Thank You for purchasing this Factory Service Manual on EBAY from PCTECHINFO!

Click Here for more Factory Service Manuals for other Computer and Printer / Copier Manufacturers from PCTECHINFO!

LexmarkTMC750 5060-XXX

Table of Contents Start Diagnostics Safety and Notices Trademarks Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

5060-XXX

Edition: March 2002

The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PostScript is a registered trademark of Adobe Systems Incorporated. Other trademarks are the property of their respective owners.

Copyright Lexmark International, Inc. 2001, 2002. All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550. U.S.A. U.S.A. P/N: 12G9113

5060-XXX

Table of Contents
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Laser Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv-ix Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv-xii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Options and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Print Speed and Performance Print Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Media Size Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Input Media Types and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Output Media Types and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 POR (Power On Reset) Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Symptom Table - Base Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Symptom Table - 500 Sheet Drawer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Symptom Table - HCIT 2000 Sheet Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Symptom Table - Output Expander Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Symptom Table - 5-Bin Mailbox Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Symptom Table - Finisher Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Sub Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 HCIT System Board LED Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 HCOF Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2XX Paper Jam Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 User Attendance Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 900 Error Code Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Cartridge Drive Assembly Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Fan Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 AC and DC Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Second Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Output Expander Option Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

iii

5060-XXX

5-Bin Mailbox Option Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 Operator Panel LCD/Status LED/Buttons Service Check . . . . . . . . . . . . . . . . 2-83 100 ITU Error Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 ITU Drive Motor Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Printhead Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 Cover Open/HV Interlock Switch Service Check . . . . . . . . . . . . . . . . . . . . . . 2-102 PSD Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103 Tray 1 Paper Size Sensing Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 Tray 1 Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 Autocompensator Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 Multipurpose Feeder (MPF) Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 Close Door/HVPS/Printhead Interlock Switch Service Check . . . . . . . . . . . . 2-114 500 Sheet Drawer Option Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 Duplex Option Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 HCIT 2000 Sheet Option Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126 Finisher Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Black and White Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Fuser Count Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Size Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Type Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Sensed Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Calibrate Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Download Emuls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ITU Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Auto Color Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Exit Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

iv

5060-XXX

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Exiting the Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Duplex Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Input Tray Sensor Test (500-Sheet Trays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Input Tray Tests (2000-Sheet Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Output Bin Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Output Bin X Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 5-Bin Mailbox Diverter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Finisher Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Staple Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Finisher Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Finisher Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Hole Punch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

5060-XXX

Miscellaneous Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Automated Motor Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Print Tests (input source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Print Line Length Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Setting Printer Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 HCIT Standalone Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Repair Information

..........................................................

4-1

Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Printhead Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Printhead Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Printhead Electronic Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Outer EMC Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 RIP Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 HVPS Transfer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Rear Fan Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Fuser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Fuser Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Lower Right Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Fuser Top Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Fuser Bottom Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Fuser Web Oiler Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Redrive Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

vi

5060-XXX

Cartridge Drive Assembly (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Cartridge Drive Assembly (Cyan, Magenta, Black) . . . . . . . . . . . . . . . . . . . . . 4-28 Front Right Handle Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Front Left Handle Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Lower Jam Access Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Paper Path Access Door Cover/Front Lower Left Cover . . . . . . . . . . . . . . . . . 4-32 Multipurpose Feeder (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Waste Container Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Left Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 PSD Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 RIP Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 RIP Board Shield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 HVPS Developer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 VTB Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 ITU Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 ITU Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 ITU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Engine Board Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Waste Container Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Paper Size Sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Second Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 BOR Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Cartridge Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Connector Locations

........................................................

5-1

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 RIP Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 LVPS Cable Connectors to Engine Board & RIP Board . . . . . . . . . . . . . . . . . 5-18 LVPS Fuser Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 HCIT 2000-Sheet Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 HVPS Developer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 HCOF Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

vii

5060-XXX

Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Assembly 1: Assembly 2: Assembly 3: Assembly 4: Assembly 5: Assembly 6: Assembly 7: Assembly 8: Assembly 9: Assembly 10: Assembly 11: Assembly 12: Assembly 13: Assembly 14: Assembly 15: Assembly 16: Assembly 17: Assembly 18: Assembly 19: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Vacuum Belt Transport Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Paper Feed Output (Redrive) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Multipurpose Feeder (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 500-Sheet Integrated Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Autocompensator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 ITU Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Cartridge Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Output Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 5-Bin Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 500-Sheet Tray Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 HCIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Finisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

viii

5060-XXX

Notices and Safety Information

Laser Notices
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825. Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Laser
Der Drucker erfllt gem amtlicher Besttigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J fr Laserprodukte der Klasse I (1). In anderen Lndern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825 gem amtlicher Besttigung erfllt. Laserprodukte der Klasse I gelten als unschdlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Lnge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, da im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I bersteigen wrde, Menschen keinesfalls erreicht.

Avis relatif lutilisation de laser

Pour les Etats-Unis : cette imprimante est certifie conforme aux provisions DHHS 21 CFR alina J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante rpond aux normes IEC 60825 relatives aux produits laser de Classe I. Les produits laser de Classe I sont considrs comme des produits non dangereux. Cette imprimante est quipe dun laser de Classe IIIb (3b) (arsniure de gallium dune puissance nominale de 5 milliwatts) mettant sur des longueurs donde comprises entre 770 et 795 nanomtres. Limprimante et son systme laser sont conus pour impossible, dans des conditions normales dutilisation, dentretien par lutilisateur ou de rvision, lexposition des rayonnements laser suprieurs des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825.

Notices and Safety Information ix

5060-XXX

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) allarseniuro di gallio della potenza di 5mW che opera sulla lunghezza donda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Avisos sobre el lser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos lser de Clase I (1) establecidos en el subcaptulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los dems pases, rene todas las condiciones expuestas en la norma IEC 60825 para productos lser de Clase I (1). Los productos lser de Clase I no se consideran peligrosos. La impresora contiene en su interior un lser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanmetros. El sistema lser y la impresora estn diseados de forma que ninguna persona pueda verse afectada por ningn tipo de radiacin lser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situacin de servicio tcnico.

Declarao sobre Laser

A impressora est certificada nos E.U.A. em conformidade com os requisitos da regulamentao DHHS 21 CFR Subcaptulo J para a Classe I (1) de produtos laser. Em outros locais, est certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825. Os produtos laser da Classe I no so considerados perigosos. Internamente, a impressora contm um produto laser da Classe IIIb (3b), designado laser de arseneto de potssio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanmetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiao laser superior a um nvel de Classe I durante a operao normal, a manuteno feita pelo utilizador ou condies de assistncia prescritas.

Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.

Service Manual

5060-XXX

Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder p blgelngdeomrdet 770-795 nanometer. Lasersystemet og printeren er udformet sledes, at mennesker aldrig udsttes for en laserstrling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

Huomautus laserlaitteesta
Tm kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J mrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825 -mrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia kyttjlle. Kirjoittimessa on sisinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometri. Laserjrjestelm ja kirjoitin on suunniteltu siten, ett kyttj ei altistu luokan I mrityksi voimakkaammalle steilylle kirjoittimen normaalin toiminnan, kyttjn tekemien huoltotoimien tai muiden huoltotoimien yhteydess. VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle lasersteilylle. l katso steeseen. VARNING! Osynlig laserstrlning nr denna del r ppnad och sprren r urkopplad. Betrakta ej strlen.

Laser-notis
Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J fr laserprodukter av Klass I (1). I andra lnder uppfyller skrivaren kraven fr laserprodukter av Klass I enligt kraven i IEC 60825. Laserprodukter i Klass I anses ej hlsovdliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som bestr av en laserenhet av gallium-arsenid p 5 milliwatt som arbetar i vglngdsomrdet 770-795 nanometer. Lasersystemet och skrivaren r utformade s att det aldrig finns risk fr att ngon person utstts fr laserstrlning ver Klass I-niv vid normal anvndning, underhll som utfrs av anvndaren eller annan freskriven servicetgrd.

Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825.

Notices and Safety Information xi

5060-XXX

Klasse I-laserprodukter er ikke betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som bestr av en gallium-arsenlaserenhet som avgir strling i blgelengdeomrdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstrling ut over klasse I-niv under vanlig bruk, vedlikehold som utfres av brukeren, eller foreskrevne serviceoperasjoner.

Avs sobre el Lser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes lser de classe I (1), i segons ha estat certificat en altres llocs, s un producte lser de classe I que compleix els requisits dIEC 60825. Els productes lser de classe I no es consideren perillosos. Aquesta impressora cont un lser de classe IIIb (3b) darsenir de gal.li, nominalment de 5 mil.liwats, i funciona a la regi de longitud dona de 770-795 nanmetres. El sistema lser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci lser per sobre dun nivell de classe I durant una operaci normal, durant les tasques de manteniment dusuari ni durant els serveis que satisfacin les condicions prescrites.

Safety Information
This product is designed, tested and approved to meet strict global safety standards
with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

Consignes de Scurit
Ce produit a t conu, test et approuv pour respecter les normes strictes de
scurit globale lors de l'utilisation de composants Lexmark spcifiques. Les caractristiques de scurit de certains lments ne sont pas toujours videntes. Lexmark ne peut tre tenu responsable de l'utilisation d'autres pices de rechange. Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de maintenance qualifi. Le dmontage et l'entretien de ce produit pouvant prsenter certains risques lectriques, le personnel d'entretien qualifi devra prendre toutes les prcautions ncessaires.

Norme di sicurezza
Il prodotto stato progettato, testato e approvato in conformit a severi standard di
sicurezza e per lutilizzo con componenti Lexmark specifici. Le caratteristiche di

xii

Service Manual

5060-XXX

sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non responsabile per lutilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona pi elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

Sicherheitshinweise
Dieses Produkt und die zugehrigen Komponenten wurden entworfen und getestet,
um beim Einsatz die weltweit gltigen Sicherheitsanforderungen zu erfllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung fr dieses Produkt bernommen. Die Wartungsinformationen fr dieses Produkt sind ausschlielich fr die Verwendung durch einen Wartungsfachmann bestimmt. Whrend des Auseinandernehmens und der Wartung des Gerts besteht ein zustzliches Risiko eines elektrischen Schlags und krperlicher Verletzung. Das zustndige Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen.

Pautas de Seguridad
Este producto se ha diseado, verificado y aprobado para cumplir los ms estrictos
estndares de seguridad global usando los componentes especficos de Lexmark. Puede que las caractersticas de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La informacin sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga elctrica y de daos personales durante el desmontaje y la reparacin de la mquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

Informaes de Segurana
Este produto foi concebido, testado e aprovado para satisfazer os padres globais
de segurana na utilizao de componentes especficos da Lexmark. As funes de segurana de alguns dos componentes podem no ser sempre bvias. A Lexmark no responsvel pela utilizao de outros componentes de substituio. As informaes de segurana relativas a este produto destinam-se a profissionais destes servios e no devem ser utilizadas por outras pessoas. Risco de choques elctricos e ferimentos graves durante a desmontagem e manuteno deste produto. Os profissionais destes servios devem estar avisados deste facto e tomar os cuidados necessrios.

Notices and Safety Information xiii

5060-XXX

Informaci de Seguretat
Aquest producte est dissenyat, comprovat i aprovat per tal d'acomplir les estrictes
normes de seguretat globals amb la utililitzaci de components especfics de Lexmark. Les caracterstiques de seguretat d'algunes peces pot ser que no sempre siguin bvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informaci pel manteniment daquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui. El risc de xoc elctric i de danys personals pot augmentar durant el procs de desmuntatge i de servei daquest producte. El personal professional ha destar-ne assabentat i prendre les mesures convenients.

xiv

Service Manual

5060-XXX

Preface
This manual describes the Lexmark C750 Color Printer (5060-XXX) and contains maintenance procedures for service personnel only. It is divided into the following chapters:

1. General Information contains a general description of the printer and the 2. 3. 4. 5. 6. 7.

maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. Diagnostic Information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs). Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems. Repair Information provides instructions for making printer adjustments and removing and installing FRUs. Connector Locations uses illustrations to identify the connector locations and test points on the printer. Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems. Parts Catalog contains illustrations and part numbers for individual FRUs.

Preface xv

5060-XXX

xvi

Service Manual

5060-XXX

1. General Information
The LexmarkTM C750 is a network color printer that uses electrophotographic technology to deliver high quality images, presentation graphics, line art, and text. It prints up to 20 pages per minute (ppm) for both four-color and monochrome print jobs. The printer's flexible design allows it to support a variety of printing needs. For example, if you need the printer to match the color process used in a particular application, you can select RGB or CMYK color corrections. You can also adjust the printed colors to more closely represent the colors on your computer display. A variety of connectivity options enable the printer to be used in all types of system environments. You can attach one internal adapter to support network configurations requiring Ethernet, Token-Ring, LocalTalk, serial, infrared, or additional parallel ports. The printer has flexible paper handling. It supports a wide variety of paper sizes, and has a standard multipurpose feeder that makes it easy to print on envelopes, transparencies, labels, card stock, and non-standard size paper. You can add up to three optional drawers to the base printer, which can increase the printer's paper capacity to 2000 sheets. The Lexmark C750 (5060-XXX) laser printer is available in two models: 5060-001 5060-002

Tools Required For Service

Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade T10 Torx Screwdriver Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964

General Information

1-1

5060-XXX

Options and Features

Lexmark C750 printers support only Lexmark C750 paper-handling options. These options are not compatible with any other Lexmark printer.

500-Sheet Drawer - (includes 500-sheet tray and support unit) installs beneath the
printer and holds approximately 500 sheets of 20 lb. paper. Multiple optional drawers are supported simultaneously. 2,000-Sheet Drawer - is designed to be installed beneath the printer and below any other optional input sources and holds approximately 2,000 sheets of 20 lb. paper 500-Sheet Tray - for environments with space or budget constraints this can be ordered for special media. This would temporarily replace the standard tray in a 500sheet drawer and will hold approximately 500 sheets of 20 lb. paper. Duplex Unit - offers two-side printing and is designed to complement the Lexmark C750 printers Output Expander - installs above the printer's primary output bin to offer an additional output destination. This holds approximately 650 sheets of 20 lb. paper. The C750 supports only one output option above the printer. 5-Bin Mailbox - installs above the printer's primary output bin to offer 5 output destinations in one part. Each of the five bins supports approximately 100 pages of 20 lb. paper. The C750 supports only one output option above the printer Finisher - offers stapling, hole punching, offset stacking and an additional output bin. Two models will be available. 2-, 3- or 4-hole left-edge hole punching will be available. The single staple position is the upper left corner. The Finisher can support up to 3,000 sheets of non-stapled, non-punched media. For stapled media, the output bin supports up to 90 stapled sets or 2,700 sheets. The stapler can staple a maximum of 30 sheets per set. Each C750 can support one Finisher.

High performance
Up to 20 ppm black or color 350 MHz RISC processor 64MB RAM Time to first page Black: less than 17.5 seconds Color: less than 20 seconds

1-2 Service Manual

5060-XXX

Print quality True 1200 x 1200 dpi and 2400 image quality Heavy volume reliability Up to 4,000-page average monthly duty cycle Up to 60,000-page maximum duty cycle based on a single months usage Automatic Calibration
The C750 performs an automatic calibration under the following conditions.

At power-on After 8 hours of power saver Approximately every 500 pages, at the end of a job After changing a print cartridge After changing an intermediate transfer unit

A manual calibration can be initiated by selecting "Color Adjustment from the Utilities Menu.

Resolution 1200 x 1200 dpi 2400 image quality Toner Darkness

Toner darkness settings offer five (5) user-selectable 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 setting is available through the operator panel under the "Print Quality" menu or through the Lexmark C750 PostScript driver.

General Information

1-3

5060-XXX

Printer Specifications
Description
Printer Lexmark C750(n) Lexmark C750dn Options Duplex Unit 2,000-Sheet Tray Output Expander 500-Sheet Drawer 500-Sheet Tray 5-Bin Mailbox Finisher 28.2 in. (715 mm) 24 in. (600 mm) 20.7 in. (525 mm) 28.2 in. (715 mm) 17.3 in. (440 mm) 20.2 in. (513 mm) 47.7 in. (1,213 mm) 21.3 in. (540 mm) 31 in. (800 mm) 16.1 in. (410 mm) 21.3 in. (540 mm) 16.1 in. (410 mm) 13.1 in. (333 mm) 25.7 in. (653 mm) 7.8 in. (197 mm) 21 in. (521 mm) 20.3 in (515 mm) 9.1 in. (230 mm) 4.3 in. (110 mm) 10.7 in. (272 mm) 35.1 in. (892 mm) 17 lb. (7.7 kg) 55 lb. (25 kg) 10.5 lb. (4.7 kg) 15.6 lb. (7.1 kg) 4.5 lb. (2.0 kg) 6.2 lb. (2.8 kg) 94.6 lb. (43 kg) 29.1 in. (740 mm) 30.5 in. (775 mm) 21.6 in. (550 mm) 23.8 in. (605 mm) 31.3 in. (795 mm) 50.2 in (1,275 mm) 127.7 lb. (57.9 kg) 167.3 lb. (75.9 kg)

Width

Depth

Height

Weight

Power and Electrical Specifications

Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts.

Printing States
Printing - average power Base model All options Idle - average power Power Saver On Power Saver Off Printing - maximum current

Lexmark C750(n)

Lexmark C750dn

500 540

500 540

28 145 10.2

31 145 10.2

1-4 Service Manual

5060-XXX

Note: Using a 220 to 110 power converter with the 110 volt printer is not recommended.

Electrical Specifications
110 Volt Model

110 to 127 VAC at 47 to 63 hertz (hz) nominal 99 to 137 VAC, extreme Operating Clearances
Left side: 24 in. (609.6 mm) Right side: 15 in. (381 mm)* Front: 20 in. (508 mm) Rear: 12 in. (304.8 mm) Top:** C750(n) 42 in. (1,066.8 mm) C750dn 34 in. (863.6 mm) Note: Allow 1,219.2 mm (48 in.) clearance to the right if you will be adding a C750 finisher. Note: **Allow clearance above the printer front door clearance and for adding options, such as additional input drawers, output expander or 5-bin mailbox.

Acoustics
All measurements were made in accordance with ISO 7779 and reported in conformance with ISO 9296. Lexmark C750(n)

2400 image quality printing: 51 dBA Idle (standby): 42 dBA

Lexmark C750dn

2400 image quality printing: 53 dBA Idle (standby): 42 dBA

General Information

1-5

5060-XXX

Environment
Printer Temperature and Humidity

Operating Temperature: 60 to 90o F (15.6 to 32.3o C) Relative Humidity: 8 to 80% Maximum Wet Bulb Temperature: 73o F (22.8o C) Altitude: 10,000 ft. (0 to 3,048 meters) Atmospheric Pressure: 74.6 kPa Power Off Temperature: 50 to 110o F (10 to 43.3o C) Relative Humidity: 8 to 80% Maximum Wet Bulb Temperature: 80.1o F (26.7o C) Altitude: 10,000 ft. (0 to 3,048 meters) Atmospheric Pressure: 74.6 kPa Ambient Operating Environment* Temperature: 60 to 90o F (15.6 to 32.2o C) Relative Humidity: 8 to 80% Storage and Shipping (packaged printer) with or without print cartridge Temperature: -40 to 110o F (-40 to 43.3o C) Print Cartridge Temperature: -40 to 110o F (-40 to 43.3o C)
In some cases, performance specifications (such as paper OCF, EP cartridge usage) are specified to be measured at an ambient condition.

1-6 Service Manual

5060-XXX

Print Speed and Performance Print Speed

2400 Image Quality 1200 x 1200 dpi

Simplex printing on letter-size media (pages per minute) Letter 8.5 in. x 11 in. A4 3.4 in. x 11.7 in. Legal 8.5 in. x 14 in. Transparencies Envelopes 20 19 16.2 10 10 10 9.5 8.1 10 10

Duplex printing on letter-size media (sides per minute) Letter 8.5 in. x 11 in. A4 3.4 in. x 11.7 in. Legal 20 19 8.5 in. x 14 in. 10 9.5 16.2

Performance
The Lexmark C750 printers support the speeds in the previous table. Performance depends on the following:

Interface to the host (USB, serial, parallel, network) Host system and application Page complexity and content Certain printer options installed or selected Available printer memory Media size and type Resolution Printer usage setting

Time to First Print

Time to first print from standby mode:

Black: <17.5 seconds Color: <20 seconds

General Information

1-7

5060-XXX

Time to first print from power saver mode:

Black: <180 seconds Color: <180 seconds

Note: All first copy times are measured for 2400 image quality, simplex printing on lettersize paper, The test job consists of the character "A" followed by a form feed (single-page job). The first copy time is defined as the elapsed time from hitting enter on the PC keyboard to the page exiting to the output bin. All tests will pick paper from the primary input tray and the page will exit into the primary output bin.

Processor 350 MHz Duty Cycle Up to 60K page maximum one-time usage Up to 4K pages per month average usage Memory Configuration
DRAM Memory
Standard Maximum

Lexmark C750(n)
64MB 512MB

Lexmark C750dn
128MB 512MB

Available Memory Options

Optional 64MB, 128MB and 256MB SDRAM DIMMs are available from Lexmark. The memory options for the C750 printers are 168-pin synchronous DRAM DIMMs (dual inline memory modules). Flash Memory Options

Memory slots for extra flash or DRAM: 2 Expansion slots for optional interface cards: 1 Code expansion slots (application solution firmware cards): 1 On-board hard disk interface (for optional hard disk): 1

Additional memory may be required for printing complex pages or full-page, highresolution images in 1200 image quality at rated speeds.

