attached securely and correctly Go to step 4 Reseat the cables 4 Voltage check base printer autoconnect connector Turn th...

Page 138: ...ontact your next level of support 3 Voltage Check the voltages at J5 3 and J5 4 The voltages should measure approximately 5 V dc Are the voltages correct Replace the sensor Replace the control board S...

Page 139: ...ect printer driver for the installed software can cause print quality problems Incorrect characters could print and the copy may not fit the page correctly Note Some 201 xx Paper Jam errors can be cau...

Page 140: ...and another color Does the color of the full bleed plane stay the same Replace the printhead see Printhead removal and adjustments on page 4 73 Replace the system board See System board removal on pag...

Page 141: ...ny of the bellcranks broken Replace the broken bell cranks Go to step 3 3 Perform the partial print test See Partial Print Test on page 3 4 Is the image well developed on the PC drum but the same plan...

Page 142: ...Go to step 8 Replace the cartridge contact assembly See Cartridge contact assembly removal on page 4 35 8 Perform a continuity check on the developer HVPS cable Does the cable check out Replace in or...

Page 143: ...artridge Make sure the cartridge is seated properly and all packaging material is removed from the cartridge Has all packaging material been removed and the cartridge seated correctly Go to step 2 Rem...

Page 144: ...by a cleaner problem in the print cartridge Are streaks magenta cyan or yellow Replace the cartridge Replace in order Black print cartridge ITU assembly See ITU assembly removal on page 4 49 Step Acti...

Page 145: ...tion has not been disabled in the Diagnostics menus especially if the printer has been previously serviced Was color calibration disabled Set Color Calibration on Go to step 2 2 Toner density calibrat...

Page 146: ...the quality of the transparency poor or do brown colors appear when projected Go to step 3 Go to step 4 3 Fuser settings From the Diagnostics menu select fuser settings and set to high Does this fuser...

Page 147: ...rs have uneven print replace the ITU assembly The uneven print may appear as spots or streaks that are different on each page The most likely cause for this type of problem is damage to the ITU belt i...

Page 148: ...d Replace the fuser assembly See Fuser assembly removal on page 4 44 Step Actions and questions Yes No 1 Remove the ITU assembly and check for any signs of debris near the paper feed reference edge me...

Page 149: ...ITU assembly Replace the ITU assembly See ITU assembly removal on page 4 49 If only one color streaks in the printed area go to step 1 Step Actions and questions Yes No 1 Media settings Does the media...

Page 150: ...igns of contamination on the lens of the printhead Is the printhead contaminated Go to Printhead removal and adjustments on page 4 73 Contact your next level of support Step Actions and questions Yes...

Page 151: ...in Check the first transfer bellcranks and springs or replace the image transfer unit if the defects occur every 101 mm 4 in Replace the fuser if the defects occur every 148 mm 5 8 in Marks occur on e...

Page 152: ...ng from another tray Replace the color print cartridge causing the streaks Print irregularities Paper has absorbed moisture due to high humidity You are using paper that does not meet the printer spec...

Page 153: ...dark spots toner is smeared horizontal or vertical light bands appear or color does not project You are using transparencies that do not meet the printer specifications The Paper Type setting for the...

Page 154: ...ions for the size loaded Incorrect margins Guides in the selected tray are set for a different size paper than what is loaded in the tray Auto size sensing is set to off but you loaded a different siz...

Page 155: ...ment Change Paper Type Paper Texture and Paper Weight to match the paper or specialty media loaded in the printer Load paper from a fresh package Store paper in its original wrapper until you use it S...

Page 156: ...hat is having transfer problems Is the cable disconnected or broken Reinstall or replace the cable Go to step 7 7 Transfer terminal contact assembly and ITU transfer bellcrank Check the transfer termi...

Page 157: ...cables at J1A and J1B bottom autoconnect to the stapler card assembly to make sure they are attached securely Are the cables secure Go to step 2 Reconnect the cables securely 2 Check the voltages of t...

Page 158: ...stapler option Does the side cover door actuate the switch when it closes Replace the stapler option Replace the stapler access door switch assembly Step Actions and questions Yes No 1 Left side bail...

Page 159: ...drop 4 Check the stapler assembly for damaged or broken parts Check the flag and spring assembly on the front of the stapler assembly to see if the flag or spring are broken or missing Is the flag or...

Page 160: ...ng broken or missing Replace the broken or missing flag or spring Go to step 2 2 Carefully cycle the large gear on the side of the stapler assembly and try to free the cartridge holder assembly Note L...

Page 161: ...per tray guide damaged loose or missing Replace the paper tray guide Go to step 4 4 Check the following parts for wear damage or missing parts Wear strips Restraint pads Wear clip Side restraint Back...

Page 162: ...he printer Is the tray correctly installed Go to step 2 Install tray 1 correctly If there is still a problem go to Tray 1 service check on page 2 117 2 Is another 500 sheet tray available Go to step 3...

Page 163: ...o access the menu index A message indicating the menus are unavailable will appear if the printer is not ready Stop Press the Stop button to stop the mechanical operation of the printer After pressing...

Page 164: ...t a host computer Numeric pad The numeric pad consists of numbers a pound sign and a backspace button The 5 button has a raised bump for non visual orientation The numbers are used to enter numeric va...

Page 165: ...dge Black Cartridge Waste Toner Box Fuser ITU Reports Menu Settings Page Device Statistics Network Setup Page Wireless Setup Page Profiles List NetWare Setup Page Print Fonts Print Directory Print Dem...

Page 166: ...is specified Customization is performed using the selections available under the Manual Color menu item Print Resolution Selects the quality of printed output 1200 dpi 4800 CQ default Toner Darkness L...

Page 167: ...e Black Prints RGB samples using Display True Black color conversion tables Vivid Prints RGB samples using Vivid color conversion tables Off RGB No color conversion is implemented US CMYK Prints CMYK...

Page 168: ...ting Color adjustment can be manually started by this operation No selections exist for this operation Pressing initiates this operation Enhance Fine Lines A selection to enable a print mode preferabl...

Page 169: ...Prints a listing of all job statistics stored on the hard disk or clears all statistics on the disk Print Prints all statistics available for the most recent print jobs Clear Deletes all accumulated...

Page 170: ...Use current to print on media currently in the printer Cancel the current job Change src Custom String Change src size Change src type size Check device Connection The specified device is either not f...

Page 171: ...l displays the percent complete of the current phase Wait for the message to clear Enabling Menus Wait for the message to clear Encrypting Disk yyy DO NOT POWER OFF Warning Do not turn the printer off...

Page 172: ...he Busy Waiting Menu Cancel Job Reset Printer Reset Active Bin Check Supply Levels Install duplex Invalid Engine Code Download valid engine code to the printer Note You can download engine code while...

Page 173: ...es Wait for the message to clear Note The only supported file type is PDF Not ready The printer is offline Press to return to normal operation Overflow Bin Full The mailbox s designated overflow bin i...

Page 174: ...emove the paper from all output bins Remove paper from linked set bin name The printer automatically senses media removal and resumes printing If removing the media does not clear the message press Re...

Page 175: ...orted Remove the USB device to clear the message USB drive removed Wait for the message to clear Insert the USB drive USB hub unsupported Remove the USB device to clear the message View supplies Displ...

Page 176: ...ustomer should install additional memory or set each link buffer to Auto Once all link buffers are returned to Auto you should exit the menu to activate the link buffer changes Once the printer return...

Page 177: ...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 can be taken Determine how to make more memory...

Page 178: ...nformatted flash detected Press to clear the message and continue printing You must format the flash memory before you can store any resources on it If the error message remains the flash memory may b...

Page 179: ...cross a serial port but the port is disabled Note Once the error is displayed the first time reporting of further errors is suppressed until the printer is reset or menus are entered The following act...

Page 180: ...is connected when it is not supported C770 More than one duplex unit is installed More than one option tray 500 sheet tray envelope feeder or outdoor media tray are connected above the HCIT The duplex...

Page 181: ...clock position Undue pressure is not required to operate the lever Turn the printer off insert the ITU move the lever to the 6 o clock position and turn the printer back on If this does not resolve re...

Page 182: ...2 138 Service Manual 5061...

Page 183: ...Remove the top cover See Top cover assembly removal on page 4 13 2 Remove the outer system board shield See Outer system board shield removal on page 4 69 3 Verify that all the connectors are properl...

Page 184: ...orded Note If an automatic calibration begins 36 Printer Service Required may appear Check the printhead cable connections Press to clear the error If the error code remains the same replace the syste...