1-8 Service Manual

5060-XXX

Media Size Supported

Media Size Supported 500Sheet Input Multipurpose Tray 2,000Sheet Drawer Duplex Standard Output 5-Bin Mailbox Output Expander Finisher to Staple, Hole Punch, Offset Stack Or with Output Bin x 5, 6, 7

A4 8.27 in. x 11.7 in. (210 mm x 297 mm) A5 5.83 in. x 8.27in. (148 mm x 210 mm) JIS-B5 7.17 in. x 10.23 in. (182 mm x 257 mm) Statement 5.5 in. x 8.5 in. (140 mm x 216 mm) Letter 8.5 in. x 11 in. (216 mm x 279 mm) Folio 8.5 in. x 13 in. (216 mm x 330 mm) Legal 8.5 in. x 14 in. (216 mm x 256 mm) Executive 7.25 in. x 10.5 in. (184 mm x 267 mm) Universal*

x5

x5

x5

x 5, 6, 7

x 5, 6, 7

x 5, 6, 7

x 6, 7

General Information

1-9

5060-XXX

Media Size Supported

500Sheet Input

Multipurpose Tray

2,000Sheet Drawer

Duplex

Standard Output

5-Bin Mailbox

Output Expander

Finisher to Staple, Hole Punch, Offset Stack Or with Output Bin

5.5 x 8.27 in. to 8.5 x 14 in. (139.7 x 210 mm to 215.9 x 355.6 mm) 2.75 x 5 in. to 8.5 x 14 in. (69.85 x 127 mm to 229 x 355.6 mm) 5.83 x 7.17 in. to 8.5 x 14 in. (148 x 182 mm to 215.9 x 355.6 mm) 7 Envelope 3.875 in. x 7.5 in. (98 mm x 191 mm) 9 Envelope 3.875 in. x 8.9 in. (98 mm x 225.4 mm) 10 Envelope 4.125 in. x 9.5 in. (105 mm x 241 mm) DL Envelope 4.33 in. x 8.66 in. (110 mm x 220 mm)

1-10 Service Manual

5060-XXX

Media Size Supported

500Sheet Input

Multipurpose Tray

2,000Sheet Drawer

Duplex

Standard Output

5-Bin Mailbox

Output Expander

Finisher to Staple, Hole Punch, Offset Stack Or with Output Bin

C5 Envelope 6.38 in. x 9.01 in. (162 mm x 229 mm) B5 Envelope 6.93 in. x 9.84 in. (176 mm x 250 mm) Other Envelope** 3.87 x 6.38 in. to 6.93 x 9.84 in. (98.4 x 162 mm to 176 x 250 mm) Media Type Paper Card Stock Transparen cies Envelopes x x x

x x x x

x x

x x x

x x x

General Information

1-11

5060-XXX

Media Size Supported

500Sheet Input

Multipurpose Tray

2,000Sheet Drawer

Duplex

Standard Output

5-Bin Mailbox

Output Expander

Finisher to Staple, Hole Punch, Offset Stack Or with Output Bin

Labels Vinyl Paper Polyester Dual Web Integrated Labels x x x x x x x x x x x x x x x x x x x x x x x

1. When Universal is selected, the page is formatted for 8.5 x 14 in. (215.9 x 355.6
mm), unless the size is specified in the software application.

2. Narrow media should be loaded with the length in the feed direction (portrait). 3. When Other Envelope is selected, the page is formatted for 8.5 x 14 in. (215.9 x
355.6 mm) unless the size is specified in the software application.

4. Statement and Folio are supported as standard size through software only. Tray size 5. 6. 7.
sensing must be turned off before this standard size is visible in the paper-size menu on the operator panel. 2-hole punch is supported. 3-hole punch is supported. 4-hole punch is supported.

1-12 Service Manual

5060-XXX

Input Media Types and Weights

Media Weight

Integrated Trays f and Optional 500-Sheet Drawer Paper b, f Xerographic or business paper 16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 47 lb. bond (75 to 176 g/ m2 grain long) 60 to 120 lb. book (88 to 176 g/m2 grain long) 60 to 65 lb. cover (162 to 176 g/m2 grain long)

Specialty papers Gloss book Gloss cover Card stock - upper limit (grain long)a, f Index Bristol Tag Cover Card stock - upper limit (grain short) a, f Index Bristol Tag Cover Transparencies i, j Laser printer type Labels - upper limit Paper Dual-web paper Polyester Vinyl g, h Integrated forms Pressure sensitive area c Paper base (grain long) Multipurpose Feeder Paper b, f Xerographic or business paper

90 lb. (163 g/m2) 100 lb. (163 g/m2) 65 lb. (176 g/m2)

110 lb. (199 g/m2) 125 lb. (203 g/m2) 80 lb. (216 g/m2) 43 to 45 lb. bond (161 to 169 g/m2)

48 lb. bond (180 g/m2) 48 lb. bond (180 g/m2) 59 lb. bond (220 g/m2) 92 lb. liner (300 g/m2)

(140 to 175 g/m2) 20 to 36 lb. bond (75 to 135 g/m2)

16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 47 lb. bond (75 to 176 g/ m2 grain long)

Specialty papers Gloss book 60 to 120 lb. book (88 to 176 g/m2 grain long)

General Information

1-13

5060-XXX

Media
Gloss cover Card stock - upper limit (grain long)a, f Index Bristol Tag Cover Card stock - upper limit (grain short) a, f Index Bristol Tag Cover Transparencies i, j Laser printer type Labels - upper limit Paper Dual-web paper Polyester Vinyl g, h Integrated forms Pressure sensitive area c Paper base (grain long) Envelopes d, e Sulfite, wood-free or up to 100% cotton bond 2,000-Sheet Drawer Paper b, f Xerographic or business paper Specialty papers Gloss book Gloss cover

Weight
60 to 65 lb. cover (162 to 176 g/m2 grain long)

90 lb. (163 g/m2) 100 lb. (163 g/m2) 65 lb. (176 g/m2)

110 lb. (199 g/m2) 125 lb. (203 g/m2) 80 lb. (216 g/m2) 43 to 45 lb. bond (161 to 169 g/m2)

53 lb. bond (199 g/m2) 53 lb. bond (199 g/m2) 59 lb. bond (220 g/m2) 78 lb. liner (260 g/m2)

Up to 47 lb. bond (140 to 175 g/m2) 20 to 36 lb. bond (75 to 135 g/m2) 16 to 28 lb. bond (60 to 105 g/m2)

16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 47 lb. bond (75 to 176 g/ m2 grain long)

60 to 120 lb. book (88 to 176 g/m2 grain long) 60 to 65 lb. cover (162 to 176 g/m2 grain long)

1-14 Service Manual

5060-XXX

Output Media Types and Weights

Media Weight

Standard Output Bin and Optional Output Expander Paper b, f Xerographic or business paper 16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 47 lb. bond (75 to 176 g/ m2 grain long)

Specialty papers Gloss book Gloss cover Card stock - upper limit (grain long)a Index Bristol Tag Cover Card stock upper limit (grain short) a Index Bristol Tag Cover Transparencies Laser printer type Labels - upper limit Paper Dual-web paper Polyester Vinyl G, H Integrated forms Pressure sensitive area c Paper base (grain long) Envelopes d, e Sulfite, wood-free or up to 100% cotton bond Finisher (Output Bin, Offset Stack) Paper b, f Xerographic or business paper 16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 47 lb. bond (75 to 176 g/ m2 grain long) Up to 47 lb. bond (140 to 175 g/m2) 20 to 36 lb. bond (75 to 135 g/m2) 16 to 28 lb. bond (60 to 105 g/m2) 48 lb. bond (180 g/m2) 48 lb. bond (180 g/m2) 59 lb. bond (220 g/m2) 92 lb. liner (300 g/m2) 110 lb. (199 g/m2) 125 lb. (203 g/m2) 80 lb. (216 g/m2) 43 to 45 lb. bond (161 to 169 g/m2) 90 lb. (163 g/m2) 100 lb. (163 g/m2) 65 lb. (176 g/m2) 60 to 120 lb. book (88 to 176 g/m2 grain long) 60 to 65 lb. cover (162 to 176 g/m2 grain long)

General Information

1-15

5060-XXX

Media
Specialty papers Gloss book60 to 120 lb. book (88 to 176 g/m2 grain long) Finisher (Staple and Hole Punch) Paper Xerographic or business paper

Weight

16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 32 lb. bond (75 to 120.4 g/m2 grain long) 60 to 84.5 lb. book (88 to 125 g/m2 grain long)

Specialty papers Gloss book 5-Bin Mailbox Paper Xerographic or business paper

16 to 19.9 lb. bond (60 to 74.9 g/m2 grain long) 20 to 24 lb. bond (75 to 90 g/ m2 grain long)

a. For 60 to 176 g/m2 paper, grain long fibers are recommended. For papers b. c. d. e. f. g. h.
heavier than 176 g/m2, grain short is preferred. Paper less than 75 g/m2 limited to less than 60% relative humidity and is not supported in duplex Pressure-sensitive area must enter the printer first. 100% cotton content maximum weight is 24 lb. bond. 28 lb. envelopes are limited to 25% cotton content. 28 lb. bond envelopes are limited to 25% cotton content The duplex option does not support 16 to 19.9 lb. (60 to 74.9 g/m2 grain long paper, transparencies, labels, envelopes or A5 card stock. Vinyl labels are supported only when printing environment and media are 20 to 23 deg. C (68 to 90 deg. F) Refer to the Converter Listing on Lexmark's Home Page and Automated FAX system (LEXFAX) for information on whether your vinyl label converter has passed Lexmark's criteria. Refer to the Card Stock and Label Guide for more details. Lexmark transparency numbers 12A5940 and 12A5941 are supported from the standard tray, optional 500-sheet trays and the multipurpose feeder Lexmark transparency numbers 12A5150 and 12A5151 are supported from the multipurpose feeder only

i. j.

1-16 Service Manual

5060-XXX

Acronyms
BLDC BOR C CSU DIMM DRAM EDO EP EPROM ESD FRU GB HVPS ITU K LASER LCD LED LVPS M MROM MS NVRAM OEM OPT PC POR POST PSD PWM RIP ROM SDRAM SIMM SRAM UPR V ac V dc VTB Y Brushless DC Motor Black Only Retract Cyan Customer Setup Dual Inline Memory Module Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable, Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High Voltage Power Supply Intermediate Transfer Unit Black Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Power Supply Magenta Masked Read Only Memory Microswitch Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor Power-On Reset Power-On Self Test Position Sensing Device Pulse Width Modulation Raster Imaging Processor Read Only Memory Synchronous Dual Random Access Memory Single Inline Memory Module Static Random Access Memory Used Parts Return Volts alternating current Volts direct current Vacuum Transport Belt Yellow

General Information

1-17

5060-XXX

1-18 Service Manual

5060-XXX

2. Diagnostic Information
Start
CAUTION: Remove the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The printer weighs 47.7 kg (105 lb) and requires at least two people to lift it safely. Make sure your fingers are not under the printer when you lift or set the printer down. Use the POR sequence, symptom tables, error code tables, sub error code table, system board LED error code table, 2xx paper jam message table, user attendance message table, and service checks to determine the corrective action necessary to repair a malfunctioning printer. Note: There may be printer error messages that are not contained in this service manual. Call your next level support for assistance.

POR (Power On Reset) Sequence on page 2-1 Symptom Table - Base Printer on page 2-2 Symptom Table - 500 Sheet Drawer Option on page 2-4 Symptom Table - HCIT 2000 Sheet Option on page 2-4 Symptom Table - Output Expander Option on page 2-5 Symptom Table - 5-Bin Mailbox Option on page 2-5 Symptom Table - Finisher Option on page 2-6 Error Code Table on page 2-7 Sub Error Code Table on page 2-19 HCIT System Board LED Error Code Table on page 2-22 HCOF Error Code Table on page 2-23 2XX Paper Jam Message Table on page 2-24 User Attendance Message Table on page 2-28 Service Checks on page 2-48

POR (Power On Reset) Sequence

The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed.

1. 2. 3. 4. 5. 6.

Power the machine On. +5V LED (Power ON) on the engine board comes on. Front Panel LED comes On solid. All diamonds appear on the display. While code is being loaded into DRAM, dots scroll across the display. The following is an example of the screen that displays after the code is loaded. 96MB 96MB = Amount of Memory 350MHZ 350Mhz = Processor Speed

Diagnostic Information

2-1

5060-XXX

7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Performing Self Test is displayed. Fuser drive motor turns On. Main fan turns On. RIP fan turns On. Heartbeat LED on engine boards turns On. Fuser lamps turn On. Vacuum belt transport fan turns On. "ITU Missing" is posted if the ITU is missing. "Fuser Missing" is posted if the fuser is missing. "Close Door" is posted if the front cover is open. Busy displays Front panel LED blinks. Redrive exit roller turns. Any cartridge errors are posted such as a defective cartridge, prebate information or missing cartridge. Any applicable maintenance messages display such as "80 Fuser Maintenance" or "83 "Maintenance ". One of the Toner Low, "88 Yellow Toner Low","88 Magenta Toner Low", "88 Cyan Toner Low" or "88 Black Toner Low" display when applicable. Color calibration may be initiated. This is displayed if one of the following occurs: The printer detects at power On, or the front cover is closed, that a new or different toner cartridge has 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 degrees C. When coming out of power saver if power saver has been active or 8 hours or longer. If the printer is turned On when a calibration cycle was in progress since the printer was last powered Off. Ready is displayed.

Symptom Table - Base Printer

Symptom
Fuser Fan fails to run or is noisy RIP Fan Fails to run or is noisy VTB Fan fails to run or is noisy Machine inoperative Operator Panel: One or more buttons do not work Operator Panel: Display is blank, printer does not sound 5 Beeps

Action
Go to the Fuser Fan Service Check on page 2-54. Go to the RIP Fan Service Check on page 2-55. Go to the VTB Fan Service Check on page 2-55. Go to the AC and DC Power Service Check on page 2-56. Go to Operator Panel LCD/Status LED/Buttons Service Check on page 2-83. Replace the Operator Panel on page 4-26.

2-2 Service Manual

5060-XXX

Symptom
Operator Panel: Operator Panel displays all diamonds continuously, sounds 5 beeps and POST inoperative Operator Panel: One PEL or random PELS are missing Paper feed problems, base printer Paper feed problems, integrated tray Paper fails to pick from Tray 1 Paper feed problems, MPF Printer prints black only, no colors

Action
Go to Operator Panel LCD/Status LED/Buttons Service Check on page 2-83. Replace the Operator Panel on page 4-26. Go to the Paper Path Service Check on page 2-112. Go to the Tray 1 Service Check on page 2-105. Go to Autocompensator Service Check on page 2-106. Go to the Multipurpose Feeder (MPF) Service Check on page 2-109. Check to make sure that the printer is not set up to print black only. If the printer is set up correctly, check the Black Retract Motor and gears for correct operation. If the gears are operating correctly, replace the Retract Motor Assembly. If this does not correct the problem, replace the Engine Board on page 4-14. Go to Print Quality Service Checks on page 2-72.

Print Quality:100% Single color printed * All Black Print * All Cyan Print * All Magenta Print * All Yellow Print Print Quality: Blank Page (No Image) Print Quality: Evenly spaced horizontal marks or lines on the printed page Print Quality: Black Line

Go to Blank Page (No Image) on page 2-73. Go to Evenly spaced horizontal marks or lines on the page on page 2-76. Black horizontal lines are most likely caused by a shorted charge roll in the print cartridge. Replace the black print cartridge. Go to Colored lines, streaks, or smudges on page 2-76. Go to Light lines or streaks appear on the page on page 2-83. Go to Light print over the entire page on page 2-75. Go to Missing Colors on page 2-74. Go to Uneven printing on page 2-81. Go to Poor Color Registration on page 2-78. Go to Toner is on the back of the printed page on page 2-82.

Print Quality: Colored lines, steaks, or smudges Print Quality: Light lines or streaks appear on the printed page Print Quality: Light Print Print Quality: Missing Colors Print Quality: Uneven printing Print Quality: Poor Color Registration Print Quality: Toner on the back of the page

Diagnostic Information

2-3

5060-XXX

Symptom
Print Quality: Toner smears or rubs off the page Fuser Problem - Fuser Cold Fuser Problem - Fuser running too hot Fuser Problem - Excessive Fuser Drive Motor Assembly Noise Paper Jams in base printer "Close Door" displays constantly, unable to clear the message, POR incomplete

Action
Go to Toner smears or rubs off the page with no error code displayed on page 2-82. Go to the Cold Fuser Service Check on page 2-95. Go to the Hot Fuser Service Check on page 2-99. Go to Excessive Fuser Drive Motor Assembly Noise on page 2-100. Go to the Paper Path Service Check on page 2-112. Go to Cover Open/HV Interlock Switch Service Check on page 2-102.

Symptom Table - 500 Sheet Drawer Option

Symptom
Printer fails to recognize the option is installed Paper jams in the option tray Paper fails to pick from the 500 sheet option tray Paper does not feed from the option to the next option above Media fails to pass thru from the lower attached paper tray option to the next higher mounted option The option fails to sense the correct paper size

Action
Go to the 500 Sheet Drawer Option Service Check on page 2-116. Go to the 500 Sheet Drawer Option Service Check on page 2-116. Go to the 500 Sheet Drawer Option Service Check on page 2-116. Go to the 500 Sheet Drawer Option Service Check on page 2-116. Go to the 500 Sheet Drawer Option Service Check on page 2-116. Go to the 500 Sheet Drawer Option Service Check on page 2-116.

Symptom Table - HCIT 2000 Sheet Option

Symptom
The printer fails to recognize the option is installed Problem with the media not feeding from the HCIT option HCIT does not function. There is no response. The HCIT is completely inoperative.

Action
Go to the HCIT 2000 Sheet Option Service Check on page 2-126. Go to the HCIT 2000 Sheet Option Service Check on page 2-126. Go to the HCIT 2000 Sheet Option Service Check on page 2-126.

2-4 Service Manual

5060-XXX

Symptom
Elevator does not move HCIT does not recognize the correct paper size

Action
Go to the HCIT 2000 Sheet Option Service Check on page 2-126. Go to the HCIT 2000 Sheet Option Service Check on page 2-126.

Symptom Table - Output Expander Option

Symptom
The printer fails to recognize the option is installed. The paper feeds into the standard bin. The printer does not display "Output Bin Full" The printer does not feed all the way into the output tray Excessive Static electricity buildup

Action
Go to Output Expander Option Service Check on page 2-60 Go to Output Expander Option Service Check on page 2-60 Go to Output Expander Option Service Check on page 2-60 Go to Output Expander Option Service Check on page 2-60

Symptom Table - 5-Bin Mailbox Option

Symptom
Printer fails to recognize the option is installed. The paper feeds into the standard bin. The printer does not display "Output Bin(s) Full" The media does not feed into selected output bin "Check Bin X" displays Excessive static electricity buildup Bin X is full but no message displays that Bin X is full "Bin X Full" message displays. You may be able to feed media into Bin X

Action
Go to 5-Bin Mailbox Option Service Check on page 2-66 Go to 5-Bin Mailbox Option Service Check on page 2-66 Go to 5-Bin Mailbox Option Service Check on page 2-66 Go to 5-Bin Mailbox Option Service Check on page 2-66 Go to 5-Bin Mailbox Option Service Check on page 2-66 Go to 5-Bin Mailbox Option Service Check on page 2-66

Diagnostic Information

2-5

5060-XXX

Symptom Table - Finisher Option

Symptom
Finisher fan inoperative Printer fails to recognize option installed Printer only prints to the standard bin No error is displayed Finisher does not staple or staple properly Finisher does not punch holes Finisher does not punch holes in selected hole pattern Printer message that the bin is full is displayed 280 Paper Jams, media in finisher Check Finisher is displayed, unable to clear Finisher is completely inoperative, no motor movement, no LEDs On Front door open, no indication on display Front Door Open is displayed, unable to clear No indication that the chad box is full No message on the operator panel Chad Box Full message is displayed when the chad box is not full 990 Error Code is displayed 202 Error Code is displayed, media jammed at the output of the fuser or the input to the finisher 201 Error Code is displayed, media jammed at the exit of the fuser

Action
Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131.

Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131.

Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131. Go to Finisher Service Check on page 2-131.

2-6 Service Manual

5060-XXX

Error Code Table

Error code
900 RIP Software 902 Service Engine Error 0

Action
Go to 900 Error Code Service Check on page 2-48. General Engine Software Errors 902 through 908 indicate an unrecoverable engine software error. The Engine Board may cause this type of error. Turn the printer off and on to try and clear the error code. If this does not fix the problem after several attempts, call your next level support before replacing the Engine Board. Interface violation by RIP - Check all cabling and connections to the RIP board. If no problem is found, replace the RIP Board on page 4-10. Interface violation by Paper Port Device - Turn the printer off and on to try and clear the error code. If this does not fix the problem after several attempts, do the following: Check each paper handling option to isolate which one is causing the problem. If you do not find a problem with any of the options, replace the Engine Board on page 4-14. Engine RAM Error - Replace the Engine Board on page 4-14. Engine Flash Error - The Engine Board might be causing the error code. Try the following: Reflash the Engine Board with the correct level code. If this does not fix the problem, replace the Engine Board on page 4-14. Engine ASIC Error - Replace the Engine Board on page 4-14. Tray 1 Transparency Sensor Error - Replace Tray 1 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Tray 2 Transparency Sensor Error - Replace Tray 2 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Tray 3 Transparency Sensor Error - Replace Tray 3 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Tray 4 Transparency Sensor Error - Replace Tray 4 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Tray 1 Transparency Sensor Error - Replace Tray 1 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Tray 2 Transparency Sensor Error - Replace Tray 2 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Tray 3 Transparency Sensor Error - Replace Tray 3 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14.

904 Engine Software

905 Engine Software

906 Engine Software 907 Engine Software

908 Engine Software 910 Trans Sensor

911 Trans Sensor

912 Trans Sensor

913 Trans Sensor

914 Trans Sensor

915 Trans Sensor

916 Trans Sensor

Diagnostic Information

2-7

5060-XXX

Error code
917 Trans Sensor

Action
Tray 4 Transparency Sensor Error - Replace Tray 4 Transparency Sensor Assembly. If this does not fix the problem, replace the Engine Board on page 4-14. Unrecoverable TPS Gain Error - Replace the ITU Assembly on page 4-41. Unrecoverable TPS Error - Replace the ITU Assembly on page 4-41. Unrecoverable TPS Invalid Belt - Replace the ITU Assembly on page 4-41. Fuser Fan - Go to Fuser Fan Service Check on page 2-54. VTB Fan - Go to VTB Fan Service Check on page 2-55. RIP Fan - Go to RIP Fan Service Check on page 2-55. Unable to find zero crossover point - Replace the LVPS on page 4-15. Invalid AC Frequency - The AC Power Line Frequency may be incorrect. Go to the AC Power Service Check on page 2-56. The RIP card processor cannot communicate with the engine processor. Check the RIP to Engine cable for correct installation. If installed correctly replace the following FRU's: RIP Board on page 4-10 If this does not fix the problem, replace: Engine Board on page 4-14 Cyan TMC switch failure - Go to the Cyan Cartridge Drive Assembly Service Check on page 2-52. Magenta TMC switch failure - Go to the Magenta Cartridge Drive Assembly on page 2-51. Yellow TMC switch failure - Go to the Yellow Cartridge Drive Assembly Service Check on page 2-53. Black TMC switch failure - Go to the Black Cartridge Drive Assembly Service Check on page 2-50. Transfer Servo Start Error - Cyan - Check the cable connections to Engine Board and Transfer HVPS. If the connections are good, check the continuity of the cable. If the cable measures continuity, replace the HVPS Transfer Board on page 4-12. If this does not correct the problem, replace the Engine Board on page 4-14. Transfer Servo Start Error - Magenta - Check the cable connections to Engine Board and Transfer HVPS. If the connections are good, check the continuity of the cable. If the cable measures continuity, replace the HVPS Transfer Board on page 4-12. If this does not correct the problem, replace the Engine Board on page 4-14.

920 Color Calibrate 921 Color Calibrate 922 Color Calibrate 925 Fan Stalled 926 Fan Stalled 927 Fan Stalled 930 LV Power Supply 931 LV Power Supply 939 RIP Engine Comm

940 TMC Error 941 TMC Error 942 TMC Error 943 TMC Error 945 Transfer Roll

946 Transfer Roll

2-8 Service Manual

5060-XXX

Error code
947 Transfer Roll

Action
Transfer Servo Start Error - Yellow - Check the cable connections to Engine Board and Transfer HVPS. If the connections are good, check the continuity of the cable. If the cable measures continuity, replace the HVPS Transfer Board on page 4-12. If this does not correct the problem, replace the Engine Board on page 4-14. Transfer Servo Start Error - Black - Check the cable connections to Engine Board and Transfer HVPS. If the connections are good, check the continuity of the cable. If the cable measures continuity, replace the HVPS Transfer Board on page 4-12. If this does not correct the problem, replace the Engine Board on page 4-14. Transfer Servo Start Error - ITU - Check the cable connections to Engine Board and Transfer HVPS. If the connections are good, check the continuity of the cable. If the cable measures continuity, replace the HVPS Transfer Board on page 4-12. If this does not correct the problem, replace the Engine Board on page 4-14. NVRAM Chip Failure Engine Board - Replace the Engine Board on page 4-14. NVRAM CRC Failure Engine Board - Replace the Engine Board on page 4-14. NVRAM Chip Failure RIP Board - Replace the RIP Board on page 4-10. NVRAM CRC failure - Replace the RIP Board on page 4-10. RIP Board - This error indicates that the Code ROM or NAND failed the CRC check. The location of the failure is indicated by <loc>. Errors 956 and 957 indicate which area of the controller (RIP) card failed. Replace the RIP Board on page 4-10. Replace the RIP Board on page 4-10. Replace the RIP Board on page 4-10. RAM soldered on board is bad. Replace the RIP Board on page 4-10. Errors 961 through 963 indicate that a memory error has occurred on RAM x in slot x installed on the RIP card. If available, switch memory from the failing slot with one from a non-failing slot to see if this fixes the problem. If it does not fix the problem, replace the RIP Board on page 4-10. If it does fix the problem replace the defective RAM. Download Emulation CRC failure has occurred. Unrecognizable network Errors 975 through 979 indicate a failure with the standard network port located on the controller board or a network card in the specified slot x, x=1, 2 or 3.

948 Transfer Roll

949 Transfer Roll

951 NVRAM Failure 952 NVRAM Failure 953 NVRAM Failure 954 NVRAM Failure 955 Code CRC <loc> 956 System Board Processor Failure 957 System Board ASIC Failure 958 NAND Failure 960 RAM Memory Error 961 RAM Memory Error 962 RAM Memory Error 963 RAM Memory Error

964 Emulation Error 975 Standard Network or Network Card X 975 Network Card X 976 Standard Network

Unrecoverable software or error in network port. Network Card X

Diagnostic Information

2-9

5060-XXX

Error code
978 Standard Network or Network Card X 979 Standard Network or Network Card X 980 <device> comm

Action
Bad checksum while programming network Network Card X port.

Flash parts failed while programming Network Card X port.

Engine is experiencing unreliable communications to the specified device. Errors 980 through 984 indicate the specified device has detected a Paper Port communication failure. Engine protocol violation detected by the specified device. * Engine * Duplex unit * Tray x (where x=1,2,3,4, or 5) Communications error detected by the specified device. * Output Bin (where x=1,2,3,or 6) Note: This message is used for single bin output devices. * Bins x to y (where x to y= 1 to 5, 2 to 6, or 6 to 10) Invalid command received by the specified device. Note: This message is used for multiple bin output devices. Note: Check the autoconnects above and below the failing option to make sure they are seated and connected correctly. Go to the service check for the device indicated. Invalid command parameter received by the specified device. This error message indicates that an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure. Go to 990 Error Code displayed for Tray x on page 2-122. Note: <device> can be one of the following: * Duplex unit * Tray x (where x=1,2,3,4, or 5) * Output Bin x (where x=1,2,3, or 6) Note: This message is used for single bin output devices. * Output Bin x to y (where x=1 to 5, 2 to 6, or 6 to 20) Note: This message is used for multiple bin output devices. This error message indicates that a device has detected an equipment check in its system board. Note: <device> can be one of the following. * Duplex unit * Tray x (where x=1,2,3,4 or 5) * Output Bin x (where x=1,2,3, or 6) Note: This message is used for single bin output devices. * Output Bin x to y (where x=1 to 5, 2 to 6, or 6 to 20) Note: This message is used for multiple bin output devices. Go to the service check for the device indicated.

981 <device> comm

982 <device> comm

983 <device> comm

984 <device> comm 990 <device>

991 <device> Card

2-10 Service Manual

5060-XXX

Error code
100 ITU Error 101 ITU Error 102 ITU Error 103 ITU Error 106 Printhead Error

Action
ITU Stall - Go to 100 ITU Error Service Check on page 2-86. Invalid ITU Memory - Replace ITU Assembly on page 4-41. ITU Shorted Thermistor - Replace ITU Assembly on page 4-41. Memory Load Error - Replace ITU Assembly on page 4-41. Cyan Printhead Lost Hsync Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J5, and J6 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Cyan Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1. Magenta Printhead Lost Hsync Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J7 and J8 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Magenta Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1. Yellow Printhead Lost Hsync Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J2 and J3 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Yellow Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1.

107 Printhead Error

108 Printhead Error

Diagnostic Information

2-11

5060-XXX

Error code
109 Printhead Error

Action
Black Printhead Lost Hsync Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J9, J10 and J11 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Black Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1. No first Hysnc - Cyan Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J4, J5 and J6 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Cyan Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1. No first Hysnc - Magenta Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J7, J8 and J9 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Magenta Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1. No first Hysnc - Yellow Check for the correct installation of the all the cables to the RIP Board assembly and to the Printhead assembly; J2, J3 and J4 on the RIP Board. Go to RIP Board on page 5-11. If the cables are connected correctly to the RIP Board and to the Printhead assembly, replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Yellow Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced, it is necessary to perform the Printhead Adjustments on page 4-1.

110 Printhead Error

111 Printhead Error

112 Printhead Error

2-12 Service Manual

5060-XXX

Error code
113 Printhead Error

Action
No first Hysnc - Black Replace the following FRU: RIP Board on page 4-10 If this does not fix the problem replace: Black Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever a printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. A Black Printhead Servo Error has been detected - Go to Error Code 114 on page 2-91. A Cyan Printhead Servo Error has been detected. Go to Error Code 115 on page 2-92. A Magenta Printhead Servo Error has been detected. Go to Error Code 116 on page 2-93. A Yellow Printhead Servo Error has been detected. Go to Error Code 117 on page 2-94. Wrong Fuser Lamp - Hot Roll - Replace with correct lamp. Go to Error Code 120 Error Code 121 on page 2-95. Wrong Fuser Lamp - BUR - Replace with correct lamp. Go to Error Code 120 Error Code 121 on page 2-95. Fuser below temperature when printing - Hot Roll - Go to Cold Fuser Service Check on page 2-95. Fuser below temperature when printing - BUR - Go to Cold Fuser Service Check on page 2-95. Fuser over temperature - Hot Roll - Go to Error Code 124 Error Code 134 on page 2-99. Fuser over temperature - BUR - Go to Error Code 125 Error Code 135 on page 2-99. Fuser Open Thermistor Hot Roll - Go to Error Code 126 on page 2-97. Fuser Open Thermistor BUR - Go to Error Code 127 on page 2-98. Fuser Under Temperature in Standby - Hot Roll - Go to Error Code 128 on page 2-95. Fuser Under Temperature in Standby - BUR - Go to Error Code 129 on page 2-95. Fuser failed to reach standby temperature - Hot Roll - Go to Error Code 130 on page 2-96. Fuser failed to reach standby temperature -BUR - Go to Error Code 131 on page 2-96. Fuser cold roll - Hot Roll - Go to Error Code 132 - Cold Hot Roll Error Code 133 - Cold Backup Roll on page 2-97.

114 Printhead Error 115 Printhead Error 116 Printhead Error 117 Printhead Error 120 Fuser Error 121 Fuser Error 122 Fuser Error 123 Fuser Error 124 Fuser Error 125 Fuser Error 126 Fuser Error 127 Fuser Error 128 Fuser Error 129 Fuser Error 130 Fuser Error 131 Fuser Error 132 Fuser Error

Diagnostic Information

2-13

5060-XXX

Error code
133 Fuser Error 134 Fuser Error 135 Fuser Error 136 Fuser Error 140 Motor

Action
Fuser cold roll - BUR - Go to Error Code 132 - Cold Hot Roll Error Code 133 - Cold Backup Roll on page 2-97. Fuser Lamp on too long Hot Roll - Go to Error Code 124 Error Code 134 on page 2-99. Fuser Lamp on too long BUR - Go to Error Code 125 Error Code 135 on page 2-99. Fuser cam position not found - Go to Fuser assembly cam position is not found on page 2-100. DC Motor Accel Stall - Staging - Replace the following FRU: Staging Motor Assembly If this does not fix the problem, replace: Engine Board on page 4-14 DC Pick Motor Excessive PWM - Staging Motor - Replace the following FRU: Engine Board on page 4-14 If this does not fix the problem, replace: Replace the Staging Motor Assembly DC Pick Motor, over speed - Staging Motor - Replace the Staging Motor Assembly DC Pick Motor, No encoder Feedback - Staging Motor - Replace the Staging Motor Assembly DC Motor accel stall - Autocompensator Motor - Replace the following FRU: Autocompensator Assembly If this does not fix the problem, replace: Engine Board on page 4-14 DC Motor Excessive PWM Autocompensator Motor - Replace the following FRU: Autocompensator Assembly If this does not fix the problem, replace: Engine Board on page 4-14 DC Motor over speed Autocompensator Motor - Replace the Autocompensator Assembly DC Motor Pick Motor, No encoder Feedback - Autocompensator Motor - Replace the Autocompensator Assembly. ITU Belt Motor, Unable to lock - Go to ITU Drive Motor Service Check on page 2-89. Fuser Drive Motor unable to lock - Go to Error Code 149 Error Code 155 on page 2-100. Black Cartridge Motor unable to lock - Go to Black Cartridge Drive Assembly Service Check on page 2-50.

141 Motor

142 Motor 143 Motor 144 Motor

145 Motor

146 Motor 147 Motor 148 Motor 149 Motor 150 Motor

2-14 Service Manual

5060-XXX

Error code
151 Motor 152 Motor 153 Motor 154 Motor 155 Motor 156 Motor 157 Motor 158 Motor 159 Motor 160 Motor 161 Motor 162 Motor 163 Motor 164 Motor 165 Motor 167 Motor 168 Motor

Action
Magenta Cartridge Motor Unable to lock - Go to Magenta Cartridge Drive Assembly on page 2-51. Cyan Cartridge Motor unable to lock - Go to Cyan Cartridge Drive Assembly Service Check on page 2-52. Yellow Cartridge Motor unable to lock - Go to Yellow Cartridge Drive Assembly Service Check on page 2-53. ITU Belt Motor - lost lock - Go to ITU Drive Motor Service Check on page 2-89. Fuser Drive Motor - lost lock - Go to Error Code 149 Error Code 155 on page 2-100. Black Cartridge Motor lost lock - Go to Black Cartridge Drive Assembly Service Check on page 2-50. Magenta Cartridge Motor lost lock - Go to Magenta Cartridge Drive Assembly on page 2-51. Cyan Cartridge Motor lost lock - Go to Cyan Cartridge Drive Assembly Service Check on page 2-52. Yellow Cartridge Motor lost lock - Go to Yellow Cartridge Drive Assembly Service Check on page 2-53. ITU Belt BLDC Motor MFG. Unknown - Go to ITU Drive Motor Service Check on page 2-89. Fuser Drive BLDC motor mfg. unknown - Go to Error Code 161 on page 2-99. Black Cartridge BLDC motor mfg. unkown - Go to Black Cartridge Drive Assembly Service Check on page 2-50. Magenta Cartridge BLDC motor mfg. unknown - Go to Magenta Cartridge Drive Assembly on page 2-51. Cyan Cartridge BLDC motor mfg. unknown - Go to Cyan Cartridge Drive Assembly Service Check on page 2-52. Yellow Cartridge BLDC motor Mfg. Unknown - Go to Yellow Cartridge Drive Assembly Service Check on page 2-53. Web Oiler encoder error, unexpected encoders - Replace the Fuser Assembly on page 4-16. Unknown manufacture type - Perform Automated Motor Detection on page 3-20. If you do not find the problem after performing the test, call your next level support. Mirror Motor lock not achieved - Black - Replace the following FRU: RIP Board on page 4-10 If this does not fix the problem, replace: Black Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1.

169 Motor

Diagnostic Information

2-15

5060-XXX

Error code
170 Motor

Action
Mirror motor lost lock - Black - Replace the Black Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. Mirror Motor lock not achieved - Cyan - Replace the following FRU: RIP Board on page 4-10 If this does not fix the problem, replace: Black Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. Mirror motor lost lock - Cyan - Replace the Cyan Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. Mirror Motor lock not achieved - Magenta - Replace the following FRU: RIP Board on page 4-10 If this does not fix the problem, replace: Magenta Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. Mirror motor lost lock - Magenta - Replace the Magenta Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. Mirror Motor lock not achieved - Yellow - Replace the following FRU: RIP Board on page 4-10 If this does not fix the problem, replace: Yellow Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. Mirror motor lost lock - Yellow - Replace the Magenta Printhead Assembly - Go to Printheads on page 4-34. Note: Whenever the printhead assembly is replaced it is necessary to perform the Printhead Adjustments on page 4-1. PSD sensor error (Black) - Replace the Black PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. PSD sensor error (Cyan) - Replace the Cyan PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1.

171 Motor

172 Motor

173 Motor

174 Motor

175 Motor

176 Motor

180 PSD Error

181 PSD Error

2-16 Service Manual

5060-XXX

Error code
182 PSD Error

Action
PSD sensor error (Magenta) - Replace the Magenta PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. PSD sensor error (Yellow) - Replace the Yellow PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range scan direction (Black) - Replace the Black PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Black Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range scan direction (Cyan) - Replace the Cyan PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Cyan Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range scan direction (Magenta) - Replace the Magenta PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Magenta Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range scan direction (Yellow) - Replace the Yellow PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Yellow Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range process direction (Black) - Replace the Black PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range process direction (Cyan) - Replace the Cyan PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. EOS sensor out of range process direction (Magenta) - Replace the Magenta PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1.

183 PSD Error

184 PSD Error

185 PSD Error

186 PSD Error

187 PSD Error

188 PSD Error

189 PSD Error

190 PSD Error

Diagnostic Information

2-17

5060-XXX

Error code
191 PSD Error

Action
EOS sensor out of range process direction (Yellow) - Replace the Yellow PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. No EOS reading (Black) - Go to PSD Service Check on page 2-103. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. No EOS reading (Cyan) - Go to PSD Service Check on page 2-103. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. No EOS reading (Magenta) - Go to PSD Service Check on page 2-103. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. No EOS reading (Yellow) - Replace the Yellow PSD Sensor Assembly on page 4-36. Note: It is necessary to remove the Printhead Assembly to access the PSD Sensor Assembly, therefore it is necessary to perform the Printhead Adjustments on page 4-1. This message indicates that the printer has detected an invalid version of the RIP code and must be reflashed to the approved version. Contact your next level support.

192 PSD Error

193 PSD Error

194 PSD Error

195 PSD Error

199 Service Reflash RIP

2-18 Service Manual

5060-XXX

Sub Error Code Table

The Sub-Error code table may be helpful troubleshooting the printer when 9xx and 1xx Error Codes have been displayed. When a 9xx or 1xx Error Code is displayed, press and hold Return and press Select to view the Sub Error Code.

Sub Error Code

2D 00 2D 02 2D 03 2D 04 2D 05 2D 06 2D 07 2D 08 2D 09 2D 0A 2D 0B 2D 0C 2D 0D 2D 14 2D 15 2D 16 2D 17 2D 18 2D 19 2D 1A 2D 1B 2D 1C 2D 1D 2D 1E 2D 1F

Explanation
No media available in Duplex unit. Paper jam detected. Sensor S2 was activated at an unexpected time. Paper jam detected. Sensor S2 was not activated within the time-out period. Paper jam detected. Sensor S2 did not deactivate during the time-out period. Paper jam detected. Sensor NM was activated at an unexpected time. Paper jam detected. Sensor NM did not deactivate during the time-out period. Paper jam detected. The fuser exit sensor was activated at an unexpected time. Paper jam detected. The fuser exit sensor did not deactivate by the previous page or the current page did not activate the fuser exit sensor within the time-out period. Paper jam detected. The fuser exit sensor did not deactivate during the time-out period. Paper jam detected. A paper jam detected in the Duplex unit. Paper jam detected. A paper jam detected in Tray 2. Paper jam detected. A paper jam detected in Tray 3. Paper jam detected. A paper jam detected in Tray 4. Prism Sensor detected different media from the tray sensor. Paper jam detected. A paper jam detected in Stacker 1. Paper jam detected. A paper jam detected in Stacker 2. Paper jam detected. A paper jam detected in Stacker 3. Paper jam detected. A paper jam detected in Stacker 4. Paper jam detected. A paper jam detected in Stacker 5. Paper jam detected. A paper jam detected in Stacker 6. Sensor (S2) has been activated or an obstructed. Fuser narrow media sensor obstructed. Fuser exit sensor obstructed. Duplex Senor(s) obstructed. Tray 2 sensor obstructed.

Diagnostic Information

2-19

5060-XXX

Sub Error Code

2D 20 2D 21 2D 22 2D 23 2D 24 2D 25 2D 26 2D 27 2D 28 2D 29 2D 2A 2D 2B 2D 2C 2D 2D 2D 2E 2D 2F 2D 30 2D 31 2D 32 2D 33 2D 34 2D 35 2D 36 2D 37 2D 38 2D 39 2D 3A 2D 3B 2D 3C 2D 3D

Explanation
Tray 3 sensor obstructed Tray 4 sensor obstructed Passthru sensor in Stacker 1 obstructed. Passthru sensor in Stacker 2 obstructed. Passthru sensor in Stacker 3 obstructed. Passthru sensor in Stacker 4 obstructed. Passthru sensor in Stacker 5 obstructed. Passthru sensor in Stacker 6 obstructed. Paper jam detected. A paper jam detected in the Duplex unit. Paper jam detected. A paper jam detected in Tray 2. Paper jam detected. A paper jam detected in Tray 3. Paper jam detected. A paper jam detected in Tray 4. Duplex input motor error detected, the engine detected a stall condition. Duplex input motor error detected, the engine detected a PWM error. Duplex input motor error detected, the engine detected a motor encoder error. Duplex reversing motor error detected, the engine detected a stall condition. Duplex reversing motor error detected, the engine has detected a PWM error condition. Duplex reversing motor error has been detected, the engine detected a motor encoder error. A Tray 2 pick motor stall error detected A Tray 2 pick motor PWM error detected A Tray 2 pick motor encoder error detected A Tray 2 feed motor stall error detected A Tray 2 feed motor PWM error detected A Tray 2 feed motor Encoder error detected A Tray 3 pick motor stall error detected A Tray 3 pick motor PWM error detected A Tray 3 pick motor Encoder error detected A Tray 4 feed motor stall error detected A Tray 4 feed motor PWM error detected A Tray 4 feed motor Encoder error detected

2-20 Service Manual

5060-XXX

Sub Error Code

2D 3E 2D 3F 2D 40 2D 41 2D 42 2D 43 2D 44 2D 45 2D 46 2D 47 2D 48 2D 49 2D 4A 2D 4B 2D 4C 2D 4E 2D 4F 2D 50 2D 51 2D 52 2D 53

Explanation
A Tray 4 pick motor stall error detected A Tray 4 pick motor PWM error detected A Tray 4 pick motor Encoder error detected A Tray 4 feed motor stall error detected A Tray 4 feed motor PWM error detected A Tray 4 feed motor encoder error detected A Staging Motor stall error detected when picking media from the MPF. An autocompensator motor stall error detected when picking media from the MPF. An autocompensator motor stall error detected when picking media from Tray 1. A staging motor PWM error detected An autocompensator motor PWM error detected when picking media from the MPF. An autocompensator motor PWM error detected when picking media form Tray 1. A staging motor Encoder error detected An autocompensator motor Encoder error detected when picking media from the MPF. An autocompensator motor Encoder error detected when picking media from Tray 1. The output expander sensor was not activated by the media. The topmost output option sensor obstructed. The 5-Bin Mailbox pass thru sensor was not deactivated by the previous page or not activated by the current page. The 5-Bin Mailbox pass thru sensor was not activated by the media. The 5-Bin Mailbox sensor was not deactivated by the previous page or not activated by the current page. The 5-Bin Mailbox sensor was not activated by the media.

Diagnostic Information

2-21

5060-XXX

HCIT System Board LED Error Code Table

If a failure is detected by the system board, an error code may be displayed. If the System Board LED is On solid, the HCIT detects that the tray or side door is not closed. The LED on the system board may blink. Count the number of times the LED blinks and use the following table to determine the problem.

LED blinks
1 2 3 4 5 6 7 8 9 10 11 12

Problem
Jam at registration sensor S2 Jam before the leading edge of the paper reaches the registration sensor S2 Paper jam is still detected in the HCIT after removing the jam Paper jam is still detected even with front of jam door closed Paper jam detected at pick sensor Error detected with the tray Error detected at the registration roller home position Error detected at the pick roller home position sensor (S1) An error has been detected with the Lift Motor - no motor lock or loss of lock Not used Communication error Other error - Failure of the adjustment of the mirror reflection sensors or EEPROM initialization

2-22 Service Manual

5060-XXX

HCOF Error Code Table

Led Number
33 34 35 36 37 38 39 42 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Error detected by Punch Timing Sensor Error detected by Inverter Jam Sensor Error detected by Drop Timing Sensor Error detected by Exit Timing Sensor Error detected for the Jogger Motor Error detected for the Punch Motor Error detected for the Stapler Motor Error detected for the Belt Motor Error detected for the Tray Motor The HCOF detects the front door is open An error is detected with the communications to the printer Error detected for the Offset Motor Tray near full is detected Tray Full is detected Error detected with Stapler - Stapler not mounted correctly Error detected with Stapler - Stapler Cartridge not installed correctly Error detected with Stapler - runs short Error detected with Punch Timing Sensor - Media not reaching sensor Error detected with Inverter Jam Sensor - Media not reaching sensor Error detected with Drop Timing Sensor - Media not reaching sensor Error detected with Exit Timing Sensor - Media not reaching sensor Error detected with Chad Box - Box full

Description

Diagnostic Information

2-23

5060-XXX

2XX Paper Jam Message Table

Note: A secondary message only displays if the finisher option is installed. Use the Sub Error Code Table on page 2-19 to help diagnose paper jam problems.