Page 185: ...ency of the defect locator chart go to the back of the hard copy service manual Note If you want to copy the chart then the following should be observed Since fax machines digital scanners and xerogra...

Page 186: ...VTB through the access door and once again watch the test pages pass over the VTB 9 When the top half of the second page passes over the VTB quickly open the front cover assembly The printing stops 1...

Page 187: ...inter mounted above the optional HCIT Note During normal operation the red LED on the HCIT system board blinks on for one second and off for one second Dip switch settings Do the following steps to se...

Page 188: ...nd operations used while manufacturing and servicing the printer See Diagnostics mode on page 3 7 for more information Configuration Menu 1 Turn off the printer 2 Press and hold and 3 Turn on the prin...

Page 189: ...N on page 3 10 Top Margin Bottom Margin Left Margin Right Margin Quick Test See Quick Test on page 3 11 ALIGNMENT See ALIGNMENT MENU on page 3 11 Cyan Yellow Magenta Factory Scanner Factory Manual Dri...

Page 190: ...page 3 21 Sensor Test See Sensor Test on page 3 22 Diverter Test See Diverter Test on page 3 22 FINISHER TESTS Staple Test See Staple Test on page 3 23 Feed Test See Finisher Feed Test on page 3 23 S...

Page 191: ...ee EP Defaults on page 3 28 Fuser Temp See Fuser Temp on page 3 28 DC Charge Adjust See DC Charge Adjustment on page 3 28 Dev Bias Adj See Dev Bias Adj on page 3 28 Transfer Adjust See Transfer Adjust...

Page 192: ...age to expand or compress It is easier to adjust the Top and Left margins first then adjust the Bottom and Right 6 Press Select to save the value Submitting Selection appears 7 To verify the margin va...

Page 193: ...ellow and magenta The black image should be aligned using REGISTRATION before the individual colors are aligned Setting alignment for color 1 Select ALIGNMENT MENU from the Diagnostics mode 2 Select C...

Page 194: ...opriate thermistor cyan magenta yellow or black to make sure it is installed correctly to the system board and to the thermistor board If correct go to step b b Check the continuity of the appropriate...

Page 195: ...isplay For example 3 To exit the test press any button Belt Tracking ITU 4th point adjustment This test is used to determine the need for the ITU Shim to correct 4th point alignment following the ITU...

Page 196: ...within the Print Tests menu The content of the test page varies depending on the media installed in the selected input source If a source is selected that contains paper then a page similar to the Qu...

Page 197: ...rom the menu Once the test is started it cannot be canceled When the test pages print the printer returns to the original screen HARDWARE TESTS LCD Test This test verifies the operator panel LCD funct...

Page 198: ...aximum fail count being 99 999 Once the maximum pass count or fail count is reached the test stops the power indicator turns on solid and the final results appear If the test fails SDRAM Error appears...

Page 199: ...However if the test fails one of the following messages appears for approximately three seconds Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Er...

Page 200: ...Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 However if the test fails one of the following failure messages appears for approximatel...

Page 201: ...djustment is necessary the Top Margin in the Registration menu must be adjusted first The Duplex Top Margin Offset may be adjusted next A positive offset moves the text down the page and widens the to...

Page 202: ...eeds one sheet of media from the selected source or Continuous continues to feed from the selected source until Back or Stop is pressed 4 Press Back or Stop to exit test Sensor Test This test can be u...

Page 203: ...TESTS Feed Test Note If the Configure Bins printer setting is link rather than mailbox the printer selects its own internal bin linking regardless of which output bin is selected for the feed test Th...

Page 204: ...s open Open displays 4 To exit the test press Back or Stop Diverter Test Note This test checks the operation of each mailbox output diverter Also if more than one 5 Bin mailbox option is installed the...

Page 205: ...ee To run the Finisher Feed Test select Finisher Feed Test from the menu The printer feeds eight pieces of media to the finisher output bin This test cannot be canceled or terminated once the test has...

Page 206: ...sors on page 5 3 for locations for these sensors See Cartridge contact assembly pin locations cyan magenta and yellow on page 5 4 or Cartridge contact assembly pin locations black on page 5 5 To run t...

Page 207: ...ue with the test press Select If is selected Disk Test Clean BAD 000000 00 is displayed The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 3...

Page 208: ...ed 3 The left most digit blinks indicating it is the first digit to be changed To change the value press or until the desired value is displayed Press Select to move to the next digit The digit blinks...

Page 209: ...h F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs The default standard model Configuration ID is used instead Configuration ID is the only functi...

Page 210: ...ore each of the printer settings contained in the EP Setup menu to their factory default value To restore the EP Setup settings to factory defaults select Restore To exit the menu without restoring th...

Page 211: ...nt Log The history of printer errors can be printed The first page of the event log contains a Printer Information section similar to what is printed on a Menu Setting Page Printed at the top of each...

Page 212: ...the Diagnostics mode 2 Select Yes to clear the Event Log or No to exit the Clear Log menu If Yes is selected the Empty Event Log displays on the screen 3 Press Back or Stop to exit the Clear Log menu...

Page 213: ...mal mode Configuration Menu Reset Fuser Cnt See Reset Fuser Cnt on page 3 32 Black Only Mode See Black Only Mode on page 3 32 Prt Quality Pgs See Prt Quality Pgs on page 3 32 Color Trapping See Color...

Page 214: ...d on A4 Legal or Letter paper 1 Select Prt Quality Pgs from the Config Menu 2 Press Select Go to Print tests on appendix page B 1 for representative samples of the pages Color Trapping Color trapping...

Page 215: ...only available on models with an integrated network adapter In either case Restoring Factory Defaults is displayed after the operation is selected 1 Select Factory Defaults from the Config Menu 2 Sele...

Page 216: ...of the user or the PJL command 1 Select Auto Color Adjust from the Config Menu 2 Select Off or a value from 100 to 1000 The default value is 500 Use to increase the value The values are in increments...

Page 217: ...Settings are Delete and Do Not Delete default Disk Encryption This setting only appears if a hard disk is installed the disk is not read only and Disk Encryption is enabled Warning When the settings a...

Page 218: ...the diagram Access doors and trays on page 3 36 for an overview of the paper path and areas where jams may occur The path varies depending on the paper source and output bins Access doors and trays Th...

Page 219: ...r For instructions see Clearing fuser jams 230 xx Paper Jam duplex area E J Follow the instructions for clearing Area E and Area J 24 x xx Paper Jam trays 1 4 B C T x Follow the instructions for clear...

Page 220: ...sure all printer covers doors and trays are closed and then press to resume printing Note The printer also displays x Pages Jammed Be sure to remove all the jammed pages before pressing Area A 1 If yo...

Page 221: ...e the door Note Open Tray 1 and make sure the entire media stack is pushed all the way down into the tray Area C If you have one or more optional 500 sheet drawers 1 Open the 500 sheet drawer access d...

Page 222: ...door Area D 1 Open the front access door 2 Hold down the front access door Remove jams in the rollers under the image transfer unit Note Any image printed will not be fused to the page Area T1 1 If c...

Page 223: ...lex mechanism in the printer Area T x If you cannot clear all the 500 sheet drawer jams from Area C 1 Carefully open trays 2 through 4 all 500 sheet trays and remove jams Note Make sure the paper is p...

Page 224: ...3 42 Service Manual 5061 Area J 1 Remove the duplex tray J 2 Remove any jams and then reinstall the tray Area K 1 Open the lower right access door 2 Remove any jams and then close the door...

Page 225: ...per right access door 2 Remove jams from the rollers and then close the door Clearing mailbox finisher or output expander jams Area M 1 Open the rear door of the 5 bin mailbox or output expander 2 Pul...

Page 226: ...2 2 Open both the upper right and the lower right access doors Areas K and L 3 Pull down the latches They slide toward the center to release the fuser 4 Pull the fuser out and set it on a clean flat s...

Page 227: ...pull up to refasten them 11 Close the doors Clearing image transfer unit jams 1 Open the front access door and the left access door 2 While holding down the front access door insert a folded piece of...

Page 228: ...n the front cover assembly 5 Remove all the print cartridges a Pull up slightly on the cartridge handhold b Pull the cartridge straight out and use the handle to lift it off the guides c Place the car...

Page 229: ...ostic aids 3 47 5061 6 Release the latches to open the multipurpose feeder area A all the way 7 Remove the image transfer unit a Raise the lever to unlock the image transfer unit b Pull down on the ha...

Page 230: ...urface Warning Do not touch the transfer belt Touching the belt will damage the image transfer unit 8 Look inside the printer Remove all torn paper or other jams 9 Insert the image transfer unit back...