2xx code
200

Primary Message
Paper Jam Clear Paper Path Go to the Paper Path Service Check on page 2-112

Secondary Message
Leave sheets in Finisher area 5

Description
Primary: Paper is jammed at the printers input sensor. Open the printers left door to access the paper jam. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

201

Paper Jam Clear Paper Path Go to the Paper Path Service Check on page 2-112

Leave sheets in Finisher area 5

Primary: Paper is jammed at the fuser, open the right door to access the jam area. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

202

Paper Jam Clear Paper Path Go to the Paper Path Service Check on page 2-112

Leave sheets in Finisher area 5

Primary: A paper jam has occurred at the fuser. Open the right door to access the jam area. If sheets have been accumulated to be stapled or offset when the jam is detected, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure. The printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

2-24 Service Manual

5060-XXX

2xx code
203

Primary Message
Paper Jam Clear paper Path

Secondary Message
Leave Job in Finisher

Description
Primary: The media is jammed due to a transparency sensor mismatch. Open the printer left door to access the jammed media. If sheets have been accumulated to be stapled or offset when the jam is detected, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure. The printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

230

Paper Jam Clear Paper Path

Leave Job in Finisher

Primary: The media is most likely jammed in the duplex unit, remove the duplex tray to access the jam area. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

24x

Paper Jam Clear Paper Path

Leave Job in Finisher

Primary: Media is jammed around Tray x (Tray x=2 through 4) and applies to both a 500 Tray and HCIT tray. Try opening Tray x. If the tray is difficult to remove then you may need to remove the tray above or below Tray x to remove the jam. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

Diagnostic Information

2-25

5060-XXX

2xx code
250

Primary Message
Paper Jam Clear Paper Path Go to the Multipurpose Feeder (MPF) Service Check on page 2-109

Secondary Message
Leave Job in Finisher

Description
Primary: Media is jammed in the MP Feeder. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

251

Paper Jam Clear Paper Path Go to the Autocompensator Service Check on page 2-106

Leave Job in Finisher

Primary: Media is jammed in the paper path near the MP Feeder due to an in-line transparency sensor mismatch. If sheets have been accumulated to be stapled or offset when the jam is detected, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure. Secondary: Do not remove accumulated sheets during the jam clearance procedure. The printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

271

Paper Jam Clear Paper Path

Leave Job in Finisher

Primary: Media is jammed at output Bin 1. Open the rear door of Bin 1 to access the jam. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

2-26 Service Manual

5060-XXX

2xx code
272

Primary Message
Paper Jam Clear Paper Path

Secondary Message
Leave Job in Finisher

Description
Primary: Media is jammed in output Bin x. Open the door of output Bin X to access the jam. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

280

Paper Jam Clear Paper Path

Leave Job in Finisher

Primary: Paper is jammed in the Finisher option, open the side door or top cover to access the jam. If sheets have been accumulated to be stapled or offset when the jam occurred, the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets not be removed during the jam clearing procedure. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

Diagnostic Information

2-27

5060-XXX

User Attendance Message Table

User Primary Message
200 Paper Jam Clear Paper Path

User Secondary Message

Leave sheets in Finisher area 5

Explanation
Primary: This message indicates that a paper jam has occurred at or near the printer Input Sensor. Open the printers left door (Paper Jam Removal Door) to access the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: Media has jammed before the fuser, open the printer left door to access the jammed media Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: Media has jammed at the fuser, open the printer right door to access the jam area. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled.

201 Paper Jam Clear Paper Path

Leave sheets in Finisher area 5

202 Paper Jam Clear Paper Path

Leave sheets in Finisher area 5

2-28 Service Manual

5060-XXX

User Primary Message

203 Paper Jam Clear Paper Path

User Secondary Message

Leave Job in Finisher area 5

Explanation
Primary: Media has jammed due to a transparency sensor mismatch. Open the printer left door to access the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: Paper has most likely jammed in the Duplex unit. Remove the duplex tray to access the jam. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: This paper jam message can apply to both the 500 Sheet Option Tray and HCIT option. Tray x(x=2 thru 4). Try opening Tray x, if the tray is difficult to remove then you may need to remove the tray above or below Tray x to remove the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled.

230 Paper Jam Clear Paper Path

Leave Job in Finisher area 5

24x Paper Jam Clear Paper Path

Leave Job in Finisher area 5

Diagnostic Information

2-29

5060-XXX

User Primary Message

250 Paper Jam Clear Paper Path

User Secondary Message

Leave Job in Finisher area 5

Explanation
Primary: Paper is jammed in the MPF. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: The paper has jammed in the paper path near the MPF due to an in-line transparency sensor mismatch. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: Paper has jammed at Output Bin 1, open the door of Bin 1 to access the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. Primary: Media is jammed in the 5-Bin Mailbox Option. Open the rear door of option to access the jammed media. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled.

251 Paper Jam Clear Paper Path

Leave Job in Finisher area 5

271 Paper Jam Clear Paper Path

Leave Job in Finisher area 5

272 Paper Jam Clear Paper Path

Leave Job in Finisher area 5

2-30 Service Manual

5060-XXX

User Primary Message

280 Paper Jam Clear Paper Path

User Secondary Message

Leave sheets in Finisher area 5

Explanation
Primary: Media has jammed in the Finisher Option, open the Finisher Option Side door to top cover to access the jammed pages. Secondary: If sheets have been accumulated to be stapled when the jam is detected, the printer alternately flashes the primary and secondary messages indicating the accumulated sheets should not be removed during jam clearance. Note: When the secondary message is displayed, if the accumulated sheets are removed the printer will not reprint these sheets. Also if the print job is completed, the portion of the job printed after the jam will not be stapled. These messages will be displayed when the stapler device detects a paper jam. 282 Staple Jam message indicates that a staple jam has been detected during normal stapler operation such as when printing and stapling jobs. 283 Staple Jam message indicates that a staple jam has been detected during a priming operation. No secondary message will be displayed. Note: After the error has been cleared, the printer does not reprint any pages which existed in the accumulator for stapling. The following actions can be taken while either the primary or secondary messages are displayed: * Press Go to initiate priming and resume printing. Note: Use of the Sub Error Code Chart may help in diagnosing 282 and 283 Errors. This message will be displayed when the printer has detected at POST, that packing material is still installed and must be removed. The user should verify that the machine is properly setup. * Press Go and Reflash Code. This message will be displayed when an ITU Alignment Procedure is in process and the printer is prompting the user for the X (X=A thru L) alignment value. Alignment values for A thru L (=X.X*) -7 to +7 in 0.5 increments. * Enter the alignment value and press Select to continue to the next alignment value. * To abort the alignment operation press Go or Return.

282 Staple Jam Check Stapler 283 Staple Jam Check Stapler

Remove Job from Finisher

Setup Required

A Alignment =X.X*

Diagnostic Information

2-31

5060-XXX

User Primary Message

Calibrate <Tray x> Load Paper

User Secondary Message

Explanation
This message will be displayed when the user has initiated a tray calibration procedure. <Tray x> = Tray 1 thru 4, MPF, Envelope Feeder, Manual Paper and Manual Envelope. The following actions can be taken while this message is displayed: * Load paper into Tray x and press Go to initiate the calibration. * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu: * Reset Printer * Reset Active Bin * Check Supply Levels This message will be displayed when a tray has been detected that is uncalibrated. This message usually means a user-correctable NVRAM problem or the tray was not calibrated at the factory or needs to be calibrated. Perform the following steps to calibrate a tray:
1. Turn the printer off. 2. Press and hold the SELECT and RETURN buttons while powering on the machine. 3. Release the buttons when Performing Self Test is displayed. 4. Select Calibrate Trays from the menu. 5. Select Tray X from the menu. 6. The display will prompt load paper if necessary. 7. Load paper. 8. Press Go. 9. Calibrating Tray X will be displayed 10. Repeat for any other Trays that might need to be calibrated. 11. Exit Configuration Menu.

Tray x Not Calibrated

Change Cartridge <Color> Invalid Refill

This message will be displayed when the printer has detected a refilled prebate cartridge. <Color> can be one of the following: *Black, CYAN, Magenta or Yellow. The following actions can be taken while this message is displayed. * Remove the toner cartridge and install a new cartridge. Note: The user will receive this message for every invalid cartridge installed. This message will be displayed when the printer is requesting the operator to change the media installed in one of the input sources. <input source>=Tray 1 thru 5, MPF or Envelope Feeder.

Change <custom Type Name> <input source>

2-32 Service Manual

5060-XXX

User Primary Message

Change <input source> <Custom String> Change <input source> <Size> Change <input source> <type> <size> Reattach Output Bin x Reattach Bins x-y Check Tray x Connection

User Secondary Message

Explanation
One of the following will be displayed on line two. * The user can define a name for each of the custom types (Custom 1 thru 6)

These messages will be displayed anytime the printer loses communications with one of the following options: * Output Bin x(x=1,2 or 3) * Bins (x-y=1 thru 5) * Tray x (x=2,3,4 or 5) * Duplex * Finisher This message may be displayed in two ways. The specified option could have been removed form the printer, maybe to clear a paper jam or to uninstall the option or the option may be still installed but experiencing a communications problem such as not being fully installed or has a hardware failure. The most likely cause of this message is a failure to reattach the option when removed to service a printer intervention. The following actions can be taken while this message is displayed. If the option was temporarily removed or not connected properly, then reattach or reconnect it. When the option is recognized, the printer will automatically clear the attendance message and continue. Press GO to execute a configuration change which will tell the printer the option has been Hot Uplugged removed. In this case it is assumed that the user wishes to continue to operate the printer with the option removed. If the problem continues, turn the printer off and back on. If the message continues to be displayed, turn the printer off, remove the option and call for service. This message will be displayed when the printer upper front cover (door) is open. * Close the upper front cover (door) This message will be displayed when the Finisher Option top cover is open. Close the finisher top cover.

Check Duplex Connection Check Finisher Connection

Close Door

Close Finisher Door

Diagnostic Information

2-33

5060-XXX

User Primary Message

Disk Corrupted

User Secondary Message

Explanation
This message will be displayed when the printer has detected that there are errors on the hard disk that could not be corrected. The disk cannot be used until it has been reformatted. The following actions can be taken while this message is displayed: * Press Return or Stop to clear the message. The disk cannot be used without reformatting the disk. Note: All data will be lost for the following action: * Press Go to format the disk. This message will be displayed when the Hole Punch Alarm is ON and any of the following is true: * The code has determined that the Hole Punch Waste Box is completely full. The following actions may be taken while this message is displayed: * The user may empty the Hole Punch Box and put it back to clear the message. * Press Go to ignore the message, the job will be printed without hole punching. Each time a new job that requests Hole Punch will cause this message to be displayed again if the box has not been emptied. This message will be displayed when an error has occurred during the printer staple priming operation. The following actions can be taken while this message is displayed: * Press Go to initiate the priming operation again or * Press Return or Stop to cancel the priming operation. Note: If no action is taken and the printer Auto Continue setting is not disabled, the printer will eventually clear the message and the priming operation will be cancelled and the printer will resume printing.

Hole Punch Waste Full

Priming Failed, Retry. GO/Stop

2-34 Service Manual

5060-XXX

User Primary Message

Insert Staple Cartridge

User Secondary Message

Explanation
This message will be displayed when the staple cartridge is missing or installed incorrectly. This message can be displayed at any of the following times, regardless of the Staple Alarm setting. * At POST * After the Stapler Door has been closed. The following actions can be taken when this message is displayed: * Install the staple cartridge or * Press Go to ignore this message. The printer will now handle staple jobs as if the staple unit were installed with no staples. The Staples Empty warning will appear on the status line and Load Staples may immediately appear. This message will be displayed when the Staples Empty Alarm is activated and one of the following has occurred: * There are no staples in the staple unit or the staple unit is not installed. This message may be displayed at any of the following times: * Prior to printing the first page of a batch of pages that are to be stapled or during the printing of a batch of pages that are to be stapled (if the condition cannot be detected prior to printing the first page of the batch). The following actions can be taken while this message is displayed: * A new staple cartridge may be installed to clear this message and start/continue printing the staple batch or * Ignore the Load Staples request for this print job by pressing Go or Select. The printer will resume printing, however the print job for which stapling was selected will not be stapled or press Menu> or Menu< to access the Busy/Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group.

Load Staples

Diagnostic Information

2-35

5060-XXX

User Primary Message

Install Tray x or Cancel Job Install Bin x or Cancel Job Install Duplex or Cancel Job

User Secondary Message

Explanation
This message will be displayed when the printer requests the user to insert tray x before it can continue printing the job. This message is displayed because the printer needs to pick media from the missing tray or the trays below it. *Tray=Tray 1, Tray 2, Tray 3, Tray 4 or Tray 5 Note: This message will most likely be displayed when refilling the trays during a job. Before filling tray x take the printer off line by pressing the Stop button and waiting for pages to reach the output bin before refilling trays. The following actions can be taken while this message is displayed. * Insert the requested tray or * Press Menu> or Menu< to access the Busy/Waiting Menu Group The following functions will be available via the Busy/Waiting Menu: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels This message will be displayed when the user has Hot Unplugged a paper handling option and the printer requires the reinstallation of the option to print a page which has been formatted by an install Tray x interpreter prior to removal of the option or Cancel Job * Bin x(x=1,2 or 3) * Tray x(x=2,3,4 or 5) * Duplex The following actions can be taken while this message is displayed: * Insert the requested option or * Press Menu> or Menu< to access the Busy/Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels This message will be displayed when the printer is turned on and no DRAM is installed. The following actions can be taken while this message is displayed: * Turn the printer off, install DRAM and turn the printer back on.

No DRAM Installed

2-36 Service Manual

5060-XXX

User Primary Message

30 ITU Missing

User Secondary Message

Explanation
This message will be displayed when the ITU is missing. The following action can be taken while this message is displayed: * Turn the printer off, insert the ITU and turn the printer back on. This message will be displayed when the printer is missing the Yellow, Magenta, Cyan or Black toner cartridge. Open the front cover, insert the toner cartridge and close the cover.

30 Yellow Toner Cart Missing 30 Magenta Toner Cart Missing 30 Cyan Toner Cart Missing 30 Black Toner Cart Missing 31 Defective Black Cartridge 31 Defective Yellow Cartridge 31 Defective Magenta Cartridge 31 Defective Cyan Cartridge 32 Unsupported

This message will be displayed when the top cover is closed and a defective print cartridge is detected. It may take the printer 10 to 20 seconds to determine whether or not the print cartridge The printer may be allowed to print pages during this 10 to 20 second interval If pages are allowed to print, then they will not be reprinted once a valid print cartridge is inserted. Replace the defective print cartridge. This message will be displayed when the front cover is closed with the wrong print cartridge installed. This message will be displayed when the printer has detected a calibration error for a particular color.

33 Calibration Error Cyan 33 Calibration Error Magenta 33 Calibration Error Yellow 33 Calibration Error Black

Diagnostic Information

2-37

5060-XXX

User Primary Message

34 Incorrect Media <type> <size> Change MP Feeder

User Secondary Message

Explanation
This message will be displayed when the printer has detected a media mismatch feeding from the MPF. Primary Message: Incorrect Media detected Secondary Message: <type>= Bond, Cardstock, Colored, Labels, Envelopes, Letterhead, Plain, Preprint, Transparency or Glossy. <size>= Lettter, Legal, B5, A4, Exec, Univ, A5, A3, 11x17, Folio or Stmt, 73/4, 9, 10, DL, C5, B5 or other. The following actions can be taken while this message is displayed. * Replace the media in the MPF with the requested media and press Go or * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. This message will be displayed when the printer has determined that the paper length is too short to print the data as formatted. The following actions can be taken while this message is displayed: * Press Go to clear the error and continue printing pages or * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group.

34 Short Paper

2-38 Service Manual

5060-XXX

User Primary Message

36 Printer Service Required

User Secondary Message

Explanation
This message will be displayed when background toner has prevented a completion of a TPS calibration cycle. Service will be required to fix the problem. The following action can be taken while this message is displayed: * Press Go to clear the error. The following Warning message may be displayed: Service Printer This Warning message means that a TPS failure has most likely occurred. The printer will continue to operate but the color quality will most likely be degraded. The most probable cause for this error message is a defective print cartridge or ITU. This message will be displayed when the printer memory and disk used to store pages is too full to collate the print job. The following actions can be taken while this message is displayed: * Press Go to clear the message and continue collating the remaining pages of the job or * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu. * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group.

37 Insufficient Collation Area

Diagnostic Information

2-39

5060-XXX

User Primary Message

37 Insufficient Defrag Memory

User Secondary Message

Explanation
This message will be displayed when insufficient printer memory is available to perform Flash Memory Defragment operation. Note: This message sill be posted prior to the actual start of the defragment operation. The following actions can be taken while this message is displayed: * Press Go to clear the message. To perform the defragment operation you can: * Delete fonts, macros and other data in RAM * Install additional printer memory * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions will be available via the Busy/Waiting Menu: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group.

37 Insufficient Memory

Held Jobs May Not be Restored

These messages may be displayed when the printer has attempted to Print and Hold jobs from the disk and found that some or all of the jobs could not be restored. Each of the three messages 57 Configuration Held Jobs May describe different conditions under which the restore failed. Primary Message: 37 Insufficient Memory. The printer firmware ran out of memory while attempting to restore the jobs. Secondary Message: Held Jobs May Not Be Restored. Primary Message: 57 Configuration Change The printer firmware could not restore jobs from the disk because the configuration of the printer has changed. Secondary Message: Held Jobs May Not Be Restored. Primary Message: Held Jobs May Not Be Restored handles any other conditions where any of the Print and Hold jobs could not be restored from the disk. Note: Some of the Print and Hold jobs may not be restored. They will remain on the disk but cannot be accessed.

2-40 Service Manual

5060-XXX

User Primary Message

38 Memory Full

User Secondary Message

Explanation
This message will be displayed when the printer is processing an incoming job and there is not enough memory available to continue processing the job. The following actions can be taken while this message is displayed: You may want to determine how to make more memory available to your print job by: * Deleting Fonts, macros and other data in RAM * Simplify your print job * Install additional Memory * Press Go to clear the message, however some data may be lost * Press Menu> or Menu< to access the Busy/ Waiting Menu Group The following functions may be available. * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. This message will be displayed when a page is too complex to print. The following actions can be taken while this message is displayed: * Press Go to clear the message and continue processing the job, some data loss may occur. * Try to simply the print job Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions may be available: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. This message will be displayed when the printer detects a defective flash. The following actions can be taken while this message is displayed: * Press Go to clear the message The flash will marked as bad and normal operation will continue. No flash operation will be allowed until the flash problem is resolved.

39 Complex Page

51 Defective Flash

Diagnostic Information

2-41

5060-XXX

User Primary Message

52 Flash Full

User Secondary Message

Explanation
This message will be displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. Note: The following action will delete all downloaded Fonts and Macros written to disk: *Press Go to clear the message and continue processing the print job. * Press >Menu or Menu< to access the Busy/ Waiting Menu group The following functions may be available: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. This message will be displayed when the printer detects an unformatted flash at POST. The following actions can be taken while this message is displayed: * Press Go to clear the message. The flash will be marked bad and normal operation will continue. Flash operations will not be allowed until the flash is formatted. This message will be displayed when the printer detects during POST that the connection to an ENA has been lost. Once a connection is initially established, a printer setting is modified to 54 Par x ENA to note a connection exists. Each time the power is cycled on, the connection is lost. This message will be displayed when the RIP software has detected that a network port is installed but cannot establish communications with it. The following actions can be taken while this message is displayed: * Press Go to clear this message. The printer will disable all communications to the associated network interface. No data may be received or sent from or to the associated interface. The user cannot program new firmware in the network via the parallel port after this message has been cleared.

53 Unformatted Flash

54 Std Par ENA Connection Lost

54 Std Network Software Error

54 Network x Software Error

2-42 Service Manual

5060-XXX

User Primary Message

54 Serial Option x Error

User Secondary Message

Explanation
This message will be displayed when a serial error either framing, parity or overrun, has been detected on the specified (option x) serial port. This usually means the serial port has not been set up correctly. The following actions can be taken while this message is displayed: * Press Go to clear the message and continue processing the print job. Note: If the print job does not print correctly, make sure that the correct cable is being used. If you still have a problem go to the Serial Port Service Check. These messages may be displayed when data is sent to the printer across a serial port, but the port has been disabled. Note: Once the error has been displayed for the first time, reporting of further errors will be suppressed until the printer is reset or menus are entered. The following actions can be taken while this message is displayed: * Press Go to clear the message. Any data received on the serial port will be discarded. * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions may be available: * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group.

56 Standard Serial Disabled 56 Serial Port x Disabled

Diagnostic Information

2-43

5060-XXX

User Primary Message

56 Std Parallel Port Disabled 56 Parallel Port x Disabled

User Secondary Message

Explanation
These messages may be displayed when data is sent to the printer across a parallel port, but the port has been disabled. Note: Once the error has been displayed for the first time, reporting of further errors will be suppressed until the printer is reset or menus are entered. The following actions can be taken while this message is displayed: * Press Go to clear the message. Any data received on the parallel port will be discarded. * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions may be available: * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. These messages may be displayed when data is sent to the printer across the USB port, but the port has been disabled. Note: Once the error has been displayed for the first time, reporting of further errors will be suppressed until the printer is reset or menus are entered. The following actions can be taken while this message is displayed: * Press Go to clear the message. Any data received on the USB port will be discarded * Press Menu> or Menu< to access the Busy/ Waiting Menu Group. The following functions may be available: * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. This message will be displayed when too many trays have been attached to the printer. Check the specifications check the number of trays allowed on each printer model. This message will be displayed when too may optional bins have been attached to the printer or if an unsupported combination of bins has been installed.

56 Standard USB Port Disabled 56 USB Port x Disabled

58 Too Many Trays Attached

58 Too Many Bins Attached

2-44 Service Manual

5060-XXX

User Primary Message

58 Too Many Disks Installed

User Secondary Message

Explanation
This message will be displayed when too many disks have been installed. Note: Some configurations of different output options require the installation of one option before the other. This message will be displayed when too many Flash Options have been installed. Check for the maximum number of flash memory options which may be installed. Note: For this error you may press Go to clear the message. The extra flash memory options will be ignored. These messages will be displayed when the user installs an incompatible option. The following options may be incompatible for use on one or more 50xx models: Output Bix x(x=1, 2 or 3) Tray x(x=2,3,4 or 5) Duplex The following actions can be taken while this message is being displayed: * The user is required to remove the incompatible option and press Go to clear the message. Note: If the user has installed the incompatible option to satisfy a Check Option Connections/ Reattach Option attendance condition, the user must reinstall an associated compatible option or Hot Unplug the option. This message will be displayed when the printer detects a defective disk. This error may occur at power on, or during disk format and write operations. The following actions can be taken while this message is displayed: * Press Go to clear the message. The disk will be marked as defective and normal printer operation will continue. Disk operations will not be allowed with a defective disk and the Format Disk menu item will not be shown.

58 Too Many Flash Options

59 Incompatible Output Bin x 59 Incompatible Tray x

61 Defective Disk

Diagnostic Information

2-45

5060-XXX

User Primary Message

62 Disk Full

User Secondary Message

Explanation
This message will be displayed when there is not enough free space on the disk to hold the data that have been requested to be written to the disk. This message will be displayed for both resource collection and PostScript when the disk is full. The following actions can be taken while this message is displayed, however this will delete all downloaded Fonts and Macros written to disk. * Press Go to clear the message and continue processing the print job * Press >Menu or Menu< to access the Busy/ Waiting Menu group The following functions may be available: * Cancel Job * Reset Printer * Reset Active Bin * Check Supply Levels Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu Group. This message will be displayed when the printer detects an unformatted disk at POST. The following actions can be taken while this message is displayed: * Press Go to clear the message. The disk will be marked as bad and normal operation will continue, however disk operation will not be allowed until the disk is formatted. This message will be displayed when the printer detects an unsupported disk format at POST. This message may appear if the disk was formatted on another system with a different format. The following actions can be taken while this message is displayed: * Press Go to clear the message. The disk will be marked as bad and normal operations will continue, however disk operations will not be allowed until the disk is formatted. These messages will be displayed when the printer requires replacement of some worn assemblies. These messages are independently posted when either the ITU or Fuser need to be replaced. Press Go to clear this message.

63 Unformatted Disk

64 Unsupported Disk Format

80 Fuser Maintenance 83 ITU Maintenance

2-46 Service Manual

5060-XXX

User Primary Message

81 Engine Code CRC Failure

User Secondary Message

Explanation
This message will be displayed when microcode is programmed into the engine flash code has failed a CRC check. The following action can be taken while this message is displayed: * Press Go to clear the message. The code data will be discarded and must be resent from the host. This message will be displayed when the waste container is full. The following actions can be taken while this message is displayed: * Replace the waste container and press Go. This message will be displayed when the waste container is missing. The following actions can be taken while this message is displayed: * Insert the waste container and press Go. This message will be displayed when the waste container is nearly full. The following actions can be taken while this message is displayed * Press Go Nearly Full will be reflected in the Supplies Menu. This message will displayed when the web oiler is exhausted or missing. Replace the Web Oiler. This message will be displayed when the Wed Oiler is nearly exhausted. Press Go to continue or the Web Oil can be replaced. This message will be displayed when the engine has detected that the fuser is missing. The following actions can be taken while this message is displayed: * Turn the printer off and insert the fuser assembly.

82 Waste Toner Bottle Full

82 Waste Toner Bottle Missing

82 Waste Bottle Nearly Full

84 Replace Oiler 84 Oiler Nearly Exhausted 87 Fuser Missing

Diagnostic Information

2-47

5060-XXX

User Primary Message

88 Yellow Toner Low 88 Magenta Toner Low 88 Cyan Toner Low 88 Black Toner Low

User Secondary Message

Explanation
These messages will be displayed when either the Yellow, Magenta, Cyan or Black toner cartridge is low on toner. The following actions can be taken while this message is displayed: * Open the front door, remove the old toner cartridge, insert a new toner cartridge and close the door or * Press Go without changing the toner cartridge and continue. This message will appear when the IPDS emulation version contained in the SIMM will not function with the printer code. This message will automatically clear in 30 seconds, and the IPDS emulation will be disabled. No other printer functions will be affected. The correct IPDS emulation must be downloaded.

1565 Emul Error Load Emul Option

Service Checks 900 Error Code Service Check

Error Code 900 Displayed

Step

Actions and Questions

Turn the printer off and on to see if the 900 Error continues to be displayed. Does the 900 Error continue to be displayed after turning printer power Off and On several times? Reseat the ITU electrical autoconnect. Does reseating the autoconnect fix the problem? Restore Factory Defaults on page 3-5. This will reset the non-critical areas of the NVRAM. Does Error Code 900 continue to be displayed? With the 900 Service error displayed on the Operator Panel, press Select, and Return. Record the Sub Error Codes. Make sure you record the complete list of codes and go to Step 5. Go to Sub Error Code Table on page 2-19.

Yes
Go to step 2

No
Problem solved

2 3

Problem solved Go to step 4

Go to step 3 Problem solved

2-48 Service Manual

5060-XXX

Step

Actions and Questions

Turn the printer off and on to see if the 900 Error continues to be displayed. Does the 900 Error continue to be displayed after turning printer power Off and On several times?

Yes
Contact your next level support

No
Recheck the printer several times to see if Error Code 900 is displayed

Error Code 900 displayed when the machine is connected to a network while still in Setup Required Mode
Step Actions and Questions
Perform the following steps:
1. Power the printer Off. 2. Disconnect the printer from the network. 3. Power the printer On and complete the setup process. 4. When Setup is complete, power Off the printer and reconnect to the network.

Yes
Contact your next level support

No
Problem solved

Do you still have the same 900 Service Error displayed?

Cartridge Drive Assembly Service Checks

Black Cartridge Drive Assembly
Error Codes associated with this Service Check: 150, 156 and 162 Magenta Cartridge Drive assembly Error Codes associated with this Service Check: 151, 157 and 163 Cyan Cartridge Drive Assembly Error Codes associated with this Service Check: 152, 158 and 164 Yellow Cartridge Drive Assembly Error Codes associated with this Service Check: 153, 159 and 165 Note: Anytime any of the Cartridge Drive Motor Assemblies have been replaced it will be necessary to perform the Automated Motor Detection on page 3-20. If this procedure is not performed Error Code 168 will be displayed.

Diagnostic Information

2-49

5060-XXX

Black Cartridge Drive Assembly Service Check Error Code 162

Step Actions and Questions
Black Cartridge Drive Assembly - Error Code 162 indicates that an incorrect motor is detected. Replace the Black Cartridge Drive Assembly. Go to Cartridge Drive Assembly (Cyan, Magenta, Black) on page 4-28. Perform Automated Motor Detection on page 3-20. Does the printer display Error Code 162? Reflash the NVRAM on the Engine Board. Is Error Code 162 still being displayed?

Yes
Go to Step 2

No
Problem Solved

Call your next level support

Problem Solved

Error Code 150 Error Code 156

Step Actions and Questions
Error Codes 150 and 156. These error codes indicate that the Black Cartridge Drive Motor has either failed to lock or has lost lock. Check the Black Cartridge Drive Motor Cable connection to J64 on the Engine Board. Is the cable installed correctly? Check the Black Cartridge Drive Motor Cable connection to the Black Cartridge Drive Motor card. Is the Cable installed Correctly? Check continuity of the Black Cartridge Drive Motor Cable. Is there continuity?

Yes
Go to Step 2

No
Install the cable correctly

Go to Step 3

Install the cable correctly Replace the Black Cartridge Assembly Cable Go to step 5

Go go Step 4

Replace the Black Cartridge Drive Assembly. Perform Automated Motor Detection on page 3-20. Does this fix the problem? Replace the Engine Board. Does this fix the problem

Problem Solved Problem Solved

Call your next level support

2-50 Service Manual

5060-XXX

Magenta Cartridge Drive Assembly Error Code 163

Step Actions and Questions
Magenta Cartridge Drive Assembly - Error Code 163 indicates that an incorrect motor is detected. Replace the Magenta Cartridge Drive Assembly. Go to Cartridge Drive Assembly (Cyan, Magenta, Black) on page 4-28. Perform Automated Motor Detection on page 3-20. Does the printer display Error Code 163? Reflash the NVRAM on the Engine Board. Is Error Code 163 still being displayed?

Yes
Go to step 2

No
Problem Solved

Call your next level support

Problem Solved

Error Code 151 Error Code 157

Step

Actions and Questions

Error Codes 151 and 157. These error codes indicate that the Magenta Cartridge Drive Motor has either failed to lock or has lost lock. Check the Magenta Cartridge Drive Motor Cable connection to J47 on the Engine Board. Is the cable installed correctly? Check the Magenta Cartridge Drive Motor Cable connection to the Magenta Cartridge Drive Motor card. Is the cable installed Correctly? Check continuity of the Magenta Cartridge Drive Motor Cable. Is there continuity?

Yes
Go to step 2

No
Install the cable correctly

Go go Step 3

Install the cable correctly Replace the Magenta Cartridge Assembly Cable Go to step 4

Go to Step 4

Replace the Magenta Cartridge Drive Assembly. Perform Automated Motor Detection on page 3-20. Does this fix the problem? Replace the Engine Board. Does this fix the problem?

Problem Solved Problem Solved

Call your next level support

Diagnostic Information

2-51

5060-XXX

Cyan Cartridge Drive Assembly Service Check Error Code 164

Step Actions and Questions
Cyan Cartridge Drive Assembly - Error Code 164 indicates that an incorrect motor is detected. Replace the Cyan Cartridge Drive Assembly. Go to Cartridge Drive Assembly (Cyan, Magenta, Black) on page 4-28. Perform the Automated Motor Detection on page 3-20. Does the printer display Error Code 164? Reflash the NVRAM on the Engine Board. Is Error Code 164 still being displayed?

Yes
Go to step 2

No
Problem Solved

Call your next level support

Problem Solved

Error Code 152 Error Code 158

Step Actions and Questions
Error Codes 152 and 158. These error codes indicate that the Cyan Cartridge Drive Motor has either failed to lock or has lost lock. Check the Cyan Cartridge Drive Motor Cable connection to J47 on the Engine Board. Is the cable installed correctly? Check the Cyan Cartridge Drive Motor Cable connection to the Cyan Cartridge Drive Motor card. Is the cable installed Correctly? Check continuity of the Cyan Cartridge Drive Motor Cable. Is there continuity?

Yes
Go to step 2

No
Install the cable correctly

Go go Step 3

Install the cable correctly Replace the Cyan Cartridge Assembly Cable Go to step 5

Go to Step 4

Replace the Cyan Cartridge Drive Assembly. Perform Automated Motor Detection on page 3-20. Does this fix the problem? Replace the Engine Board. Does this fix the problem?

Problem Solved Problem Solved

Call your next level support

2-52 Service Manual

5060-XXX

Yellow Cartridge Drive Assembly Service Check Error Code 165

Step Actions and Questions
Yellow Cartridge Drive Assembly - Error Code 165 indicates that an incorrect motor is detected. Replace the Yellow Cartridge Drive Assembly. Go to Cartridge Drive Assembly (Cyan, Magenta, Black) on page 4-28. Perform the Automated Motor Detection on page 3-20. Does the printer display Error Code 165? Reflash the NVRAM on the Engine Board. Is Error Code 165 still being displayed?

Yes
Go to step 2

No
Problem Solved

Call your next level support

Problem Solved

Error Code 153 Error Code 159

Step Actions and Questions
Error Codes 153 and 159. These error codes indicate that the Yellow Cartridge Drive Motor has either failed to lock or has lost lock. Check the Yellow Cartridge Drive Motor Cable connection to J47 on the Engine Board. Is the cable installed correctly? Check the Yellow Cartridge Drive Motor Cable connection to the Yellow Cartridge Drive Motor card. Is the cable installed Correctly? Check continuity of the Yellow Cartridge Drive Motor Cable. Is there continuity?

Yes
Go to step 2

No
Install the cable correctly

Go go Step 3

Install the cable correctly Replace the Yellow Cartridge Assembly Cable Go to step 5

Go to Step 4

Replace the Yellow Cartridge Drive Assembly. Perform Automated Motor Detection on page 3-20. Does this fix the problem? Replace the Engine Board. Does this fix the problem?

Problem Solved Problem Solved

Call your next level support

Diagnostic Information

2-53

5060-XXX

Fan Service Checks

Fuser Fan Service Check Error Code 925

Step

Actions and Questions

Turn the power off and manually spin the fan and check that it rotates freely. Does the fan rotate freely? Check the Fuser Fan Cable connection to the Engine Board, J2 for correct installation. Is the cable installed correctly? Disconnect the Fuser Fan from J2 on the Engine Board and check the voltages on J2 (refer to Table 1). Are the voltages correct?

Yes
Go to Step 2

No
Replace the Fuser Fan on page 4-14 Install the cable correctly. Replace the Engine Board on page 4-14

Go to Step 3

Replace the Fuser Fan on page 4-14

Table 1

Connector Pin No.

J2-1 J2-2 J2-3 J2-4

Fan On
+1.6 V dc 0V +1.9 V dc +24 V dc

Fan Off
+3.3 V dc 0V 0 V dc +24 V dc

Fan Disconnected Fan Switch On

+3.3 V dc 0V 0V +24 V dc

Fan Disconnected Fan Switch Off

+3.3 V dc 0V +2 V dc * +24 V dc

2-54 Service Manual

5060-XXX

VTB Fan Service Check Error Code 926

Step Actions and Questions
Turn the power off and manually spin the fan and check that it rotates freely. Does the fan rotate freely? Check the VTB Fan Cable connection to the Engine Board, J2 for correct installation. Is the cable installed correctly? Disconnect the VTB fan from J4 on the Engine Board and check the voltages on J4 (refer to Table 2). Are the voltages correct?

Yes
Go to Step 2

No
Replace the VTB Fan on page 4-39 Install the cable correctly. Replace the Engine Board on page 4-14

Go to Step 3

Replace the VTB Fan on page 4-39

Table 2
Connector Pin No.
J4-1 J4-2 J4-3 J4-4

Fan On
+1.6 V dc 0V +3.1 V dc +24 V dc

Fan Off
+3.3 V dc 0V 0 V dc +24 V dc

Fan Disconnected Fan Switch On

+3.3 V dc 0V 0V +24 V dc

Fan Disconnected Fan Switch Off

+3.3 V dc 0V +2 V dc * +24 V dc

RIP Fan Service Check Error Code 927

Step Actions and Questions
Turn the power off and manually spin the fan and check that it rotates freely. Does the fan rotate freely? Check the RIP Fan Cable connection to the Engine Board, J2 for correct installation. Is the cable installed correctly? Disconnect the RIP fan from J53 on the Engine Board and check the voltages on J53 (refer to Table 3). Are the voltages correct?

Yes
Go to Step 2

No
Replace the RIP Fan on page 4-37 Install the cable correctly. Replace the Engine Board on page 4-14

Go to Step 3

Replace the RIP Fan on page 4-37

Diagnostic Information

2-55

5060-XXX

Table 3
Connector Pin No.
J53-1 J53-2 J53-3 J53-4

Fan On
+1.6 V dc 0V +1.9 V dc +24 V dc

Fan Off
+3.3 V dc 0V 0 V dc +24 V dc

Fan Disconnected Fan Switch On

+3.3 V dc 0V 0V +24 V dc

Fan Disconnected Fan Switch Off

+3.3 V dc 0V +2 V dc +24 V dc

AC and DC Power Service Check

Before proceeding with this service check remove or disconnect any options that may be installed. Turn the machine on. If it operates correctly, reattach one option at a time until the failing option is located. Note: Before proceeding with this service check turn the printer on and check to see if the Power ON LED on the Engine board is turned on.

Step

Actions and Questions

Is the LED turned on?

Yes
Go to the AC Power Service Check on page 2-56

No
Go to the DC Power Service Check on page 2-57

AC Power Service Check

The printer appears to be inoperative when turned on with the Power ON/Status LED Off, the LCD display is blank, the Fuser lamps do not come on and no motors turn.

Step

Actions and Questions

Main AC Power - Check to make sure the printer is receiving main AC power. Is the printer receiving AC power?

Yes
Go to Step 2

No
Inform the customer that AC power to the printer is incorrect. Inform the customer that the AC line voltage is incorrect.

AC Power Check (Wall Outlet) - Check the AC line voltage at the AC outlet. Is the AC line voltage correct?

Go to Step 3

2-56 Service Manual

5060-XXX

Step

Actions and Questions

AC Power Cord Is the power cord in good condition and correctly installed?

Yes
Go to Step 4

No
If the cord is in poor condition, replace the cord. Replace the Line Cord Replace the LVPS on page 4-15

AC Power Check (AC Line Cord) - Check the AC line voltage at the end of the AC line cord. Is the AC line voltage correct? Low Voltage Power Supply - Turn the power off and Disconnect the LVPS from the RIP and Engine Boards. Check for +5 V dc on the LVPS cables. Engine Board +5 V dc: J9-2 and J9-3. RIP Board +5 V dc: J23-13, J23-14, and J23-15. Is there approximately +5 V dc on any of these connector pins?

Go to Step 5

Go to the DC Power Service Check on page 2-57

DC Power Service Check

The machine is partially operative, a motor turns, display is on or the Power On LED may be on or off.

Step

Actions and Questions

Does the printer Beep 5 times and the Operator Panel display all diamonds?

Yes
Go to the Operator Panel LCD/ Status LED/ Buttons Service Check on page 2-83 Go to Step 3

No
Go to Step 2

DC Power to Engine Board - Turn the power off and disconnect the LVPS cable to J9 on the Engine Board. Turn the power on and check the following voltages on the LVPS cable. * J9-1 +3.3 V dc * J9-2 +5 V dc * J9-3 +5 V dc * J9-4 +24 V dc * J9-5 +24 V dc * J9-6 Ground * J9-7 Ground * J9-8 Ground * J9-9 Ground * J9-10 Ground Note: All voltages are approximate values. Are the voltages correct?

Replace the LVPS on page 4-15

Diagnostic Information

2-57

5060-XXX

Step

Actions and Questions

DC Voltages at RIP Board - Turn the power off and disconnect the LVPS cable to J23 on the RIP Board. Turn the Power Supply Assembly power on and check the following voltages on the LVPS cable: * J23-1 Ground * J23-2 Ground * J23-3 Ground * J23-4 Ground * J23-5 Ground * J23-6 Ground * J23-7 Ground * J23-8 Ground * J23-9 * J23-10 +3.3 V dc * J23-11 +3.3 V dc * J23-12 +3.3 V dc * J23-13 +5.0 V dc * J23-14 +5.0 V dc * J23-15 +5.0 V dc * J23-16 +24 V dc Note: All voltages are approximate values. Are the voltages correct?

Yes
Problem Solved

No
Replace the LVPS on page 4-15

Second Transfer Roll Service Check

Note: The second transfer roll is 51.03 mm (2.009 inches) in circumference. Any print quality problems such as lines that are spaced apart indicate you should check the second transfer roll for damage, toner or foreign material. Note: The second transfer roll is also part of the maintenance kit and should be replaced when a 83 ITU Maintenance message displays. Ask the customer if they have replaced the second transfer roll recently. Note: If any of the following problems occur go to the Print Quality Service Check

A problem with only one color Light or very light print

CAUTION: Make sure the printer is powered OFF before making any checks on the second transfer roll or associated parts for personal safety and to prevent damage to the printer.

Step

Actions and Questions

Second Transfer Roll Assembly - Check the second transfer roll for any signs of toner buildup, surface damage to the roll, oil or other contaminants on the surface of the roll. Do you see any problems with the second transfer roll? Transfer Arms, Springs and associated hardware - Call your next level of support. None of these parts are service related parts. Is there any problem see with the associated hardware?

Yes
Replace the Second Transfer Roll on page 4-43 Call your next level support

No
Go to Step 2

Go to Step 3

2-58 Service Manual

5060-XXX

Step

Actions and Questions

Transfer High Voltage Power Supply, HV wiring and contacts - Check the Second Transfer Cable (Transfer HVPS contact I to the Second Transfer Roll Rear Arm Contact) for correct installation. Is the cable installed correctly? Check the continuity of the Second Transfer Cable. Is there continuity?

Yes
Go to step 4

No
Install the cable correctly

Replace the FRU's in order: 1) Second Transfer Roll on page 4-43 2)HVPS Transfer Board on page 4-12. If this does not correct the problem, go to step 5. Repair as necessary Reinstall or replace the cable Repair or replace as necessary. If this does not correct the problem, contact your next level support.

Replace the Second Transfer Cable

Check to make sure the ITU Bias Spring is not broken or missing for the color(s) that is having Transfer problems. Is the ITU Bias Spring broken, off or missing? Check the Transfer HVPS to ITU HV Transfer Terminal for the color(s) that is having transfer problems. Is the cable disconnected or broken? Transfer Terminal Contact assembly and ITU Transfer Bellcrank - Check the Transfer terminal contact, transfer cable and ITU Transfer Bellcrank assemblies to make sure they are installed correctly, not loose or broken. Are there any problems with the Transfer terminal contact, transfer cable connection or ITU Transfer Bellcrank assemblies?

Go to step 7

Go to step 7

Replace the FRU's in order: 1)HVPS Transfer Board on page 4-12 2) Engine Board on page 4-14 3)ITU Assembly on page 4-41

Diagnostic Information

2-59

5060-XXX

Output Expander Option Service Check

Note: The majority of the mechanical components can be observed during operation by removing the covers. The output expander functions without the covers installed. Make sure the option is correctly installed before attempting to service the unit.

Step

Symptoms
The printer does not recognize one or more output expander options as being installed.

Yes
Go to Printer does not recognize that one or more output options as being installed. on page 2-61 Go to 202 Paper Jam, Open Rear Door Message Displays. on page 2-62 Go to Remove paper Output Bin X is displayed, POST is incomplete unable to clear the message. on page 2-63 Go to 271 Paper Jam Check Bin X, POST Incomplete. on page 2-63 Go to 271 Paper Jam Check Bin X, Post Complete, first sheet of paper feeds into Output Bin X. on page 2-64

No
Go to Step 2

202 Paper Jam Open Drear Door Message displays. A sheet of paper is jammed prior to the pass thru sensor flag or a sheet of paper feeds out to the standard bin even though bin x is selected. Paper exits half way out of the redrive.