Page 231: ...Diagnostic aids 3 49 5061 b Rotate the handle up and push gently to lock the unit in place c Lower the lever to lock the image transfer unit into place...

Page 232: ...rn the multipurpose feeder to its working position Reinstall all the print cartridges 11 Close the printer door 12 Turn the printer on The printer returns to a Ready state If you still need help Turn...

Page 233: ...ricity 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 ESD...

Page 234: ...connector to shield Attach 2 102 M3 5x8 mm Thread Cutting Cartridge guides to upper frame Attach 8 Upper front cover assembly to cartridge guides Attach 4 Front cover pivot to front upper cover Attach...

Page 235: ...ches to lower right door Mounting 2 Bias latch cover to door Attach 1 MPF asm to MPF door Attach 6 Support bracket to MPF door Attach 4 MPF cable cover to door asm Mounting 1 MPF latch support bracket...

Page 236: ...pper frame redrive Mounting 2 Developer HVPS to cartridge contact asm Mounting 4 BOR drive asm to upper frame Mounting 1 ITU drive asm to lower frame Mounting 3 Fuser drive asm to lower frame Mounting...

Page 237: ...me Mounting 12 Upper door hinges to upper frame redrive Attach 2 Inner redrive assembly to upper frame Mounting 2 Paper level sensing assembly to lower frame Mounting 3 Inner deflector pick assembly t...

Page 238: ...the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printe...

Page 239: ...h overlays 1xx only Operator panel bezel with overlays 2xx only Operator panel bezel with overlays 3xx only or Operator panel bezel with overlays 4xx only on page 7 3 for the part number 1 Open the fr...

Page 240: ...4 8 Service Manual 5061 4 Lift the bezel out and then straight up Note Be careful not to swing the bezel out too far and break off the clips Note Set the lens B aside It is not part of the bezel FRU...

Page 241: ...Repair information 4 9 5061 Lens removal See Clear LCD lens on page 7 3 for the part number 1 Remove the bezel See Operator panel bezel removal on page 4 7 2 Remove the lens A...

Page 242: ...cover rear pivot cover removal See Front cover rear pivot cover on page 7 3 for the part number 1 Remove the bezel See Operator panel bezel removal on page 4 7 2 Remove the four screws A 3 Remove the...

Page 243: ...e front cover remove the front cover backplate and operator panel and reinstall on the new front cover See Front cover or Front cover backplate assembly on page 7 3 for the part numbers 1 Remove the f...

Page 244: ...or panel See Operator panel assembly removal on page 4 68 Note Set aside the operator panel assembly and front cover backplate assembly for reinstallation The operator panel is not part of the front c...

Page 245: ...art number 1 Remove the redrive cap See Redrive cap removal on page 4 12 2 Remove the front right light shield screw See Front right light shield removal on page 4 42 3 Remove the top cover screws A f...

Page 246: ...4 14 Service Manual 5061 6 Remove the top cover mounting screws C from the front of the printer 7 Remove four screws D holding the outer system board shield 8 Remove the shield...

Page 247: ...t the cable from J2 E on the system board 10 Lift the top cover and clip and remove the cable tie F 11 Pull the cable through the inner system board shield 12 Remove the autoconnect cable G from the c...

Page 248: ...rnings Be sure the cables are in the cable retainer A Be sure the cables are not pinched by the top cover ribs against the indicated surfaces B of the printer frame Be sure to replace the cable tie C...

Page 249: ...cover removal See Front lower left cover on page 7 3 for the part numbers 1 Remove the paper tray 2 Open the front cover assembly 3 Open the paper path access door carefully remove screw A type 323 o...

Page 250: ...oor 5 Remove the screw D in the front left handle cover assembly 6 Remove the front lower left cover with the paper path door attached Paper path access door removal See Paper path access door on page...

Page 251: ...ft cover See Front lower left cover removal on page 4 17 2 Remove the three front left handle cover assembly screws A type 323 on page 4 3 and remove the assembly Front lower right cover removal See F...

Page 252: ...t jam access door B if tape is available to help hold the door in place The spring loaded latch is difficult to reassemble Avoid unlatching the left side if you just need access to the right screw 4 R...

Page 253: ...nt right handle cover assembly on page 7 3 for the part number 1 Open the front cover assembly 2 Remove the toner cartridges 3 Remove the four front right handle cover assembly screws A type 323 on pa...

Page 254: ...oval See Rear cover on page 7 5 for the part number 1 Remove the outer system board shield See Outer system board shield removal on page 4 69 2 Press the releases A to open the MPF all the way 3 Loose...

Page 255: ...Repair information 4 23 5061 5 Remove 13 rear cover screws D and E 6 Remove tabs F from slots 7 Remove the rear cover E D D D E E F...

Page 256: ...right cover See Front lower right cover removal on page 4 19 3 Loosen the two screws A 4 Remove the lower right door assembly Left lower cover removal See Left lower cover on page 7 5 for part number...

Page 257: ...for the part number 1 Remove the paper path access door cover See Paper path access door removal on page 4 18 2 Remove the front left handle cover assembly See Front left handle cover assembly remova...

Page 258: ...door removal See Redrive door assembly on page 7 14 for the part number 1 Open the redrive door 2 Loosen the redrive door upper hinge screw A type 324 on page 4 5 3 Lift the redrive door from the hin...

Page 259: ...er 1 Remove the transfer plate assembly See Transfer plate assembly removal on page 4 95 2 Cut the cable tie A and remove the black mylar piece 3 Remove the front lower left cover See Front lower left...

Page 260: ...belt The third screw is located at the rear pivot point for the transfer plate This allows the paper level assembly to drop into the integrated paper drawer b Disconnect the cable from the connector D...

Page 261: ...Repair information 4 29 5061 6 Disconnect the pick motor connector E 7 Remove three screws F holding the pick assembly in place...

Page 262: ...the pick arm to fall to the bottom of the tray 9 Disconnect the spring clip H from the pick arm Be sure not to let the spring come off of the lower frame Also identify which pegs the spring clip is s...

Page 263: ...nter and drop it through the holes located next to the brackets Installation notes 1 Put the new pick assembly into the printer Make sure the pick motor connector is placed through the holes before yo...

Page 264: ...tor pin B 3 Reattach the spring clip to the pick arm Make sure the pick arm rotates freely from top to bottom in the machine 4 Once the pick assembly is in place put the three screws for the pick asse...

Page 265: ...he mylar piece and replace the cable tie Note When you place the mylar piece make sure you place it back under the metal bar C under the inner deflector Make sure that the blue cable running under the...

Page 266: ...e front cover assembly 2 Remove the yellow toner cartridge 3 Remove the front right light shield cover See Front right light shield removal on page 4 42 4 Remove the BOR housing assembly screw A type...

Page 267: ...e printheads 1 Open the front cover assembly 2 Remove the toner cartridges 3 Remove the ITU assembly See ITU assembly removal on page 4 49 4 Remove the top cover assembly See Top cover assembly remova...

Page 268: ...4 36 Service Manual 5061 7 Press the cartridge contact assembly yellow shown retaining tabs B and remove the assembly 8 Remove the screw C from the front of the printhead B C...

Page 269: ...Repair information 4 37 5061 9 Remove the screws D for the contact assembly you are removing Installation note Be sure to replace all the cable ties D...

Page 270: ...hield removal on page 4 48 2 Remove the cartridge drive assembly mounting screws A Black is shown 3 Disconnect the cable B from the cartridge drive assembly 4 Note the location of the cable ties C and...

Page 271: ...e 323 on page 4 3 and four bottom screws B type 121 on page 4 2 from the developer HVPS board 5 Remove the developer HVPS boards Installation notes Be sure to replace all the cable ties Install the la...

Page 272: ...ler and buckler housing on page 7 19 for the part number 1 Open the MPF and press the releases A to open the MPF to the lowest position 2 Remove the MPF cable cover screw B 3 Release the MPF latch C a...

Page 273: ...4 Use needlenose pliers to remove the buckler housing D Installation notes 1 Before installation insert the friction buckler into the buckler housing The tab E on the side should be aligned with the n...

Page 274: ...ush with the edge Place the housing between the two sets of slots in the printer and then slide the housing into position Front right light shield removal See Front right light shield on page 7 3 for...

Page 275: ...Repair information 4 43 5061 3 Unlatch the alignment stud C 4 Remove the front right light shield...

Page 276: ...on page 7 7 for the part numbers 1 Turn the printer off Note The printer shouldbe powered down prior to removal and or replacement of the fuser 2 Open the lower right door assembly and redrive door C...

Page 277: ...Reset Fuser counter in the Configuration Menu 1 Enter the Configuration Menu Turn off the printer turn on the printer while holding and release the buttons after about 10 seconds or when the clock fac...

Page 278: ...47 3 Remove the redrive belt cover duct A 4 Remove fuser left duct B 5 Remove fuser bottom duct Fuser drive assembly removal See Fuser drive assembly on page 7 10 for the part number 1 Remove the fus...

Page 279: ...age 4 22 2 Disconnect the fuser fan cable from connector JM1 A on the system board 3 Remove the fuser fan screws B and remove the fan Fuser top duct removal See Fuser top duct on page 7 5 for the part...

Page 280: ...ve the rear cover See Rear cover removal on page 4 22 3 Remove the transfer HVPS board See Transfer HVPS board removal on page 4 92 4 Remove the system board See System board removal on page 4 90 5 Re...

Page 281: ...1 ITU assembly removal See ITU assembly 1xx 3xx only on page 7 22 for the part number 1 Open the front cover assembly 2 Remove the toner cartridges 3 Open the MPF and press the releases A to open the...

Page 282: ...4 50 Service Manual 5061 4 Raise the ITU release lever B 5 Slide the ITU assembly from the printer...

Page 283: ...d closest to front 7 Slide the left side to the side to disengage from the gear and allow clearance to remove the roll Installation notes 1 Replace the second transfer roll 2 Be sure to replace the IT...

Page 284: ...ive assembly removal on page 4 38 3 Disconnect the ITU drive coupling cable A 4 Cut the two cable ties B 5 Disconnect the ITU drive motor cable C 6 Remove the three ITU drive assembly mounting screws...

Page 285: ...he geographic area you are in 1 Remove the fuser drive assembly See Fuser drive assembly removal on page 4 46 2 Remove the rear cover See Rear cover removal on page 4 22 3 Disconnect the J17 and J18 c...

Page 286: ...4 54 Service Manual 5061 6 Remove the screw C type 121 on page 4 2 from the top of the LVPS and remove the LVPS from the printer...

Page 287: ...conds or until the clock face appears 2 Print the Quick Test Page if possible Retain this sheet to verify the installation a Select REGISTRATION b Press Select to print the page 3 Turn the printer off...

Page 288: ...w C from the media size sensing assembly 8 Gently twist and remove the media size sensing assembly As shown the assembly touches at the spring D the fingers E the bottom F and the right side G This al...

Page 289: ...igning hole Be careful with the exposed fingers Do not allow them to press against the black plastic frame 3 Gently wiggle the entire assembly and press in and around the corner to the right 4 Grasp t...

Page 290: ...sembly Also order cable tie parts packet P N 40X1648 on page 7 16 for the part number 1 Remove the rear cover See Rear cover removal on page 4 22 2 Disconnect the cables A 3 Remove the media size sens...

Page 291: ...4 59 5061 Multipurpose feeder MPF removal See Multipurpose feeder MPF on page 7 19 for the part numbers 1 Open the MPF and press the releases A to open the MPF to the lowest position 2 Remove the MPF...

Page 292: ...anual 5061 3 Remove the three screws C that secure the MPF inner cover 4 Press the latches D to release the MPF switch cable from the MPF sensor and disconnect the cable 5 Remove the cable from the ca...

Page 293: ...Repair information 4 61 5061 6 Release the MPF latch F and remove the MPF...

Page 294: ...F autocompensator or side restraints removal See MPF autocompensator pick assembly or MPF side restraint on page 7 19 for the part numbers 1 Remove the MPF See Multipurpose feeder MPF removal on page...

Page 295: ...Repair information 4 63 5061 4 Unhook the autocompensator spring C 5 Rotate the shaft up and out of the MPF assembly...

Page 296: ...n page 4 59 2 Remove the MPF autocompensators 1 and 2 See Multipurpose feeder MPF autocompensator or side restraints removal on page 4 62 3 Remove the four screws A to secure the MPF inner cover 4 Dis...

Page 297: ...andle See Left lower cover removal on page 4 24 2 Remove waste toner container 3 Reinsert paper tray into printer 4 Remove the broken pieces of old handle a Pull up the upper piece of handle to raise...

Page 298: ...y the nip relief lever B toward the rear of the printer and insert lower portion of the handle so that it is between the nip relief lever and the reference edge plate C 3 Holding the handle in place u...

Page 299: ...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 I...

Page 300: ...cover and front cover backplate assembly See Front cover or front cover backplate assembly removal on page 4 11 2 Remove the four screws A attaching the operator panel to the front cover 3 Remove the...

Page 301: ...Repair information 4 69 5061 Outer system board shield removal See System board outer shield on page 7 33 for the part number 1 Remove four screws A 2 Remove outer system board shield...

Page 302: ...ll the pick assembly down into the bottom pan and remove the screw Note Do not attempt to remove either the shaft or the clutch races Installation notes for the front roll When you replace the front r...

Page 303: ...Reach around and depress the latch A on the end of the shaft and remove the roll Installation note for the rear roll When replacing both the front and back rolls note the directional markings on the r...

Page 304: ...ing 1 Reach through the lower jam access door opening and lift and hold the pick assembly in the proper position 2 Press the autocompensator release lever B to engage the spring Note A piece of paper...

Page 305: ...lor printhead electronic alignment on page 4 79 Do not loosen or replace more than one printhead at a time to retain factory settings The printhead alignment assemblies must be removed once the mechan...

Page 306: ...remove 4 Align the printhead alignment assembly locating pin A with the hole in the printer frame and the attachment screw B with the screw hole shown without the printhead for clarity The adjustment...

Page 307: ...selected printhead 6 Screw the printhead alignment assembly to the printer frame 7 Finger tighten the adjustment screw until the end of the screw is pressing firmly against the mounting beam 8 Disconn...

Page 308: ...assemblies in place Note Untwist the printhead motor cables before placing the printhead assembly into the printer 12 Install the new printhead assembly reconnect the printhead motor cable into the s...

Page 309: ...used to determine the printhead alignment This page contains information for black K magenta M cyan C and yellow Y printheads c Look at the line pertaining to the color of printhead you are replacing...

Page 310: ...agnostic Menu 2 Select Quick Test 3 Set the top bottom left and right margin in that order The margins are set when the tip of the triangle touches the edge of the page The print registration range is...

Page 311: ...until A is within 1 from B then go to step 2 5 Adjust the Step 2 settings Follow Step 2 of the instructions on the Test pages The goal is to change the value until the Test page shows A and B are wit...

Page 312: ...arts packet including the rear transfer bellcranks for yellow cyan and magenta 1 Power off the printer 2 Remove the four toner cartridges and leave the front door open 3 Remove the ITU assembly See IT...

Page 313: ...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 Prin...

Page 314: ...ff 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 49 4 Check each of the rear bellcranks for cracks or breaka...

Page 315: ...emoval Note Test the color coverage by running the Print Quality Pages in the Diagnostics or Configuration Menu Redrive assembly removal See Redrive assembly on page 7 14 for the part number 1 Remove...

Page 316: ...otch in the redrive assembly with tab C Registration motor removal See page 7 17 for the part number for the registration motor assembly kit 1 Remove the inner system board shield See Inner system boa...

Page 317: ...on page 7 19 for the part number 1 Open the MPF and press the releases A to open the MPF to the lowest position 2 Remove the MPF cable cover screw B 3 Release the MPF latch C and lower the MFP door d...

Page 318: ...e the rib housing D that requires replacement Installation note The end of the rib housing that goes into the printer first has tabs flush with the edge Place the housing between the two sets of slots...

Page 319: ...mm on page 7 35 for the part number 1 Remove the rear cover See Rear cover removal on page 4 22 2 Disconnect the rip fan cable from the system board at connector J3 3 Remove the front rip fan screw A...

Page 320: ...ares with the sensor cable assembly through the frame 4 Route the new cable connector through the rectangular opening in the upper frame and out through the opening in the lower frame Note Guiding the...

Page 321: ...ee S2 XPAR NMS MPF cable assembly with sensors on page 7 37 for the part number 1 Remove the rear cover See Rear cover removal on page 4 22 2 Open the MPF and press the releases A to open the MPF to t...

Page 322: ...mponent listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the p...

Page 323: ...re fully connected Replace all cable ties To verify the input sources are recognized 1 On the operator panel at the Ready prompt select Paper Menu 2 Select Paper Source 3 Make sure all installed optio...

Page 324: ...061 Transfer HVPS board removal See Transfer HVPS board on page 7 34 for the part number 1 Remove the rear cover See Rear cover removal on page 4 22 2 Remove screw A and the two screws B on the bottom...