Go to Step 3

Remove paper - Output Bin X is displayed, POST is incomplete unable to clear the message.

Go to Step 4

271 Paper Jam - Check Bin X, POST Incomplete.

Go to Step 5

271 Paper Jam - Check Bin X, Post Complete, first sheet of paper feeds into Output Bin X.

Go to Step 6

2-60 Service Manual

5060-XXX

Step

Symptoms
No indication that Bin X is full OR No indication that Bin X is near full.

Yes
Go to No indication that Bin X is full OR No indication that Bin X is near full. on page 2-65 Go to 990 Service - Bin X on page 2-65

No
Go to Step 7

990 Service - Bin X

Call your next level support

Printer does not recognize that one or more output options as being installed.

Step

Actions and Questions

Excessive static electricity buildup - Check the output expander Control Board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame. Also check to make sure the ESD is loose or damaged. Is the ESD Brush ground cable correctly installed and the ESD brush not loose or broken?

Yes
Go to Step 2

No
1. Attach the ground cable if not installed correctly. 2. Replace the cover assembly if the ESD brush is loose or damaged. Go the Autoconnect system on the Output Expander Option, base printer and check cables and connections to the Engine Board. Go to Step 4

Options Check - Note: If more than a single output expander option is installed, check each one to see if the printer recognizes any single option as being installed. If the printer recognizes any of the output expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option. Check to make sure that the output expander option is the only output option that is not recognized by the base printer Is this the only output option not recognized by the base printer?

Go to Step 3

Output Expander Assembly Mechanical Linkage (Cables) Check the output expander autoconnect cable and connector for any signs of damage especially the connector pins. Is there any signs of damage to the cable, connector or connector pins?

Replace the Autoconnect Cable

Diagnostic Information

2-61

5060-XXX

Step

Actions and Questions

Output Expander Assembly Mechanical Linkage (Electrical) Check the cables at J1A, J1B, J2A and J2B on the Control Board to make sure they are attached securely and correctly. Are the cables attached securely and correctly? Voltage check - Base printer autoconnect connector - Turn the power off and remove the output expander option from the printer and check the voltages on the base printer top autoconnect connector. Go to Autoconnect - Top. Are the voltages correct? Voltage Check - Output Expander System Board - Reinstall the output expander option and check the voltages at J1A and J1B on the connector. Are the voltages correct?

Yes
Go to Step 5

No
Reseat the cables

Go to Step 6

The problem is in the base printer. Check autoconnects in the printer. Replace the Output Expander Option Mechanical Linkage Assembly.

Replace the Output Expander Option System Board

202 Paper Jam, Open Rear Door Message Displays.

A sheet of paper is jammed prior to the pass thru sensor flag or a sheet of paper feeds out to the standard bin even though bin x is selected. Paper exits half way out of the redrive. Note: For this type of problem check the sub error codes. They can help isolate the problem 202 Paper Jam messages can also occur prior to the output expander pass thru sensor.

Step

Actions and Questions

Check of Mechanical Drive Components - Check the following parts: 1) Check the output expander Drive Belt to make sure it is installed on the drive pulley and belt idler pulley. 2) Check the belt tension spring to make sure it is not loose or broken Are there any problems with these parts? Check of Mechanical Linkage/DC Motor Drive Assembly Make the following Checks: 1) Check to see if the DC motor is functioning properly. 2) Check the gears, clutch and other linkage parts for correct operation and any signs of wear, broken teeth or damaged parts. Are there any problems with these parts?

Yes
Repair or replace as necessary

No
Go to Step 2

Replace the Mechanical Linkage/DC Motor Drive Assembly

Call your next level support

2-62 Service Manual

5060-XXX

Remove paper - Output Bin X is displayed, POST is incomplete unable to clear the message.

Step

Actions and Questions

Output Sensor Flag check - Check the flag for correct operation, binds, broken parts or interference from the sensor cable. Is there a problem with the sensor flag? Output Bin Sensor - Run the sensor test to check the Output Bin Sensor for correct operation. Does the sensor operate correctly?

Yes
Replace the flag or repair as necessary Call your next level support

No
Go to Step 2

Replace the sensor assembly. If this does not fix the problem replace the Engine Board on page 4-14.

271 Paper Jam - Check Bin X, POST Incomplete.

Step Actions and Questions
Pass Thru Sensor Flag Check the sensor flag for correct operation. Is the flag operating correctly? Pass Thru Sensor Cable - Check to make sure the pass thru sensor cable is correctly connected to Jx on the Control Board. Is the cable connected correctly? Voltage Check - Disconnect the pass thru sensor cable from the Control Board and check the voltage on J3-3. The voltage measures approximately +5 V dc. Is the voltage correct? Voltage Check - Measure the voltage at J3-2. The voltage measures approximately 0 V dc. Is the voltage correct?

Yes
Go to Step 2

No
Repair or replace as necessary Reseat the cable

Go to Step 3

Go to Step 34

Replace the Control Board

Replace the Control Board

Replace the sensor assembly

Diagnostic Information

2-63

5060-XXX

271 Paper Jam - Check Bin X, Post Complete, first sheet of paper feeds into Output Bin X.
Note: Before proceeding with this service check run the Output Bin X Sensor Test and check for the failing sensor. Sensor Tests: XNF=Near Full (Upper Part of sensor assembly) F=Full (Lower part of sensor assembly) P=Pass Thru Sensor

Step

Actions and Questions

DC Motor Cable Connection - Check the DC motor connector to make sure it is correctly installed at J4 on the Output Expander Option Board. Is the cable installed correctly? DC Motor Mechanical Linkage Assembly - Check the resistance of the motor on the cable connector. Check the resistance between J4-1 and J4-2. The resistance measures between 115 ohms and 135 ohms. Is the resistance correct? D.C. Motor Mechanical Linkage Assembly - Check for continuity between J4-1 and J4-2 and the case of the motor. It measures infinity. Is there continuity between J4-1 or J4-2 and the case of the motor? Note: If the motor is shorted from either J4-1 or J4-2 and the case of the motor, it may be necessary to replace the output expander Control Board. Output Expander Board - Disconnect the motor cable from J4 and check the voltages at J4 on the board. Note: All voltages are approximate values. J4-1 (Motor Idle) +24 V dc J4-2 (Motor Idle) +24 V dc J4-5 (Motor Idle) +5 V dc J4-6 (Motor Idle) +5 V dc Note: Use caution not to short to adjacent pins on the connector. Are the voltages correct?

Yes
Go to Step 2

No
Install the cable correctly

Go to step 3

Replace the DC Motor Mechanical Linkage Assembly Go to Step 4

Replace the DC Motor Mechanical Linkage Assembly

Replace the DC Motor Mechanical Linkage Assembly

Replace the Output Expander Control Board

2-64 Service Manual

5060-XXX

No indication that Bin X is full OR No indication that Bin X is near full.

Step

Actions and Questions

Sensor Cable installation - Check for correct installation of the sensor cable at J5 on the Control Board. Is the cable installed correctly? Dual Output Bin X Sensor Assembly Do either the Bin X Full or the Bin X Near Full Sensor fail the sensor test? Voltage - Check the voltages at J5-3 and J5-4. The voltages should measure approximately +5 V dc. Are the voltages correct?

Yes
Go to step 2

No
Install the cable correctly Call your next level support Replace the Control Board

Go to step 3

Replace the sensor

990 Service - Bin X

Step

Actions and Questions

Mechanical Linkage/DC Motor Assembly - Check the DC motor cable connector to make sure it is installed at J4 on the output expander Control Board. Is the cable connected correctly?

Yes
Go to Step 2

No
Reseat the cable and recheck for correct operation of the option Replace the Mechanical Linkage/DC Motor Assembly Go to step 4

Resistance Check - Disconnect J4 from the option board and check the resistance of the motor on the cable connector between J4-1 and J4-2. The resistance should measure between 115 and 135 ohms. Is the resistance correct? DC Motor - Check between J4-1 and between J4-2 and the case of the DC motor for shorts. Is the DC Motor Shorted? Note: If the DC Motor is found to be shorted damage may result to the RIP board. Output Expander Control Board Check - Disconnect the motor cable J4 and check the voltages at J4 on the board. Note: Use caution not to short to adjacent pins on the connector. The voltages measure approximately: J4-1 (Motor Idle) +24 V dc J4-2 (Motor Idle) +24 V dc J4-3 (Motor Idle) +5 V dc J4-4 (Motor Idle) +5 V dc Are the voltages correct?

Go to Step 3

Replace the Mechanical Linkage/DC Motor Assembly Replace the Output Expander Control Board

Replace the Mechanical Linkage/DC Motor Assembly

Diagnostic Information

2-65

5060-XXX

5-Bin Mailbox Option Service Check

Note: Before proceeding with this service check make sure the option(s) are installed correctly before attempting to service the unit. Be sure the option is correctly installed and the machine is configured correctly. The majority of the mechanical components can be observed during operation by removing the left and right side covers.

Step

Symptoms
Problems with excessive static electricity buildup.

Yes
Go to Problems with excessive static electricity buildup. on page 2-67 Go to The printer does not recognize one or more output options as installed. on page 2-67 Go to 271 Paper Jam Check Bin 1 displays on page 2-68 Go to 274 Paper Jam Check Bin 4 displays. on page 2-69 Go to Ready Bin X Full Message Displays May be able to clear message and will feed paper into Bin selected. on page 2-69 Go to Bin X Full - No message that Bin X is full displays. on page 2-70

No
Go to Step 2

The printer does not recognize one or more output options as installed.

Go to Step 3

271 Paper Jam - Check Bin 1 displays

Go to Step 4

274 Paper Jam - Check Bin 4 displays.

Go to Step 5

Ready Bin X Full Message Displays - May be able to clear message and will feed paper into Bin selected.

Go to Step 6

Bin X Full - No message that Bin X is full displays

Go to Step 7

2-66 Service Manual

5060-XXX

Step

Symptoms
Ready - Bin X Full displays and paper feeds into Bin X

Yes
Go to Ready Bin X Full displays and paper feeds into Bin X. on page 2-70 Go to Paper does not feed into the bin selected. 271 Paper Jam Check Bin 1 displays. on page 2-70 Go to 990 Service Error Displays on page 2-71

No
Go to Step 8

Paper does not feed into the bin selected. 271 Paper Jam Check Bin 1 displays

Go to Step 9

990 Service Error Displays

Call your next level support

Problems with excessive static electricity buildup.

Step Action and Questions
Excessive static electricity buildup. (Front Cover Assembly) Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the 5-Bin Mailbox frame or the ESD brush is not loose or damaged. Is the ESD Brush ground cable correctly installed and the ESD brush is not loose or broken?

Yes
Check to make sure the brush is contacting the media being fed through the option.

No
1. Attach the ground cable if not installed 2. Replace the cover assembly if the ESD brush is loose or damaged

The printer does not recognize one or more output options as installed.
Note: If more than a single output option is installed, check each one to see if the printer recognizes any single option as being installed. If the printer recognizes any of the output options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized option. Continue with this service check or go to the service check of the failing output option.

Step

Action and Questions

Options - Check to make sure that the output expander option is the only output option that is not recognized by the base printer. Is this the only output option not recognized by the base printer?

Yes
Go to Step 2

No
Check the autoconnect system in base printer

Diagnostic Information

2-67

5060-XXX

Step

Action and Questions

Mechanical Linkage (Cables) - Check the 5-Bin Mailbox autoconnect cable and connector for any signs of damage especially the connector pins. Is there any signs of damage to the cable, connector or connector pins? Mechanical Linkage (Electrical) - Check to make sure the autoconnect cables are connected correctly to the Control Board. Are the cables attached securely and correctly? Voltage check, Base printer autoconnect connector - Turn the power off and remove the 5-Bin Mailbox option from the printer. Check the voltages on the base printer top autoconnect connector. Go to Autoconnect - Top. Are the voltages correct? Voltage Check, 5-Bin Mailbox System Board - Reinstall the 5-Bin Mailbox option and check the voltages at J1A and J1B on the connector. Are the voltages correct?

Yes
Replace the Autoconnect cable

No
Go to Step 3

Go to Step 4

Reseat the cables

Go to Step 5

Check the Autoconnects in the printer

Replace the Output Expander Option System Board

Replace the Output Expander Option Mechanical Linkage Assembly

271 Paper Jam - Check Bin 1 displays

Step

Action and Questions

Bottom Pass Thru Sensor Flag - Check to make sure the Bottom Pass Thru Sensor Flag is operating correctly and is not binding, broken or any interference from the sensor cable. Is there any problem found with the sensor flag? Bottom Pass Thru Sensor - Check to make the sensor is correctly connected to J5 on the Control Board. Is the sensor connected correctly? Bottom Pass Thru Sensor voltage check1 - Disconnect the pass thru sensor cable and check the voltage at J5-3 on the board. The voltage measures approximately +5 V dc. Is the voltage correct? 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?

Yes
Fix or replace the flag

No
Go to Step 2

Go to Step 3

Reseat the cable Replace the Control Board

Go to Step 4

Replace the Sensor Assembly

Replace the Control Board

2-68 Service Manual

5060-XXX

274 Paper Jam - Check Bin 4 displays.

Note: When a 274 Paper Jam Check Bin 4 message displays, a problem exists with the top pass thru sensor assembly or the control board.

Step

Action and Questions

Top Pass Thru Sensor Flag - Check the top sensor flag for correct operation, binding, broken parts or interference from the sensor cable. Are there any problem with the sensor flag? Top Pass Thru Sensor - Check to make sure the top pass thru sensor is correctly connected to J11 on the Control Board. Is the sensor connected correctly? Top Pass Thru Sensor voltage check 1 - Disconnect the top pass thru sensor at J11 and check the voltage at J11-3. The voltage measures approximately +5 V dc. Is the voltage correct? Top Pass Thru Sensor voltage check 2 - Check the voltage at J11-2, the voltage should measure approximately 0 V dc. Is the voltage correct?

Yes
Repair as necessary

No
Go to Step 2

Go to Step 3

Reseat the cable

Go to Step 4

Replace the Control Board

Replace the Sensor Assembly

Replace the Control Board

Ready Bin X Full Message Displays - May be able to clear message and will feed paper into Bin selected.
Note: This sensor is in a normally open position with the flag out of the sensor slot.

Step

Action and Questions

Bin X Sensor (Bin X=Sensor 1 thru 5) - Check to make sure the sensor is seated correctly in the side of tray X. Is the sensor seated correctly? Bin X Sensor Cable - Check to make sure that Bin X sensor cable is connected to the sensor and to the Control Board. Is the sensor cable connected correctly? Bin X Sensor Flag - Check the Bin X sensor flag for binding and proper operation. Are there any problems with the sensor flag? Bin X Sensor Cable continuity - Check the continuity of the sensor cable. Is there continuity?

Yes
Go to Step 2

No
Install the sensor correctly Install the sensor cable correctly Go to Step 4

Go to Step 3

Repair or replace the sensor flag Replace the Bin X Sensor

Replace the Bin X Cable

Diagnostic Information

2-69

5060-XXX

Bin X Full - No message that Bin X is full displays.

Step

Action and Questions

Bin X Sensor (Bin X=Sensor 1 thru 5) - Check to make sure the sensor is seated correctly in the side of tray X. Is the sensor seated correctly? Bin X Sensor Cable - Check to make sure that Bin X sensor cable is connected to the sensor and to the Control Board. Is the sensor cable connected correctly? Bin X Sensor Flag - Check the Bin X sensor flag for binding and proper operation. Are there any problems with the sensor flag? Bin X Sensor Cable continuity - Check the continuity of the sensor cable. Is there continuity?

Yes
Go to Step 2

No
Install the sensor correctly Install the sensor cable correctly Go to Step 4

Go to Step 3

Repair or replace the sensor flag Replace the Bin X Sensor

Replace the Bin X Cable

Ready - Bin X Full displays and paper feeds into Bin X.

Step

Action and Questions

Bin X Sensor Flag - Check the Bin X sensor flag to make it is not in the up position and is operating correctly. Is the sensor flag operating correctly?

Yes
Replace the Bin X Sensor. If this does not fix the problem replace the Control Board.

No
Repair or replace as necessary

Paper does not feed into the bin selected. 271 Paper Jam - Check Bin 1 displays.

Step

Action and Questions

Bin parts - Check all the bin parts, deflector, deflector spring, deflector cover, deflector cover spring and shaft assemblies for signs of missing or loose springs. Check for binds in the deflector or deflector cover, broken or binding shaft assemblies or broken gear teeth. Are parts broken, loose, binding or missing? Bin X Solenoid - Check the solenoid for any binds or sticking problems. Is the solenoid binding or sticking?

Yes
Replace parts or repairs necessary

No
Go to Step 2

Replace the Solenoid Assembly

Go to Step 3

2-70 Service Manual

5060-XXX

Step

Action and Questions

Bin X Solenoid - Check the resistance of the solenoid. It measures between approximately 30 ohms and 50 ohms. Is the resistance correct? Mechanical Linkage/Motor Assembly - Check the gears, clutch and other linkage parts for correct operation and any signs of wear, broken gear teeth or damaged parts. Are the mechanical linkage assembly mechanical parts broken, worn or damaged?

Yes
Replace the 5 Bin Mailbox Control Board Assembly Replace the Mechanical Linkage/DC Motor Assembly

No
Replace Bin X Solenoid Assembly Replace the 5 Bin Mailbox Control Board Assembly

990 Service Error Displays

Step Action and Questions
Mechanical Linkage/DC Motor Assembly - Check the DC motor cable connector to make sure it is installed at J4 on the Control Board. Is the cable connected correctly?

Yes
Go to Step 2

No
Reseat the cable and recheck for correct operation of the option Replace the Mechanical Linkage/DC Motor Assembly Go to Step 4

Resistance Check - Disconnect J4 from the option board and check the resistance of the motor on the cable connector between J2-1 and J2-2. The resistance measures between 115 and 135 ohms. Is the resistance correct? DC Motor - Check between J2-1 and between J2-2 and the case of the DC motor for shorts. Is the DC Motor Shorted? Note: If the DC Motor is found to be shorted damage may result to the Control board. Output Expander Control Board Check - Disconnect the motor cable J2 and check the voltages at J2 on the board. Note: Use caution not to short to adjacent pins on the connector. The voltages measure: J2-1 (Motor Idle) +24 V dc J2-2 (Motor Idle) +24 V dc J2-3 (Motor Idle) +5 V dc J2-4 (Motor Idle) +5 V dc Note: All voltages are approximate values. Are the voltages correct?

Go to Step 3

Replace the Mechanical Linkage/DC Motor Assembly Replace the Control Board

Replace the Mechanical Linkage/DC Motor Assembly

Diagnostic Information

2-71

5060-XXX

Print Quality Service Checks

Note: This symptom may require replacement of one or more CRU's (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install an ITM, Fuser Assembly or Second Transfer Roll or Print Cartridge. Check the following before proceeding with any of the print quality service checks.

Use Tray 1 (internal tray) to test the print quality of the base printer. Be sure the fuser assembly is installed correctly. Be sure the ITU assembly is installed correctly. Be sure the Second Transfer Roll is installed correctly. Check the media in Tray 1 to make sure it meets paper specifications. Run a copy of the CE Test page, this will set all the printer defaults to the correct settings to check for print quality. If a specific color has a print quality problem first try a new cartridge to help isolate the problem.

An incorrect printer driver, for the installed software, can cause print quality problems. Incorrect characters could print and the copy may not fit the page correctly. Note: Some 201 Paper Jam errors can be caused by a faulty print cartridge.

Horizontal Line
Go to step 1 if there is a horizontal black line only. Go to step 2 if there is a Cyan, Magenta or Yellow horizontal line.

Step

Action and Questions

Black Print Cartridge Note: The most likely cause of this failure is a failing black print cartridge where the PC drum is shorting to the charge roll inside the print cartridge. Try a new black print cartridge. Does this fix the problem? Cyan Print Cartridge Check - Enter the CE Diagnostic Mode. Remove the Cyan Print Cartridge and run the print test. Does the problem still exist for the remaining cartridges? Magenta Print Cartridge Check - Enter the CE Diagnostic Mode. Remove the Magenta Print Cartridge and run the print test. Does the problem still exist for the remaining cartridges?

Yes
Replace the Cartridge

No
Call your next level support

Go to Step 3

Replace the failing cartridge Replace the Magenta Print Cartridge

Replace the Yellow Print Cartridge

2-72 Service Manual

5060-XXX

Blank Page (No Image)

If there is no image (blank page) and no error codes displayed, go to step 1. If there is no image (blank page) but error codes are displayed, go to the error code symptom chart and perform the necessary action.

Step

Action and Questions

Second Transfer Roll - Check to make sure the Second Transfer Roll is installed and correctly installed. Is the Second Transfer Roll installed and correctly installed?

Yes
If a Second Transfer Roll is not installed, install a new one. Go to step 3

No
Go to Step 2

Second Transfer Roll Release Lever - Check to make sure the Second Transfer Roll Release Lever is not stuck in the down position. Check for broken or damaged parts. Is the Second Transfer Roll Release Lever operating correctly? Check continuity of the Second Transfer Roll to the Transfer HVPS cable. Is there continuity?

Repair as necessary

Replace the HVPS Transfer Board on page 4-12

Replace the cable

The entire page is mostly all one color. Some printing may appear in other colors. This applies to Black, Cyan, Magenta and Yellow.

Step

Action and Questions

Print Cartridge Check - Generally this problem is caused by a bad charge roll contact in the cartridge.Try a new print cartridge for the color that is covering most of the page. Does the new print cartridge fix the problem? High Voltage Contact Block Assembly - Check the Cartridge HV Contact Block contact of the cartridge that is having a problem. Check to make sure the contact pin is not stuck. Refer to Figure 1 for the correct location of the charge roll pin in the contact block. Does the pin operate correctly? Continuity Check - High Voltage Contact Assembly - Check continuity from the Developer HVPS contact Spring to the Charge Roll Pin in the contact assembly. Is there continuity?

Yes
Problem Solved

No
Go to Step 2

Go to Step 3

Remove and repair the High Voltage Contact Assembly Remove and repair the High Voltage Contact Assembly

Go to Step 4

Diagnostic Information

2-73

5060-XXX

Step

Action and Questions

Cartridge HV contact Assembly Developer Pin Springs Check the developer pin springs in the cartridge that is having a problem to make sure they are not bent or damaged. Are the springs damaged or bent?

Yes
Replace the damaged developer Spring.

No
Replace the HVPS Developer Board on page 4-39

Missing Colors
If only one color is missing, go to Step A on page 2-74. If Cyan, Magenta or Yellow is missing, go to Step B on page 2-75.