Page 325: ...Repair information 4 93 5061 3 Remove all connectors C 4 Remove the transfer HVPS board...

Page 326: ...y HVPS on page 5 20 When installing the transfer HVPS board route the cable to the HVPS input connector at CN1 C over the cable to the yellow transfer contact D under the cable to the magenta transfer...

Page 327: ...art number 1 Remove the ITU assembly See ITU assembly removal on page 4 49 2 Remove tray 1 3 Lifting and rotate the right edge of the transfer plate up to a 45 angle to release the transfer plate 4 Re...

Page 328: ...t number 1 Remove the transfer plate assembly See Transfer plate assembly removal on page 4 95 2 Remove the fuser bottom duct See Fuser bottom duct removal on page 4 46 3 Remove the two front screws A...

Page 329: ...4 97 5061 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 an...

Page 330: ...Remove the rear cover See Rear cover removal on page 4 22 2 Disconnect VTB fan from the system board 3 Remove VTB fan with a flatblade screwdriver Waste container door removal See Waste container doo...

Page 331: ...tch Also order cable tie parts packet P N 40X1648 on page 7 26 for the part number 1 Remove the media size sensing assembly See Media size sensing assembly removal on page 4 55 2 Use a flatblade screw...

Page 332: ...e two fuser latches A 4 Remove the fuser assembly 5 Open the front cover assembly 6 Remove the yellow print cartridge 7 Remove the front light shield See Front right light shield removal on page 4 42...

Page 333: ...Repair information 4 101 5061 9 Remove screw B from the top front support bracket Swing bracket to the right 10 Remove the two screws C securing the web oiler motor assembly B C...

Page 334: ...al 5061 11 Remove the web oiler fuser motor assembly Note To reinstall the web oiler fuser motor assembly use the alignment pins D to position the assembly in holes E 12 Remove the four screws F secur...

Page 335: ...assembly in holes B and install the assembly 2 Secure the web oiler motor assembly with screws C 3 Install the web oiler card using screws 4 Plug web oiler cable D into web oiler card connector Note M...

Page 336: ...4 104 Service Manual 5061 5 Plug web oiler drive assembly cable into cable connector E 6 Reinstall paper path access door 7 Align tabs on the front right light shield with the slots F on the frame...

Page 337: ...t light shield up until alignment stud G and the screw hole H are aligned 9 Attach the new web oiler fuser housing J to new web oiler fuser 10 Insert the web oiler fuser assembly into the fuser assemb...

Page 338: ...4 106 Service Manual 5061...

Page 339: ...Connector locations 5 1 5061 5 Connector locations Locations Printer boards...

Page 340: ...5 2 Service Manual 5061 Printer motors...

Page 341: ...Connector locations 5 3 5061 Printer sensors...

Page 342: ...5 4 Service Manual 5061 Cartridge contact assembly pin locations cyan magenta and yellow...

Page 343: ...Connector locations 5 5 5061 Cartridge contact assembly pin locations black...

Page 344: ...5 6 Service Manual 5061 System board cabling reference Refer to the System board wiring diagrams for additional details...

Page 345: ...Connector locations 5 7 5061 Connectors System board...

Page 346: ...ULL_IN J2 BOR lift motor 1 LIFT_OUT 24 V dc in standby 2 LIFT_OUT 24 V dc in standby J4 Operator panel USB 1 VBUS 2 D 3 D 4 Ground J6 Developer HVPS 1 CART_METER_K_IN 2 K_AC_BIAS_ENABLE active low 3 S...

Page 347: ...N C 14 BELT_HOLE 2 15 5V_SWITCHED J10 S2 narrow media prism MPF sensor 1 Ground 2 5V dc S2 switched 3 NARROW_MEDIA_IN 4 PAPERPATH_S2_IN 5 5 V dc NM switched 6 Ground 7 Ground 8 5 V dc PRISM switched 9...

Page 348: ...D 16 N C J14 Cover open switch 24V dc switched 1 24V To Cover Open Switch 2 24V dc Switched J15 Fuser stepper motor yellow BLDC motor 1 Y_ON_OUT 2 FUSER_ON_OUT Fuser current I0 3 5V dc Through fuse F8...

Page 349: ...Ground 10 Ground 11 K_CLK_OUT 12 ITU_CLK_OUT 13 K_HALL_IN 14 ITU_HALL_IN 15 N C 16 N C J17 Fuser interface 1 EXIT_SENSOR_IN 2 FUSER_CAM_1_IN 3 Ground 4 OILER_ENC_A_IN 5 OILER_ENC_B_IN 6 HR_THERM_IN ho...

Page 350: ...13 Ground 14 Ground 15 Ground 16 Ground J19 Magenta cyan BLDC motors 1 M_ON_OUT 2 C_ON_OUT 3 5V dc Through fuse F8 4 5V dc Through fuse F8 5 M_DIR_OUT 6 C_DIR_OUT 7 24V_M_AND_C Through fuse F5 8 24V_...

Page 351: ...10 N C 11 Ground 12 WASTE_BTL_PRES 13 TRAY_SIZE_3 14 Ground 15 TRAY_SIZE_2 16 TRAY_SIZE_1 17 Ground 18 3 3 V dc Through fuse F13 19 MEM_DATA I C Data to Media Size Card 20 MEM_CLK I C Clock to Media...

Page 352: ...und 13 C_LADJ 14 Y_LPWM 15 Ground 16 5 V dc through fuse F12 and safety switches at J10 17 C_LENA 18 Ground 19 C_THERMISTOR 20 Y_DATA 21 Ground 22 Y_DATA JHD1 Optional hard disk drive JM1 Fuser fan 1...

Page 353: ...K_LPWM 10 M_LADJ 11 Ground 12 Ground 13 K_LADJ 14 M_LPWM 15 Ground 16 5 V dc through fuse F12 and safety switches at J10 17 K_LENA 18 Ground 19 K_THERMISTOR 20 M_DATA 21 Ground 22 M_DATA JMMC1 Printhe...

Page 354: ...motor 1 FUSE24V 2 Ground 3 Ground 4 V_V5FUSE 5 M_MMSTART 6 M_HSYN S0S 7 M_MMLOCK 8 Ground 9 M_MMREF 10 N C JMPF1 MPF motor and sensor 1 5 V dc 2 MPF Enc 3 Ground 4 MPF_Mtr 5 MPF_Mtr 6 Ground 7 5 V dc...

Page 355: ...d 9 AUTOCOMP_OUT1 24 V dc in standby 10 AUTOCOMP_OUT2 24 V dc in standby JUSB1 USB port G1 Ground 1 USB 5 V dc 2 USB D 3 USB D 4 Ground G2 Ground JWEB1 Web oiler motor 1 5 V dc through fuse F8 2 OILER...

Page 356: ...rvice Manual 5061 Autoconnect top Connector Pin no Color Signal CN1 Autoconnect top 1 White 24 V dc 2 Black Ground 3 Yellow Printer RXD 4 Black Ground 5 N A NC 6 Red 5 V dc 7 Black Ground 8 Blue Print...

Page 357: ...5 19 5061 Autoconnect bottom Connector Pin no Signal Signal CN1 Autoconnect bottom 1 White 24 V dc 2 Black Ground 3 Yellow Printer RXD 4 Black Ground 5 Brown STAGING_ENCODER 6 Red 5 V dc 7 Black Groun...

Page 358: ...5 20 Service Manual 5061 Transfer high voltage power supply HVPS...

Page 359: ...Txenable T102 Transformer HV Terminal I ITU 1 HV Transformer output to 2nd Transfer Roll Cable T201 Transformer HV Terminal K Black 1 HV Transformer Output Terminal to Black Transfer Cable T301 Trans...

Page 360: ...1 Developer HVPS Input 1 24 V dc Return 2 24 V dc 3 Y Ctsense 4 Y Devpwm 5 Y TnrSense 6 C Devpwm 7 C CtSense 8 M Devpwm 9 C TnrSense 10 CYM Acenable 11 M CtSense 12 CYM Chgpwm 13 M TnrSense 14 K Chgpw...

Page 361: ...V dc 3 5 V dc 4 5 V dc 5 24 V dc 6 24 V dc 7 24 V dc 8 3 3 V dc Sense 9 Ground 10 Ground 11 Ground 12 Ground 13 Ground 14 Ground 15 Ground 16 Ground LVPS to system board cable for fuser J17 1 FusExit...

Page 362: ...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 BURT...

Page 363: ...sensing board Connector Pin Signal J1 1 3 3V dc 2 EPROM Data 3 Ground 4 EPROM Clock J2 1 J3 1 Waste BTL Full 2 Ground 3 Waste BTL PRESENT SW4 4 Tray Size 1 SW3 5 Ground 6 Tray Size 2 SW2 7 Tray Size...

Page 364: ...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 C...

Page 365: ...c 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 dc...

Page 366: ...din 2 Ground 3 prtrxd 4 Ground 5 Ground J2 Feed motor 1 fdmtr1 2 fdmtr2 3 Ground 4 Ground 5 tachft 6 5Vptt J3 Stepper motor 1 stpmtr 2 stpmtr 3 stpmtr 4 stpmtr 5 crtprsnt 6 stplow 7 stpphomo 8 Ground...

Page 367: ...mpty sensor 1 Ground 2 bnempty 3 5Vsnsr2 J10 Left side sensor board 1 Ground 2 full 3 NRFull 4 Ground J12 Pass thru sensor 1 Ground 2 psthruint 3 5Vptt J13 Cover open switch 1 5V dc 2 Ground 3 cvropin...

Page 368: ...5 30 Service Manual 5061...

Page 369: ...els indicating the fuser assembly needs to be replaced to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 83 ITU...

Page 370: ...no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Use Nyogel type 774 to lubricate the Fuser Drive Assembly and Nyogel 744 to lubricate the ITU and...

Page 371: ...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 372: ...6 4 Service Manual 5061...

Page 373: ...kit or pkg refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illu...

Page 374: ...7 2 Service Manual 5061 Assembly 1 Covers 3 2 4 1 10 10 5 37 34 35 36 7 5 9 6 8 26 27 29 31 32 30 25 11 8 10 8 5 10 8 8 33 28 12 17 14 10 18 24 22 23 19 15 21 13 16 20...

Page 375: ...40X1636 4 1 Rear hold down spring 18 40X1610 4 1 Front hold down bellcrank 19 40X1609 1 1 Detent link 20 40X1623 1 1 Front access door handle 21 40X1614 1 1 Front cover 22 40X1626 1 1 Operator panel...

Page 376: ...7 4 Service Manual 5061 Assembly 1 1 Covers 3 7 2 2 2 10 6 4 8 1 2 5 2 2 2 2 2 13 14 2 12 BACK 15 9 11 18 20 16 17 FRONT 12 19...

Page 377: ...8 40X1654 1 1 Left lower cover 9 40X1656 1 1 Waste container door 10 40X1647 1 1 Ground cable 11 40X1644 1 1 Rear cover 12 40X1643 2 2 Fuser latch slide 13 40X1645 2 2 Fuser latch slide spring 14 40X1...

Page 378: ...61 Assembly 2 Cartridge mounting Asm Index Part number Units mach Units FRU Description 2 1 40X1663 4 1 Guide assembly left side 2 40X1664 4 1 Guide assembly right side 3 12 8 Screw type 102 parts pac...

Page 379: ...3 1 40X1666 1 1 Fuser assembly 220 V 500W 1xx 3xx 1 40X1832 1 1 Fuser assembly 220 V 500W 2xx 4xx 1 40X1651 1 1 Fuser assembly 115 V 500W 1xx 3xx 1 40X1831 1 1 Fuser assembly 115 V 500W 2xx 4xx 1 40X1...

Page 380: ...7 8 Service Manual 5061 Assembly 3 1 Fuser web oiler 1 3 2...

Page 381: ...5061 Assembly 3 1 Fuser web oiler Asm Index Part number Units mach Units FRU Description 3 1 1 40X1674 1 1 Web oiler assembly 2 40X1670 1 1 Web oiler driver board assembly 3 40X1669 1 1 Web oiler ind...

Page 382: ...7 10 Service Manual 5061 Assembly 4 Fuser drive Asm Index Part number Units mach Units FRU Description 4 1 4 1 Screws type 323 parts packet 40X1633 2 40X1661 1 1 Fuser drive assembly 2 1...

Page 383: ...s catalog 7 11 5061 Assembly 5 Vacuum transport belt VTB assembly Asm Index Part number Units mach Units FRU Description 5 1 40X1660 1 1 Jam access spring 2 40X1677 1 1 Vacuum transport belt assembly...

Page 384: ...7 12 Service Manual 5061 Assembly 6 Transfer Asm Index Part number Units mach Units FRU Description 6 1 40X1678 1 1 Second transfer roll 2 40X1679 1 1 Transfer plate assembly 2 1...

Page 385: ...ds Asm Index Part number Units mach Units FRU Description 7 1 40X1778 4 1 Printhead assembly do not replace more than one printhead at a time Also order cable tie parts packet P N 40X1648 2 12 12 Scre...

Page 386: ...e 2 40X1685 2 2 Upper door hinge 3 2 2 Screw type 312 322 412 423 parts packet 40X1691 4 40X1689 1 1 Redrive belt 300 T 5 40X1684 1 1 Redrive assembly 6 40X1690 1 1 Redrive door assembly 7 40X1687 1 1...

Page 387: ...Parts catalog 7 15 5061 Assembly 9 Paper feed input Asm Index Part number Units mach Units FRU Description 9 1 40X1692 1 1 S2 XPAR NMS MPF cable assembly with sensors 1...

Page 388: ...Media size sensing bracket Also order cable tie parts packet P N 40X1648 3 40X1697 4 4 Media size sensing spring Also order cable tie parts packet P N 40X1648 4 4 4 Screw type 232 parts packet 40X1676...

Page 389: ...0X1701 1 1 Nip relief handle Also order cable tie parts packet P N 40X1648 2 40X1702 1 1 Registration motor assembly kit including also order cable tie parts packet P N 40X1648 Staging motor assembly...

Page 390: ...7 18 Service Manual 5061 Assembly 12 Multipurpose feeder MPF 3 7 5 2 6 4 16 17 14 11 1 13 8 9 10 10 11 9 12 5 5 5 5 19 15 5 20 18...

Page 391: ...1 1 MPF paper out flag 8 40X1852 1 1 Paper out sensor MPF 9 40X1715 2 2 MPF support bracket cover 10 40X1707 2 2 MPF support bracket spring 11 40X1717 2 1 MPF support bracket 12 40X1713 1 1 Frame bias...

Page 392: ...et tray assembly 2 40X1720 1 1 Back restraint latch 3 40X1719 1 1 Back restraint 4 40X1723 1 1 Tray bias bellcrank assembly 5 1 1 Screw type 312 322 412 423 parts packet 40X1691 6 40X1725 1 1 Tray bia...

Page 393: ...ank 3 40X1724 1 1 Pick assembly 500 tray 4 40X1734 1 1 Bellcrank lift spring 5 40X1732 1 1 Paper level sensing assembly 6 40X1731 1 1 Tray interlock bracket 7 40X1729 1 1 Sensor paper out low 8 1 1 Sc...

Page 394: ...ndex Part number Units mach Units FRU Description 15 1 40X1739 1 1 ITU light shield assembly 2 40X0342 1 1 ITU assembly 1xx 3xx only 2 40X0343 1 1 ITU assembly 2xx 4xx only 3 40X1678 1 1 Second transf...

Page 395: ...number Units mach Units FRU Description 1 40X1823 1 1 ITU drive assembly Also order cable tie parts packet P N 40X1648 2 40X1742 1 1 58 gear Also order cable tie parts packet P N 40X1648 3 3 3 Screw...

Page 396: ...7 24 Service Manual 5061 Assembly 17 ITU loading 3 3 3 3 2 2 2 2 1 4 4 4 4 5 4 4 4 4 11 10 12 7 8 9 13 6 14 15 15 16 17 16 5...

Page 397: ...loading 1xx 3xx magenta including Magenta BOR spring Rear V block guide Rear transfer bellcrank Front V block guide Front transfer bellcrank High voltage contact spring 7 40X1849 1 1 Parts packet ITU...

Page 398: ...art number Units mach Units FRU Description 18 1 40X1756 1 1 Waste toner container 2 40X1755 1 1 Waste container latch spring Also order cable tie parts packet P N 40X1648 3 40X1754 1 1 Waste containe...

Page 399: ...Parts catalog 7 27 5061 Assembly 19 BOR drive assembly Asm Index Part number Units mach Units FRU Description 19 1 40X1758 1 1 Lift BOR assembly 1...

Page 400: ...h Units FRU Description 20 1 40X1762 4 1 Cartridge contact assembly complete Also order cable tie parts packet P N 40X1648 2 40X1636 4 1 Rear hold down spring Also order cable tie parts packet P N 40X...