Step A

Step

Action and Questions

Print Cartridge - Check to make sure the cartridge is seated properly and that all packing material has been removed from the cartridge. Has all packing material been removed and the cartridge is seated correctly? Print Cartridge - The cartridge may be out of toner or have another toner problem. Install a new toner cartridge. Does a new toner cartridge fix the problem? High Voltage Contact Block Assembly Check, PC Drum Contact Pin - Check for a stuck PC Drum Contact in the HV contact block assembly. Refer to figure 1 for the location of the PC Drum Contact Pin. Is the pin stuck or does not operate smoothly? High Voltage Contact Block Assembly Check, Continuity Check for continuity from the PC Drum Contact Pin to the PC Drum Developer Pin Spring. Is there continuity? High Voltage Contact Block Assembly Check, PC Drum Developer Pin Spring - Check the PC Drum Developer Pin Spring to make sure it is not bent or damaged. Is the spring bent or damaged?

Yes
Problem Solved

No
Go to Step 2

Problem Solved Repair the HV Contact Block Assembly.

Go to Step 3

Go to Step 4

Go to Step 5

Repair the HV Contact Block Assembly. Replace the HVPS Developer Board on page 4-39

Replace the PC Drum Developer Pin Spring.

2-74 Service Manual

5060-XXX

Step B

Step

Action and Questions

Retraction Motor Check - Generally this symptom is caused by a retracted ITU assembly. Check to see if the ITU retraction motor keeps the ITU in the retracted position. Does the motor keep the ITU in the retracted position?

Yes
Replace the Retraction Motor. If this does not correct the problem, replace the Engine Board on page 4-14.

No
Replace the HVPS Developer Board on page 4-39

Light print over the entire page

If all colors have light print, replace the HVPS Developer Board on page 4-39. If only one color has light print, go to step 1.

Step

Action and Questions

Toner Cartridge Check - The toner may be out, the toner cartridge seated improperly or the shutter has been left on the bottom of the cartridge. Is the toner cartridge seated properly and the shutter removed?

Yes
Go to Step 2

No
Install the cartridge correctly or remove the packing material from the cartridge. Go to Step 3

Toner Cartridge Check - Try a new toner cartridge for the missing color. Does a new toner cartridge fix the problem? High Voltage Contact Block Assembly Check, PC Drum Contact Pin - Check for a stuck PC Drum Contact in the HV Contact Block Assembly for the missing color cartridge. Refer to figure 1 for the location of the PC Drum Contact Pin. Is the pin stuck or does not operate smoothly? High Voltage Contact Block Assembly Check, Continuity Check for continuity from the PC Drum Contact Pin to the PC Drum Developer Pin Spring. Is there continuity? High Voltage Contact Block Assembly Check, PC Drum Developer Pin Spring - Check the PC Drum Developer Pin Spring to make sure it is not bent or damaged. Is the spring bent or damaged?

Problem Solved Repair the HV Contact Block Assembly.

Go to Step 4

Go to Step 5

Repair the HV contact Block Assembly. Replace the HVPS Developer Board on page 4-39

Replace the PC Drum Developer Pin Spring.

Diagnostic Information

2-75

5060-XXX

Colored lines, streaks, or smudges

Single color streaks in non-print areas are most likely caused by a cleaner problem in the print cartridge. Replace the print cartridge. A problem with all colors having spots or streaks that are different on each page is most likely caused by damage to the ITU Assembly. Replace the ITU Assembly on page 4-41. If only one color streaks in print areas, go to step 1.

Step

Action and Questions

Print Cartridge Check - Try a new print cartridge. Doe a new print cartridge fix the problem? Printhead Check - The printhead lens may be contaminated by toner. Check for any signs of contamination on the lens of the printhead. Is the printhead contaminated?

Yes
Problem Solved Go to Printheads on page 4-34 and replace the failing printhead

No
Go to Step 2 Replace the ITU Assembly on page 4-41

1 2

Evenly spaced horizontal marks or lines on the page

Black horizontal lines only are most likely caused by a shorted charge roll in the print cartridge. Replace the black print cartridge. If there are light horizontal lines in printed areas, go to Step A on page 2-76. If there are Cyan, Magenta or Yellow horizontal lines, go to Step B on page 2-77.

Step A

Step

Action and Questions

Print Cartridge Check Are lines spaced at 46 mm or 95 mm intervals? Cartridge Drive Assembly Check - Perform Automated Motor Detection on page 3-20. Are the lines spaced at a 4mm interval?

Yes
Replace the print cartridge. Replace the Cartridge Drive Assembly.

No
Go to step 2 No problem found

1 2

2-76 Service Manual

5060-XXX

Step B
Step Action and Questions
Print Cartridge(s) Check - Enter the CE Diagnostic Mode. Remove one print cartridge at a time and run a Test Page to help isolate the faulty print cartridge. Have you isolated the failing print cartridge?

Yes
Replace the faulty Print Cartridge

No
Run another test page after removing each print cartridge to isolate the problem.

Low Image Density

Note: If all colors have a low image density problem set the Print Darkness to "High" from the CE menu. If only one color has a problem, go to Step A on page 2-77. If all colors have a problem, go to Step B on page 2-77.

Step A

Step

Action and Questions

Print Cartridge - Check to make sure the print cartridge is seated correctly. Is the Print Cartridge seated correctly? The print cartridge may be out of toner. Try a new print cartridge. Does a new print cartridge fix the problem?

Yes
Go to Step 2

No
Install the print cartridge correctly and recheck. Replace the HVPS Transfer Board on page 4-12

Problem Solved

Step B

Step

Action and Questions

Check to make sure that Color Calibration has not been disabled in the CE menus, especially if the printer has been previously serviced. Was Color Calibration disabled?

Yes
Set Color Calibration on

No
Go to step 2

Diagnostic Information

2-77

5060-XXX

Step

Action and Questions

Toner Density Calibration - Run Toner Density Calibration from the Utility menu. Does this fix the problem?

Yes
Problem Solved

No
Replace the HVPS Transfer Board on page 4-12

Poor Color Registration

Step

Action and Questions

Print Cartridge - Check to make sure that the print cartridges are properly inserted and are seated properly in there respective V Blocks. Are the cartridges seated correctly? Front Cover - Check the front cover to make sure that all the springs and cartridge hold downs are present and correctly installed. Are all springs and cartridge hold downs present and correctly installed?

Yes
Go to Step 2

No
Install the cartridge(s) correctly. Replace any missing or damaged springs. Replace any missing or broken hold downs. Reinstall the ITU. If the problem continues, replace the ITU Assembly on page 4-41.

Go to Step 3

ITU - Check to make sure that the ITU legs are properly seated onto the rail at the right side of the machine. This is visible by removing the Yellow Print Cartridge. Is the ITU seated correctly?

Go to Step 4

Alignment - Enter the Configuration Menu. Perform the Setting Printer Alignment on page 3-23.

Transparency print quality is poor

Step

Action and Questions

Transparencies - Check the type or transparency being used. Is the transparency type being used recommended? Is the quality of the transparency poor or do brown colors appear when projected?

Yes
Go to Step 2

No
Inform the customer Go to Step 4

Go to Step 3

2-78 Service Manual

5060-XXX

Step

Action and Questions

Fuser Settings - From the CE menu select fuser settings and set to "High". Does this fuser setting fix the problem? Does the transparency have a splotchy appearance?

Yes
Problem Solved

No
Replace the Fuser Assembly on page 4-16 Replace the Second Transfer Roll on page 4-43 Go to Step 6

Go to Step 5

Transfer Setting: High - From the CE menu set Transfer setting to "High". Does this Transfer setting fix the problem? Transfer Setting: Low - From the CE menu set Transfer setting to "Low". Does this Transfer setting fix the problem?

Problem Solved Problem Solved

Replace the Second Transfer Roll on page 4-43

Residual Image
If only one color has a residual image repeated every 95mm, replace the print cartridge. If all colors have a residual image 147mm from the top of the page, replace the fuser assembly. Note: Do the following steps before you replace the fuser assembly:

1. Check Media Type setting on the Operator Panel. If the setting is for light paper, 2. 3.
select the correct setting for the current media type. If the problem continues, set the fuser temperature selection to "High". If the problem continues, check the page count. If the page count is greater than 150k copies and the fuser has not been replaced, advise the customer to install a new fuser CRU or a Maintenance Kit.

If only one color has a residual image problem, go to Step A on page 2-79. If all colors have a residual image problem, go to Step B on page 2-80.

Step A

Step

Action and Questions

Print Cartridge - This is most likely caused by a failure of the cleaner in the print cartridge. Try a new print cartridge for the faulty color. Does this fix the problem?

Yes
Problem Solved

No
Go to Step 2

Diagnostic Information

2-79

5060-XXX

Step

Action and Questions

HV Contact Block Assembly, Doctor Blade or TAR Contact Check for a stuck TAR contact pin in the HV Contact Block assembly of the color with the problem. Check figure 1 for pin location. Is the TAR contact pin stuck or operating smoothly. Doctor Blade Contact - Check to make sure the Doctor Blade cable is connected to the Doctor Blade terminal on the Developer HVPS. Is the cable connected correctly?

Yes
Go to Step 3

No
Repair the HV Block Contact for the faulty color. Connect the cable correctly. Replace the cable if it is broken or damaged. Repair the HV Block Contact for the faulty color. Repair the High Voltage Contact Assembly as necessary Replace the HVPS Developer Board on page 4-39

Go to Step 4

Doctor Blade Contact Pin in HV Contact Block Assembly Check to make sure the Doctor Blade Contact Pin in the HV Contact Block assembly is not stuck and is operating smoothly. Look at figure 1 for pin location. Is the Doctor Blade contact pin stuck operating smoothly? Continuity Check - High Voltage Contact Assembly - Check continuity from the Developer HVPS Contact Spring to the Charge Roll Pin in the contact assembly. Is there continuity? Cartridge HV contact Assembly Developer Pin Springs Check the developer pin springs for the cartridge that is having a problem to make sure they are no bent or damaged. Are the springs bent or damaged?

Go to Step 5

Go to Step 6

Replace the damaged Developer Spring

Step B
Note: It is possible that there is a problem with more than one print cartridge, HV Contact, Block Assembly, cable or assembly.

Step

Action and Questions

Print Cartridge(s) - This is most likely caused by a failure of the cleaner in the print cartridge or cartridges. Replace any of the cartridges that appear to have a problem. Does this fix the problem? HV Contact Block Assembly Check, Doctor Blade or TAR Contact - Check for a stuck TAR contact pin in the HV Contact Block Assembly of the colors with the problem. Look at figure 1 for pin locations. Is the TAR contact pin stuck or operating smoothly for the colors with the problem?

Yes
Problem Solved

No
Go to Step 2

Go to Step 3

Repair the HV Block Contact for the faulty color

2-80 Service Manual

5060-XXX

Step

Action and Questions

Doctor Blade Contact - Check to make sure the Doctor Blade Cable is connected to the Doctor Blade terminal on the Developer HVPS. Is the cable connected correctly?

Yes
Go to Step 4

No
Connect the cable correctly. Replace the cable if it is broken or damaged. Repair the HV Block Contact for the faulty color. Repair the High Voltage Contact Assembly as necessary Replace the HVPS Developer Board on page 4-39

Doctor Blade Contact Pin in HV Contact Block Assembly Check to make sure the Doctor Blade Contact Pin in the HV Contact Block assembly is not stuck and is operating smoothly. Look at figure 1 for pin location. Is the Doctor Blade contact pin stuck operating smoothly? Continuity Check - High Voltage Contact Assembly - Check continuity from the Developer HVPS Contact Spring to the Charge Roll Pin in the contact assembly. Is there continuity? Cartridge HV contact Assembly Developer Pin Springs Check the developer pin springs for the cartridge that is having a problem to make sure they are no bent or damaged. Are the springs bent or damaged?

Go to Step 5

Go to Step 6

Replace the damaged Developer Spring

Uneven printing
If all colors have uneven print, replace the ITU assembly. Note: 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 in the ITU assembly. Replace the ITU Assembly on page 4-41. If only one color is missing or printing uneven, go to step 1.

Step

Action and Questions

Print Cartridge - Check to make sure the cartridge is seated properly and that all packing material has been removed from the cartridge. Has all packing material been removed and the cartridge is seated correctly? Cartridge Check - The cartridge may be out of toner or have another toner problem. Try a new toner cartridge. Does a new toner cartridge fix the problem?

Yes
Problem Solved

No
Go to Step 2

Problem Solved

Call your next level support

Diagnostic Information

2-81

5060-XXX

Toner smears or rubs off the page with no error code displayed
Note: This type of problem is associated with improper fusing or incorrect settings for media type being used. If the toner is not fused on the page, replace the fuser assembly. If the toner is poorly fused on the page, go to step 1.

Step

Action and Questions

Media settings - Check to see if the printer is set for light paper. Is the printer set for light paper?

Yes
Set the printer for current media type and go to Step 2 Problem Solved Problem Solved

No
Go to Step 3

2 3

Does resetting the media type fix the problem? Fuser Settings - Set the fuser to "High" in the CE menu. Does setting the fuser to "High" fix the problem?

Go to Step 3 Replace the Fuser Assembly on page 4-16

Toner is on the back of the printed page

Do the following steps before proceeding with this service check:

1. Enter the CE Diagnostic Mode. 2. Select Print Test, Tray 1, Continuous from the menu. 3. Run at least 20 pages of text and see if the problem remains.
If toner is still on the back of the printed page, proceed with this service check. If the problem is on the top two inches of the page replace the second transfer roll. If the toner is "stringy" over the top half of the page, go to step 1.

Step

Action and Questions

Media settings - Check to see if the printer is set for light paper. Is the printer set for light paper?

Yes
Set the printer for current media type and go to Step 2 Problem Solved Problem Solved

No
Go to Step 3

2 3

Does resetting the media type fix the problem? Fuser Settings - Set the fuser to "High" in the CE menu. Does setting the fuser to "High" fix the problem?

Go to Step 3 Replace the Fuser Assembly on page 4-16

2-82 Service Manual

5060-XXX

Light lines or streaks appear on the page

Single color streaks in non-print areas are most likely caused by a cleaner problem in the print cartridge. Replace the print cartridge. All the colors streaking at a different spot on each page is most likely caused by a damaged ITU Assembly. Replace the ITU Assembly on page 4-41. If only one color streaks in the printed area, go to step 1.

Step

Action and Questions

Print Cartridge Check - Try a new print cartridge. Doe a new print cartridge fix the problem? Printhead Check - The printhead lens may be contaminated by toner. Check for any signs of contamination on the lens of the printhead. Is the printhead contaminated?

Yes
Problem Solved Replace the failing Printhead. Go to Printheads on page 4-34.

No
Go to Step 2 Call your next level support

1 2

Operator Panel LCD/Status LED/Buttons Service Check

Use this service check to check both the operation of the panel buttons and to test the LCD display for correct operation. Replace the operator panel assembly if the LCD display functions normally but the LED does not come on. If one or more of the operator panel buttons do not operate correctly, go to Step A on page 2-83. If any of the following symptoms occur, go to Step B on page 2-84.

Operator panel LCD is blank/Power On/Status LED off Operator panel LCD is blank/Power On/Status LED on Operator panel LCD displays all diamonds/5 beeps/Power On/Status LED on Step A

Step

Action and Questions

Buttons Test - Perform the Button Test on page 3-10. Do any or all of the Buttons fail to operate correctly? Note: If all the buttons fail to operate correctly, the LCD display is blank, Power On Status LED is on, and the Machine beeps 5 Times, go Step B.

Yes
Replace the Operator Panel on page 4-26

No
Test Passes No problem found

Diagnostic Information

2-83

5060-XXX

Step B
Note: Make sure the operator panel cable is seated firmly in J1 on the RIP board before proceeding with this step.

Step

Action and Questions

LCD Test - Perform the LCD Test on page 3-10. Can you run the Diagnostic Test? LCD Test - Does the test pass? Operator Panel - Is the operator panel operating correctly except for a few PELS missing or broken?

Yes
Go to step 2 Problem Solved Replace the Operator Panel on page 4-26 Go to step 6 Go to step 10 Go to step 7

No
Go to step 4 Go to step 3 Go to step 4

1 2 3

4 5 6

Operator Panel Assembly - Is the operator panel assembly completely blank and the Power on Status LED off? Operator Panel Assembly - Is the operator panel assembly completely blank and the Power on Status LED On? Does the printer Beep 5 times?

Go to step 5 Go to step 12 Replace the Operator Panel on page 4-26 Go to step 8

RIP Board - Measure the voltage at connector J1-2 on the RIP Board on page 5-11. The voltage measures approximately +5 V dc. Is the voltage correct? Operator Panel Cable (Operator Panel Connection) - Check to make sure that the operator panel cable is seated correctly in the connector on the operator panel board. Is the cable seated correctly? Operator Panel Cable Continuity - Check continuity of the Operator Panel Cable. Is there continuity?

Replace the Operator Panel on page 4-26 Go to step 9

Seat the cable correctly

Replace the RIP Board on page 4-10

Go to the Operator Panel on page 4-26 and replace the operator panel cable Replace the RIP Board on page 4-10

10

RIP Board - A poor ground connection between pin 4 on the Operator Panel board connector can cause this symptom. Check for continuity between Pin J1-4 and ground on the board. Go to RIP Board on page 5-11. Is there continuity?

Go to step 11

2-84 Service Manual

5060-XXX

Step

Action and Questions

Operator Panel Cable Continuity - Check continuity of the Operator Panel Cable. Is there continuity?

Yes
Replace the Operator Panel on page 4-26

No
Go to the Operator Panel on page 4-26 and replace the operator panel cable Call your next level support Go to step 14

11

12

Operator Panel Assembly - Does the Operator Panel display all diamonds, with the Power On/Status LED on and 5 Beeps? Voltage Checks at RIP Connector J1 - Go to RIP Board on page 5-11. Check the voltages on RIP Connector J1 as shown: J1 Pin No Voltage (Display Static) Voltage (Display Active) (LCD Test Running) 1 +5 V dc Voltage varies1.0 to 2.0 V dc 2 +5 V dc +5 V dc 3 +5 V dc Voltage varies 1.0 to 2.4 V dc 4 Ground Ground 5 +5 V dc +5 V dc Are the voltages correct? Operator Panel Cable Continuity - Check continuity of the Operator Panel Cable. Is there continuity?

Go to step 13

13

Replace the Operator Panel on page 4-26

14

Replace the Operator Panel on page 4-26

Go to the Operator Panel on page 4-26 and replace the operator panel cable

Diagnostic Information

2-85

5060-XXX

100 ITU Error Service Check

A 100 ITU error indicates that the printer did not detect the ITU belt home sensor. Before proceeding with this service check make sure that the Second Transfer Roll is correctly installed. After you reinstall the Second Transfer Roll, check to see if a 100 ITU error is still being displayed. If a 100 ITU error is still being displayed, continue with this check.

Step

Action and Questions

Check to make sure all packing material has been removed from the printer. The Detensioner is packing material located underneath the toner cartridges. Make sure the ITU Detensioner is removed. Remove the Detensioner by pulling upward on the red handle on the right side of the ITU. Note: All the print cartridges must be removed to gain access to the Detensioner packing material. Has all packing material been removed from the printer? Check to see if the printer is setting on a solid flat surface. Is the printer setting on a solid flat surface? Inform the customer that the printer must be setting on a solid flat surface or install the printer on a solid flat surface as available. Recheck the printer to see if a 100 ITU error is still being displayed. Is a 100 ITU error still being displayed? Check to make sure the ITU Cleaner Gear (A) is turning. The gear can be observed by opening the front Paper Jam Door above the integrated paper tray 1. Observe the white cleaner gear during POR. The gear should turn slowly and smoothly for approximately 8 seconds before the printer displays a 100 ITU error.

Yes
Go to step 2

No
Remove any remaining packing material from the printer

2 3

Go to step 3 Go to step 4

Go to step 4 Problem Solved

Go to step 5

Go to step 9

Is the ITU Cleaner Gear turning?

Check the ITU Release Lever for correct operation. The ITU Release Lever is the blue lever located on the left upper side frame above the ITU opening and can be seen by opening and lowering the MPF Assembly. When locked the lever should be at the 6 o'clock position. When unlocked it should be in a 3 o'clock position. Undue pressure should not be required to operate the lever. Does the ITU release lever operate correctly?

Go to step 6

Repair as necessary

2-86 Service Manual

5060-XXX

Step

Action and Questions

Remove the ITU assembly and check the sensor cables are seated in the handle of the ITU assembly correctly. Note: The sensor connectors are located on the side of the ITU handle assembly. Are the cables seated correctly?

Yes
Go to step 7

No
Reinstall the cables correctly. Recheck for a 100 ITU error. If 100 ITU is still displayed, go to step 11. Position the shield on top of the belt Go to step 12

The front contamination shield is attached to the front plate of the ITU frame and lies on the top of the ITU belt. Is the front contamination shield lying on the ITU belt? Remove the ITU and check the ITU Belt position. If the belt has shifted front to rear it should be replaced. The belt must not shift more than 4 mm in either direction. This can be checked by making the measurements as shown. The lower limit is 3.1 mm, the high limit is 8.1 mm, and the optimum position is 5.6 mm.

Go to step 8

Replace theITU Assembly on page 4-41

Has the ITU Belt shifted front to rear?

Diagnostic Information

2-87

5060-XXX

Step

Action and Questions

Check to see if the ITU Drive Roll Gear (A) is turning during POR. The gear can be observed by opening the MFP door to its horizontal position. Observe the gear on the left end of the ITU Drive Roll. The ITU Drive Roll Gear should turn for a few seconds slowly and smoothly before the printer posts a 100 ITU error.

Yes
Go to step 10

No
Go to step 10

Does the Gear Turn?

10

Check to see if the ITU Drive Motor is turning during POR. The ITU Motor can be observed during POR by removing the Rear Cover. Is the ITU Drive Motor turning? Check the ITU Drive Motor Assembly cable to make sure it is correctly installed to the ITU Drive Motor and at connector location J64 on the engine board. Is the cable correctly installed? Check the ITU Autoconnect Cable to make sure it is installed correctly at connector location J72 on the engine board. Is the cable correctly installed? Check the ITU Autoconnect connector in the printer to make sure it is seated correctly in the connector plate. Is the connector seated correctly? Check continuity of the ITU Autoconnect cable. Is there continuity?