Page 401: ...rive assembly Asm Index Part number Units mach Units FRU Description 1 40X1824 4 1 Cartridge drive assembly one drive assembly per package Also order cable tie parts packet P N 40X1648 2 12 12 Screw t...

Page 402: ...7 30 Service Manual 5061 Assembly 22 Electronics 3 3 3 2 1...

Page 403: ...ntina 1 40X0301 1 1 Power cord set 8 ft straight Australia 1 40X1766 1 1 Power cord set 8 ft straight Bolivia Peru 1 40X1773 1 1 Power cord set 8 ft straight Botswana Lesotho Namibia South Africa 1 40...

Page 404: ...7 32 Service Manual 5061 Assembly 22 1 Electronics 3 5 4 8 1 9 10 2 2 6 6 6 7 6 6...

Page 405: ...t with clips 6 20 20 Screw type 232 parts packet 40X1676 7 40X1775 1 1 System board network 1xx 3xx only Also order cable tie parts packet P N 40X1648 7 40X1817 1 1 System board network 2xx 4xx only A...

Page 406: ...board to frame 3 1 1 Screw type 324 parts packet 40X1635 TFR HVPS board to frame 4 40X1794 3 3 Standoff high voltage power supply developer board 5 8 8 Screw type 121 parts packet 40X1780 6 40X1795 1...

Page 407: ...Units FRU Description 22 3 1 40X1800 1 1 VTB fan 60 mm 2 40X1796 1 1 VTB fan gap cover 3 40X1798 1 1 Fuser fan assembly 4 2 2 Screws parts packet 40X1797 fuser fan mounting 5 40X1799 1 1 RIP fan 92 mm...

Page 408: ...7 36 Service Manual 5061 Assembly 23 Electronics cabling interconnections 1...

Page 409: ...assembly 11 40X1828 1 1 Printhead assembly magenta mirror motor attached to magenta printhead 12 40X1805 1 1 Laser cable black magenta 13 40X1828 1 1 Printhead assembly black mirror motor attached to...

Page 410: ...7 38 Service Manual 5061 Assembly 24 Electronics cabling interconnections 2...

Page 411: ...Units FRU Description 24 1 40X1753 1 1 Black terminal contact assembly 2 40X1759 1 1 Cyan terminal contact assembly 3 40X1761 1 1 Yellow terminal contact assembly 4 40X1757 1 1 Magenta terminal conta...

Page 412: ...Manual 5061 Assembly 25 Electronics cabling interconnections 3 Asm Index Part number Units mach Units FRU Description 25 1 40X1810 1 1 HVPS control cable developer 2 40X1762 4 1 Cartridge contact asse...

Page 413: ...7 41 5061 Assembly 26 Electronics cabling interconnections 4 Asm Index Part number Units mach Units FRU Description 26 1 40X1811 1 1 Options bottom media size sensing cable assembly 2 40X1823 1 1 ITU...

Page 414: ...7 42 Service Manual 5061 Assembly 27 Output expander 3 11 7 5 9 10 6 4 8 13 18 16 15 17 12 14 19 20 21 1 22 2 23 24...

Page 415: ...packet 40X2011 8 40X1982 1 1 Output option card shield 9 40X2013 1 1 Output expander DC motor board 10 40X1984 1 1 Front control board cover 11 40X1992 1 1 Output expander tray 12 40X2014 1 1 Diverter...

Page 416: ...7 44 Service Manual 5061 Assembly 27 1 Output expander 3 3 11 7 13 5 5 9 2 10 6 4 12 8 1 15 14 14 14...

Page 417: ...attach bracket 5 4 4 Screw parts packet 40X1813 6 40X1985 1 1 Front cover 7 40X2002 1 1 160 gear belt 8 40X2003 1 1 Belt idler arm assembly 9 40X2005 1 1 Belt tensioner spring 10 40X2010 1 1 Output t...

Page 418: ...7 46 Service Manual 5061 Assembly 28 5 Bin mailbox 11 7 13 5 9 12 8 23 28 21 31 26 24 29 22 32 27 25 30 10 33 1 2 4 34 3 3 6 8 10 35 18 16 15 17 14 19 20...

Page 419: ...p tray 15 40X2043 1 1 5 bin mailbox assembly kit 16 40X2027 1 1 Bail attach bracket assembly 17 1 1 Bail order P N 40X2043 5 bin mailbox assembly kit 18 40X2035 5 1 Paper tray support 19 40X2042 5 1 P...

Page 420: ...7 48 Service Manual 5061 Assembly 28 1 5 Bin mailbox 3 3 3 3 11 7 13 5 9 2 10 6 4 12 8 14 1 15...

Page 421: ...ator cam 5 40X2060 4 1 Diverter actuator spring 6 40X2058 4 1 Diverter actuator latch 7 40X2059 4 1 Diverter actuator arbor 8 40X2069 4 1 C clip retainer 9 40X2021 1 1 Attach front bracket 10 40X2061...

Page 422: ...7 50 Service Manual 5061 Assembly 29 500 Sheet drawer option 3 11 7 5 9 2 10 6 4 8 1...

Page 423: ...on complete 2 40X1728 1 1 500 Sheet tray assembly 3 40X1720 1 1 Back restraint latch 4 40X1719 1 1 Back restraint 5 40X1723 1 1 Tray bias bellcrank assembly 6 1 1 Screw type 312 322 412 423 parts pack...

Page 424: ...7 52 Service Manual 5061 Assembly 29 1 500 Sheet drawer option 3 11 7 13 17 15 9 2 2 2 2 2 2 2 2 2 2 2 2 2 10 16 4 12 8 14 18 1 19 20 21 5 6 16 16 16 22 23...

Page 425: ...me cover 8 40X1730 1 1 Tray interlock bellcrank 9 40X1891 1 1 Pass thru sensor 10 40X1896 1 1 Hinge 11 40X1894 1 1 Electronics size sensing assembly with system board 12 40X1741 1 1 Pick arm lift bell...

Page 426: ...7 54 Service Manual 5061 Assembly 30 Duplex option 2 3 5 6 4 8 7 9 11 10 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 16 29 15 1 5 5 5 5 5 5 5 5 5 3 3 3 30 16 16 16...

Page 427: ...ket 11 40X1964 1 1 Sensor mount plate 12 40X1927 1 1 Duplex exit sensor 13 40X1924 1 1 Duplex shaft mount 14 40X1954 1 1 Front decurl assembly 15 40X1979 1 1 F R backup shaft assembly 16 40X1951 1 1 5...

Page 428: ...7 56 Service Manual 5061 Assembly 30 1 Duplex option 1 2 3 4 7 5 5 5 5 5 20 6 13 12 10 14 6 8 14 16 19 9 12 13 15 17 18 21 11 11...

Page 429: ...ck 7 40X1937 1 1 Back support 8 40X1922 1 1 Duplex card assembly 9 40X1958 1 1 Transfer belt 10 40X1960 1 1 Right jam clearance tray assembly 11 40X1969 1 1 C clip retainer 12 40X1953 2 1 Aligner spri...

Page 430: ...7 58 Service Manual 5061 Assembly 31 High capacity input tray HCIT 1 2 3 4 5 6 7 8 30 31 29 28 28 28 28 28 27 27 26 25 24 6 6 6 9 9 21 22 22 23 32 33 9 36 34 37 35 11 10 12 9 9 13 15 14 16 17 18 19 20...

Page 431: ...15 40X2115 1 1 Paper tray guide 16 40X2134 1 1 Elevator lift belt 17 40X2136 1 1 Elevator lift 18 40X2139 3 1 Ring 7 elevator lift gear elevator lift 19 40X2135 1 1 Elevator lift gear 20 40X2114 2 1 P...

Page 432: ...7 60 Service Manual 5061 Assembly 31 1 High capacity input tray HCIT 1 2 6 3 7 11 8 8 4 4 5 5 3 9 10 12 4 4 4 4 13 14...

Page 433: ...1 Caster fixed 9 40X2144 1 1 Left side cover 10 40X2146 1 1 Upper left side jam cover 11 40X2100 1 1 Locating pin options front right 12 40X2099 1 1 Locating pin options rear left 13 40X2106 1 1 Optio...

Page 434: ...40X2155 1 1 Jam access door 4 40X2156 1 1 Front door latch 5 40X2157 1 1 Access door rear latch 6 40X2152 1 1 Front assembly cover 7 40X2153 1 1 Stapler access cover 8 40X3274 1 1 Stapler access door...

Page 435: ...Parts catalog 7 63 5061 Assembly 32 1 StapleSmart finisher Asm Index Part number Units option Units FRU Description 32 1 1 40X3278 1 1 Stapler assembly 1...

Page 436: ...Service Manual 5061 Assembly 32 2 StapleSmart finisher Asm Index Part number Units option Units FRU Description 32 2 1 40X3279 1 1 Switch assembly safety cover open 2 99A0104 1 1 Spring upper diverter...

Page 437: ...Parts catalog 7 65 5061 Assembly 32 3 StapleSmart finisher Asm Index Part number Units option Units FRU Description 32 3 1 99A2480 1 1 StapleSmart wheels maintenance kit 1...

Page 438: ...7 66 Service Manual 5061 Assembly 33 Envelope option 2 1...

Page 439: ...7 67 5061 Assembly 33 Envelope option Asm Index Part number Units option Units FRU Description 33 1 40X1842 1 1 Envelope option complete 2 40X1843 1 1 Envelope tray assembly NS 40X2080 1 1 Envelope fe...

Page 440: ...ervice Manual 5061 Assembly 34 Outdoor media tray option Asm Index Part number Units option Units FRU Description 35 1 40X2083 1 1 Outdoor media drawer assembly 2 40X2084 1 1 Outdoor media tray assemb...

Page 441: ...ts catalog 7 69 5061 Assembly 35 Banner option Asm Index Part number Units option Units FRU Description 36 1 40X2086 1 1 Paper support bail 2 40X2088 1 1 Banner option screw 3 40X2087 1 1 Wire bail 2...

Page 442: ...7 70 Service Manual 5061 Assembly 36 Options...

Page 443: ...assembly 2xx 4xx only NS 40X4754 1 1 PRESCRIBE card assembly 2xx 4xx only NS 40X0291 1 1 Adapter parallel 1284 B NS 40X2610 1 1 Hard Disk 40GB with adapter formatted NS 40X1592 1 1 MarkNet N7020e ENA...

Page 444: ...7 72 Service Manual 5061...

Page 445: ...is necessary to perform the Mechanical alignment on page 4 73 the Black printhead electronic alignment on page 4 78 if necessary and the Color printhead electronic alignment on page 4 79 The front cov...

Page 446: ...roller in these photos is only visible because the printer has been disassembled to the frame The gear will have to be located by feel to ensure proper installation Redrive gear A and auto tension ge...

Page 447: ...deflector in the fuser and the paper is diverted away from the duplex The duplex option does not receive the sheet and prompts a 230 Paper Jam message Replace the rubber deflector button with the encl...

Page 448: ...A 4 Service Manual 5061 3 Place the new button into the cam 4 Verify the new button moves freely by pressing the button firmly down and watching it snap back Note Leave the button in the up position...

Page 449: ...e pages available in various menus While they are as close as possible to what you will see variations in printing may result from individual user printer settings media and printer alignment Print te...

Page 450: ...B 2 Service Manual 5061 Print Quality Pages Page 1 total of five...

Page 451: ...Appendix B Print quality samples B 3 5061 Print Quality Pages Page 2 total of five...

Page 452: ...B 4 Service Manual 5061 Print Quality Pages Page 3 total of five...

Page 453: ...Appendix B Print quality samples B 5 5061 Print Quality Pages Page 4 total of five...

Page 454: ...B 6 Service Manual 5061 Registration and alignment Quick Test Page In Diagnostic Menu select REGISTRATION and select Quick Test...

Page 455: ...Appendix B Print quality samples B 7 5061 Printhead mechanical alignment test page In Diagnostics Menu select MISC TESTS and select Printhead Inst...

Page 456: ...B 8 Service Manual 5061 Printhead electronic alignment test page Magenta one of two In Diagnostic Menu select ALIGNMENT select a color and select Quick Test...

Page 457: ...Appendix B Print quality samples B 9 5061 Printhead electronic alignment test page Magenta two of two...

Page 458: ...B 10 Service Manual 5061...

Page 459: ...onnections 5 18 B banner tray 7 69 BASE SENSOR TEST 3 24 Belt Tracking 3 13 Black Only Mode 3 32 BOR drive assembly location 5 2 parts catalog 7 27 removal 4 34 service checks 2 80 Button Test 3 15 bu...

Page 460: ...g 3 30 Display Log 3 29 Print Log 3 29 EXIT DIAGNOSTICS 3 9 3 30 FINISHER TESTS 3 23 Finisher Feed Test 3 23 Finisher Sensor Test 3 23 Staple Test 3 23 HARDWARE TESTS 3 15 Button Test 3 15 CACHE Test...

Page 461: ...assembly location 5 1 Fuser Temp 3 28 G guidelines media 1 17 H hard disk Disk Encryption 3 35 Jobs On Disk 3 35 HCIT standalone test mode 3 5 Hex Trace 2 125 high capacity input tray HCIT connections...

Page 462: ...7 69 BOR drive assembly 7 27 cartridge contact assembly 7 28 cartridge drive assembly 7 29 cartridge mounting 7 6 covers 7 2 7 4 duplex option 7 54 7 56 electronics 7 30 7 32 7 34 7 35 electronics ca...

Page 463: ...assembly 4 11 front cover rear pivot cover 4 10 front left handle cover assembly 4 19 front lower left cover 4 17 front lower right cover 4 19 front right handle cover assembly 4 21 left lower cover...

Page 464: ...x option deflector button replacement 8 3 identifying system board cabling 5 6 identifying the printheads 8 1 redrive belt routing 8 2 setting printer alignment 3 11 SIZE SENSING 3 32 specifications a...

Page 465: ...Index I 7 5061 waste container latch 7 26 waste toner container parts catalog 7 26 web oiler fuser location 5 1 removal 4 100 upgrade kit 1 20...

Page 466: ...I 8 Service Manual 5061...

Page 467: ...MM card assembly 7 71 40X1508 128MB SDRAM card assembly 7 33 7 71 40X1509 256MB SDRAM card assembly 7 33 7 71 40X1510 512MB SDRAM card assembly 7 33 7 71 40X1512 Japanese font card assembly 7 71 40X15...

Page 468: ...de spring 7 5 40X1646 Duplex actuator arm assembly 7 5 40X1647 Ground cable 7 5 40X1648 Cable tie 6 in pack 7 5 7 53 7 57 40X1649 Cable tie mount 7 5 40X1650 Fuser left duct 7 5 40X1651 Fuser assembly...

Page 469: ...ly 7 19 40X1717 MPF support bracket 7 19 40X1718 Side restraint 7 20 40X1719 Back restraint 7 20 7 51 40X1720 Back restraint latch 7 20 7 51 40X1722 Wear strip 7 20 7 51 40X1723 Tray bias bellcrank as...

Page 470: ...led 7 33 40X1785 Ground cable 7 33 40X1786 Cable clip 7 33 40X1787 Jam access door spring 7 5 40X1791 Power cord set 8 ft Taiwan 7 31 40X1792 Power cord set 8 ft Korea 7 31 40X1793 Transfer HVPS board...

Page 471: ...ensing assembly with system board 7 53 40X1895 500 sheet option spring 7 53 40X1896 Hinge 7 53 40X1897 Wall support plate 7 53 40X1898 Paper level sensing assembly 7 53 40X1899 Media size sensing asse...

Page 472: ...7 43 40X1982 Output option card shield 7 43 40X1983 Rear attach bracket 7 45 40X1984 Front control board cover 7 43 40X1985 Front cover 7 45 40X1986 Rear cover 7 43 40X1987 Rear support cover 7 43 40X...

Page 473: ...40X2047 Roller retainer 7 49 40X2049 Rear access door roller assembly 7 47 40X2050 Main DC drive assembly 7 47 40X2052 Lower autoconnect cable assembly 7 47 40X2053 Upper autoconnect cable assembly 7...

Page 474: ...59 40X2125 Rear feed unit spring 7 59 40X2126 Plastic 5W clip 7 59 40X2127 Level sensor flag 7 59 40X2128 Near empty sensor flag 7 59 40X2129 Extension spring 7 59 40X2130 Tray present lever 7 61 40X2...

Page 475: ...only 7 71 40X4268 Front door assembly 7 47 40X4741 Bar code card assembly 2xx 4xx only 7 33 7 71 40X4742 Lexmark Forms card assembly 2xx 4xx only 7 71 40X4743 IPDS SCS card assembly 2xx 4xx only 7 71...

Page 476: ...I 18 Service Manual 5061...

Page 477: ...d Transfer Roll 144 6 5 69 M to Second Transfer Roll 245 6 9 67 C to Second Transfer Roll 346 6 13 65 Y to Second Transfer Roll 447 6 17 62 Meter 1 to Second Transfer 164 8 6 49 Meter 2 to Second Tran...

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