Replace theITU Assembly on page 4-41 Go to the ITU Drive Motor Service Check on page 2-89 Go to step 13

Go to step 11

11

Install the cable correctly

12

Install the cable correctly

13

Go to step 14

Install the connector/ cable correctly Replace the ITU Autoconnect cable

14

Replace the following FRU's in the order shown:

1. ITU Assembly on page 4-41 2. Engine Board on page 4-14

2-88 Service Manual

5060-XXX

ITU Drive Motor Service Check

If the complete ITU Drive Motor assembly is removed from the printer a lot of toner may be present in the auger tube mounted on the ITU Main plate. Cover the opening in the auger tube to prevent toner from spilling.

Error Code 160

Step

Action and Questions

Error Code 160 indicates that an incorrect motor has been detected. Replace the ITU Drive Motor on page 4-40. Note: Anytime the ITU Drive Motor or ITU Drive Motor Assembly is replaced, perform the Automated Motor Detection on page 3-20. Does the printer continue to display Error Code 160?

Yes
Call your next level support

No
Problem Solved

Error Code 148 Error Code 154

Step

Action and Questions

Connector J64 on the Engine Board - Check for correct installation of the ITU Drive Motor cable from the ITU Drive Motor to the engine board connector J64. Is the cable connected correctly? ITU Drive Motor - Check for continuity between pin 4 of CON1 on the Motor Drive Card and the remaining pins in the connector. Do you measure continuity? Note: The ITU drive motor can be removed from the printer without removing the complete ITU drive motor assembly. If the ITU drive motor assembly is removed be careful not to spill toner that may be contained in the auger system. ITU Drive Motor Cable - Check the continuity of the ITU Drive Motor Cable. Do you measure continuity?

Yes
Go to step 2

No
Install the cable correctly

Replace the drive motor

Go to step 3

Go to step 4

Replace the ITU drive motor cable

Diagnostic Information

2-89

5060-XXX

Step

Action and Questions

ITU Drive Motor voltage Check - Measure the voltage on connector J64 on the engine board. The voltages are approximately values. Voltages Motor not running J64-2 +4.2V Dc J64-4 +5.0V Dc J64-6 +3.3V Dc J64-8 +24V Dc J64-10 Ground J64-12 0V Dc J64-14 +3.3V Dc Are the voltages correct? ITU Motor Drive Assembly - Remove the ITU assembly. Manually turn the motor. The gears in the ITU motor assembly, the second transfer roll gears, and the cleaner gear should turn freely. Do the gears turn freely?

Yes
Replace the drive motor

No
Go to step 5

Replace the engine board. If this does not fix the problem, replace the ITU drive motor. Contact your next level support

Go to step 6

ITU Motor Drive Assembly - Remove the ITU drive motor assembly. Manually turn the motor. Do the gears on the ITU drive motor assembly turn freely?

Replace the ITU motor drive assembly

Error Code 100 ITU

Step Action and Questions
ITU Motor Drive Assembly - Remove the ITU assembly. Manually turn the motor. The gears in the ITU motor assembly, the second transfer roll gears, and the cleaner gear should turn freely. Do the gears turn freely?

Yes
Replace the engine board. If this does not fix the problem, replace the ITU drive motor. Contact your next level support

No
Go to step 2

ITU Motor Drive Assembly - Remove the ITU drive motor assembly. Manually turn the motor. Do the gears on the ITU drive motor assembly turn freely?

Replace the ITU motor drive assembly

2-90 Service Manual

5060-XXX

Printhead Service Checks

Error Code 114
Note: Error Code 114 can occur if the Black Printhead Control cable or the Black Printhead Video cable is open, damaged or not properly connected.

Step

Action and Questions

Check to make sure that all packing materials have been removed from the printer, especially important check at the top of the print cartridge for the cardboard or plastic packaging as well as making sure the ITU blanket have been removed. Has all the packing material been removed? Are the Black Printhead Video and Black Printhead control cables connected correctly to the Black Printhead and to J10 and J11 on the RIP Board? Check for any signs of damage to the Black Video Printhead Cable and Black Printhead Control Cable. Is there any signs of damage to the cables or connectors? Check the voltage on J11 -8. The voltage measures approximately +5.0 V dc. Is the voltage correct? Check continuity of the Black Video Cable. Is there continuity? Replace the RIP Board on page 4-10. Does this fix the problem?

Yes
Go to step 2

No
Remove the packing material from the printer

Go to step 3

Reseat the cables correctly Go to step 4

Replace the damaged cables Go to step 5

Replace the RIP Board on page 4-10 Replace the defective cable Replace the Black Printhead. Go to Printheads on page 4-34. You must perform the Printhead Adjustments on page 4-1 anytime a printhead is replaced.

Go to step 6

Problem Solved

Diagnostic Information

2-91

5060-XXX

Error Code 115

Error Code 115 can occur if the Cyan Printhead Control cable or Cyan Printhead Video cable is open, damaged or not properly connected.

Step

Action and Questions

Check to make sure that all packing materials have been removed from the printer, especially important check at the top of the print cartridge for the cardboard or plastic packaging as well as making sure the ITU blanket have been removed. Has all the packing material been removed? Are the Cyan Printhead Video and Cyan Printhead control cables connected correctly to the Cyan Printhead and to J10 and J11 on the RIP Board? Check for any signs of damage to the Cyan Video Printhead Cable and Cyan Printhead Control Cable. Is there any signs of damage to the cables or connectors? Check the voltage on J6 -8. The voltage measures approximately +5.0 V dc. Is the voltage correct? Check continuity of the Cyan Video Cable. Is there continuity? Replace the RIP Board on page 4-10. Does this fix the problem?

Yes
Go to step 2

No
Remove the packing material from the printer

Go to step 3

Reseat the cables correctly Go to step 4

Replace the damaged cables Go to step 5

Replace the RIP Board on page 4-10 Replace the defective cable Replace the Cyan Printhead. Go to Printheads on page 4-34. You must perform the Printhead Adjustments on page 4-1 anytime a printhead is replaced.

Go to step 6

Problem Solved

2-92 Service Manual

5060-XXX

Error Code 116

Error Code 116 can occur if the Magenta Printhead Control cable or Magenta Printhead Video cable is open, damaged or not properly connected.

Step

Action and Questions

Check to make sure that all packing materials have been removed from the printer, especially important check at the top of the print cartridge for the cardboard or plastic packaging as well as making sure the ITU blanket have been removed. Has all the packing material been removed? Are the Magenta Printhead Video and Magenta Printhead control cables connected correctly to the Magenta Printhead and to J10 and J11 on the RIP Board? Check for any signs of damage to the Magenta Video Printhead Cable and Magenta Printhead Control Cable. Is there any signs of damage to the cables or connectors? Check the voltage on J8 -8. The voltage measures approximately +5.0 V dc. Is the voltage correct? Check continuity of the Magenta Video Cable. Is there continuity? Replace the RIP Board on page 4-10. Does this fix the problem?

Yes
Go to step 2

No
Remove the packing material from the printer

Go to step 3

Reseat the cables correctly Go to step 4

Replace the damaged cables Go to step 5

Replace the RIP Board on page 4-10 Replace the defective cable Replace the Magenta Printhead. Go to Printheads on page 4-34. You must perform the Printhead Adjustments on page 4-1 anytime a printhead is replaced.

Go to step 6

Problem Solved

Diagnostic Information

2-93

5060-XXX

Error Code 117

Error Code 117 can occur if the Yellow Printhead Control cable or Yellow Printhead Video cable is open, damaged or not properly connected.

Step

Action and Questions

Check to make sure that all packing materials have been removed from the printer, especially important check at the top of the print cartridge for the cardboard or plastic packaging as well as making sure the ITU blanket have been removed. Has all the packing material been removed? Are the Yellow Printhead Video and Yellow Printhead control cables connected correctly to the Yellow Printhead and to J10 and J11 on the RIP Board? Check for any signs of damage to the Yellow Video Printhead Cable and Yellow Printhead Control Cable. Is there any signs of damage to the cables or connectors? Check the voltage on J8 -8. The voltage measures approximately +5.0 V dc. Is the voltage correct? Check continuity of the Yellow Video Cable. Is there continuity? Replace the RIP Board on page 4-10. Does this fix the problem?

Yes
Go to step 2

No
Remove the packing material from the printer

Go to step 3

Reseat the cables correctly Go to step 4

Replace the damaged cables Go to step 5

Replace the RIP Board on page 4-10 Replace the defective cable Replace the Yellow Printhead. Go to Printheads on page 4-34. You must perform the Printhead Adjustments on page 4-1 anytime a printhead is replaced.

Go to step 6

Problem Solved

2-94 Service Manual

5060-XXX

Fuser Service Check

Error Code 120 Error Code 121 Incorrect Lamp Installed - The Hot Roll and Backup Roll may have the wrong voltage lamp installed.
Step Action and Questions
Is Error Code 120 displayed?

Yes
Install the correct voltage hot roll lamp Install the correct voltage back up roll lamp

No
Go to step 2

Is Error Code 121 displayed?

Go to step 3

Cold Fuser Service Check

If error code 122,123,126,127,128,129,130, 131, 132 or 133 is displayed, the printer detects a problem in the fuser hot roll or back up roll fuser lamp circuits, fuser hot roll thermistor, back up roll thermistor, engine board or LVPS fuser control circuits.

Error Code 128 Fuser Hot Roll is under temperature during standby. Replace the following FRU's in the order shown: 1. Fuser Assembly on page 4-16
If this does not fix the problem replace:

2. Engine Board on page 4-14 Error Code 129 Fuser Backup Roll is under temperature during standby. Replace the following FRU's in the order shown: 1. Fuser Assembly on page 4-16
If this does not fix the problem replace:

2. Engine Board on page 4-14

Diagnostic Information

2-95

5060-XXX

Error Code 130 Hot Roll did not reach the correct standby temperature.
Step Action and Questions
Voltage Check - Go to Engine Board on page 5-1. Measure the voltage on connector J10-11. The voltage measures approximately .13 V dc to .64 V dc as the hot roll lamp turns off and on. Is the voltage correct? Thermistor Resistance Check, Hot Roll - Measure the resistance of the hot roll thermistor assembly. The resistance measures as follows: Thermistor Hot: approximately 4.0K ohms Thermistor Cold: Approximately 256K ohms Note: The resistance will vary between 4k and 256k ohms depending on the temperature of the thermistor. Is the resistance correct?

Yes
Replace the Fuser Assembly on page 4-16

No
Go to step 2

Replace the following FRU's in order:

1. LVPS on page 4-15 2. Engine Board on page 4-14

Replace the Fuser Assembly on page 4-16

Error Code 131 Backup Roll did not reach the correct standby temperature.
Step Action and Questions
Voltage Check - Go to Engine Board on page 5-1. Measure the voltage on connector J10-12. The voltage measures approximately .14 V dc to .64 V dc as the BUR lamp turns off and on. Is the voltage correct? Thermistor Resistance Check, Back Up Roll - Measure the resistance of the back up roll thermistor assembly. The resistance measures as follows: Thermistor Hot: approximately 4.0K ohms Thermistor Cold: Approximately 256K ohms Note: The resistance will vary between 4k and 256k ohms depending on the temperature of the thermistor. Is the resistance correct?

Yes
Replace the Fuser Assembly on page 4-16

No
Go to step 2

Replace the following FRU's in order:

1. LVPS on page 4-15 2. Engine Board on page 4-14

Replace the Fuser Assembly on page 4-16

2-96 Service Manual

5060-XXX

Error Code 132 - Cold Hot Roll Error Code 133 - Cold Backup Roll
Step Action and Questions
Lamp continuity Check, Hot Roll - Check continuity of the hot roll lamp. The continuity can be checked by measuring between pin 1 and pin 5 on the single line AC fuser connector located on the bottom of the fuser frame. Go to LVPS Fuser Connectors on page 5-20. Is there continuity? Hot Roll Lamp incorrectly installed or damaged - It is easier to check the lamp by removing it from the right side of the fuser frame assembly. Check to make sure the lamp is not broken, cracked or open. Is there a problem with the lamp or its installation? Lamp continuity Check, Back Up Roll - Check continuity of the back up roll lamp. The continuity can be check by measuring between pin 1 and pin 4 on the single line AC fuser connector located on the bottom of the fuser frame. Go to LVPS Fuser Connectors on page 5-20. Is there continuity? Back Up Roll Lamp incorrectly installed or damaged - It is easier to check the lamp by removing it from the right side of the fuser frame assembly. Check to make sure the lamp is not broken, cracked or open. Is there a problem with the lamp or its installation?

Yes
Replace the Fuser Assembly on page 4-16

No
Go to step 2

Reinstall the lamp. Replace as necessary.

Replace the Fuser Assembly on page 4-16 Go to step 4

Replace the LVPS on page 4-15

Reinstall the lamp. Replace as necessary.

Replace the Fuser Assembly on page 4-16

Error Code 126 Hot Roll Thermistor or thermistor circuits are open.
Step Action and Questions
Thermistor Resistance Check, Hot Roll - The thermistor resistance can be checked between pins 6 and 8 on the ten pin fuser control connector on the fuser assembly. Go to LVPS Fuser Connectors on page 5-20. Measure the resistance of the hot roll thermistor assembly. The resistance measures as follows: Thermistor Hot: approximately 4.0K ohms Thermistor Cold: Approximately 256K ohms Note: The resistance will vary between 4k and 256k ohms depending on the temperature of the thermistor. Is the resistance correct?

Yes
Go to step 2

No
Replace the Fuser Assembly on page 4-16

Diagnostic Information

2-97

5060-XXX

Step

Action and Questions

Voltage Check - Measure the voltage on J10-6. Go to Engine Board on page 5-1. The voltage will vary as the lamp turns off and on between approximately +1.5 V dc to 1.8 V dc. Is the voltage correct?

Yes
Find the correct system problem or error code

No
Replace the following FRU's in order:
1. LVPS on page 4-15 2. Engine Board on page 4-14

Error Code 127 Backup Roll Thermistor or thermistor circuits are open.
Step Action and Questions
Thermistor Resistance Check, Back Up Roll - The thermistor resistance can be checked between pins 7and 8 on the ten pin fuser control connector on the fuser assembly. Go to LVPS Fuser Connectors on page 5-20. Measure the resistance of the back up roll thermistor assembly. The resistance measures as follows: Thermistor Hot: approximately 4.0K ohms Thermistor Cold: Approximately 256K ohms Note: The resistance will vary between 4K and 256K ohms depending on the temperature of the thermistor. Is the resistance correct? Voltage Check - Measure the voltage on J10-6. Go to Engine Board on page 5-1. The voltage will vary as the lamp turns off and on between approximately +1.5 V dc to 1.8 V dc. Is the voltage correct?

Yes
Go to step 2

No
Replace the Fuser Assembly on page 4-16

Find the correct system problem or error code

Replace the following FRU's in order:

1. LVPS on page 4-15 2. Engine Board on page 4-14

2-98 Service Manual

5060-XXX

Hot Fuser Service Check

Error codes 124, 125, 134, and 135 display whenever the printer detects a problem with the fuser running over temperature or the fuser lamps have been on too long.

Error Code 124 Error Code 134

Error codes 124 and 134 indicate that the fuser is running over temperature or the hot roll fuser lamp has been on too long. These error codes indicate that a problem could exist in the fuser assembly with the hot roll bearings, hot roll thermistor or other hot roll parts. The LVPS or engine board assembly can also be failing. Replace the FRU's in the following order:

1. Fuser Assembly on page 4-16 2. LVPS on page 4-15 3. Engine Board on page 4-14 Error Code 125 Error Code 135
Error codes 125 and 135 indicate that a problem exists in the fuser assembly with the back up roll bearings, back up roll thermistor, LVPS or engine board. Replace the FRUs in the following order:

1. Fuser Assembly on page 4-16 2. LVPS on page 4-15 3. Engine Board on page 4-14 Error Code 161

Step

Action and Questions

Fuser Drive Motor Assembly - Error code 161 indicates that an incorrect motor is detected. Replace the Fuser Drive Assembly on page 4-17. Note: Anytime the Fuser Drive Assembly is replaced, perform the Automated Motor Detection on page 3-20. Does the printer continue to display error code 161?

Yes
Call your next level support

No
Problem Solved

Diagnostic Information

2-99

5060-XXX

Error Code 149 Error Code 155

Step Action and Questions
Connector J8 on the Engine Board - Check to make sure that the fuser drive motor cable is correctly connected to J8 on the Engine Board. Go to Engine Board on page 5-1. Is the cable connected correctly? FRU Replacement - Replace the following Frus in the order shown:
1. Fuser Drive Assembly on page 4-17. 2. Engine Board on page 4-14.

Yes
Go to step 2

No
Correctly install the cable Replace the Fuser Assembly on page 4-16

Replace the Fuser Drive Assembly on page 4-17

Excessive Fuser Drive Motor Assembly Noise

Step Action and Questions
Excessive Noise from the Fuser Drive Motor Assembly Check for correct installation of the fuser drive motor assembly. Is the fuser drive motor installed correctly? Install a new Fuser Assembly on page 4-16. Is there still excessive noise from the fuser drive motor assembly?

Yes
Go to step 2

No
Correctly install the Fuser Drive Assembly on page 4-17. Replace the Fuser Assembly on page 4-16

Replace the Fuser Drive Assembly on page 4-17

Error Code 136 Fuser assembly cam position is not found

Step Action and Questions
Engine Board Connector - Check Connector J10 for correct installation. Go to Engine Board on page 5-1. Is the LVPS Fuser cable correctly installed at connector J10 on the Engine Board? Voltage Check, Engine Board connector J10-2 - Go to Engine Board on page 5-1. Measure the voltage on the connector at J10-2. The voltage measures approximately +5 V dc. Is the voltage correct?

Yes
Go to step 2

No
Install the cable correctly

Replace the following Frus in order:

1. Fuser Assembly on page 4-16 2. LVPS on page 4-15

Replace the Engine Board on page 4-14

2-100 Service Manual

5060-XXX

Paper Jam 201 Paper jam is detected at or under the fuser exit sensor.
Step Action and Questions
Engine Board Connector/Cable - Check connector J10 for correct installation. Go to Engine Board on page 5-1. Is the LVPS Fuser Cable correctly installed at connector J10? Is Paper Jam 201 displayed?

Yes
Go to step 2

No
Install the cable correctly

Go to the 2XX Paper Jam Message Table on page 2-24

Problem Solved

Paper Jam 202 Paper jam is detected at the fuser assembly.

Step Action and Questions
Paper Jam at the Exit of the Fuser Assembly - Check to see if the paper is jammed after the Fuser Exit Sensor. Did the paper jam at the exit of the Fuser Assembly?

Yes
Go to step 2

No
Go to the 2XX Paper Jam Message Table on page 2-24 Go to the Paper Path Service Check on page 2-112

Fuser Assembly Check - Remove the fuser assembly and look for any signs broken parts or damage to the fuser that might cause the paper to jam at the exit of the fuser assembly. Were any broken parts or damage found to the fuser assembly?

Replace the Fuser Assembly on page 4-16

Error Code 930

This type of problem with the fuser circuits is usually associated with the zero crossover signal from the LVPS not working correctly.

Step

Action and Questions

LVPS Cable - Check the LVPS cable to J10 on the Engine Board to make sure it is seated correctly. Go to Engine Board on page 5-1. Is the cable seated correctly?

Yes
Go to step 2

No
Install the cable correctly

Diagnostic Information 2-101

5060-XXX

Step

Action and Questions

Voltage Checks - Disconnect J10 from the Engine Board assembly. Go to Engine Board on page 5-1. Check the voltage at J10-10, on the cable. It measures approximately +3.7 V dc. Is the voltage correct?

Yes
Go to step 3

No
Replace the following FRUs in order:
1. LVPS on page 4-15 2. Engine Board on page 4-14

Is Error Code 930 still displayed?

Replace the LVPS on page 4-15

Problem Solved

Cover Open/HV Interlock Switch Service Check

"Close Door" is displayed constantly, unable to clear the message from the display, POR incomplete.

Step

Action and Questions

Front Cover and HV Interlock Switches - Check to make sure both switches are mounted correctly. Are both switches mounted correctly?

Yes
Go to step 2

No
Check the Front Cover and HV Interlock Switches to make sure they are mounted correctly Go to step 3

Check the ITU assembly HV interlock switch actuator to make sure it is not damaged or broken and it actuates the switch correctly? Is the actuator damaged or broken? Front Cover Assembly Does the front cover close correctly?

Replace the ITU Assembly on page 4-41 Go to step 4

Correctly install the door or repair as necessary Go to step 5

Front Cover Assembly - Check to make sure the front cover flag is not broken or damaged. Is the flag broken or damaged? Front Cover/HV Interlock Cable Assembly to Engine Board Check to make sure that the Cable is correctly connected to J86 on the Engine Board. Is the cable connected correctly?

Replace the Front Cover Assembly on page 4-22 Go to step 6

Install the cable correctly

2-102 Service Manual

5060-XXX

Step

Action and Questions

Front Cover/HV Interlock Cable Assembly - Make sure the Front Cover is closed and the ITU is correctly installed. Disconnect the switch cable from J86 on the Engine Board. Check for continuity between J86-1 and J86-2 on the cable connector. Is there continuity?

Yes
Replace the Engine Board on page 4-14

No
Replace the Front Cover/ HV Interlock Switch/Cable Assembly

PSD Service Check

Error Code 192 Error Code 193 Error Code 194 Error Code 195
Go to step 1 for Error Codes 192 and 194. Go to step 5 for Error Codes 193 and 195

Step

Action and Questions

Check to make sure that the PSD Cable is installed correctly to connector J9 on the RIP Board. Go to RIP Board on page 5-11. Is the cable installed correctly? Measure the voltage at J9-8 on the RIP Board, the voltage should measure approximately +5 V dc. Go to RIP Board on page 5-11. Is the voltage correct? Check continuity of the PSD cable Note: The PSD cable has one connector on one end, RIP Board, and two connectors on the other end, Black PSD Board and Magenta PSD Board. Is there continuity?

Yes
Go to step 2

No
Install the cable correctly

Go to step 3

Replace the RIP Board on page 4-10 Replace the PSD cable for the Black and Magenta PSD Assemblies

Replace the PSD Sensor Assembly on page 4-36. If this does not correct the problem, replace the RIP Board on page 4-10. Whenever the the PSD assembly is replaced it is necessary to perform all Printhead Adjustments on page 4-1.

Diagnostic Information 2-103

5060-XXX

Step

Action and Questions

Check to make sure that the PSD Cable is installed correctly to connector J4 on the RIP Board. Go to RIP Board on page 5-11. Is the cable installed correctly? Measure the voltage at J4-8 on the RIP Board, the voltage should measure approximately +5 V dc. Go to RIP Board on page 5-11. Is the voltage correct? Check continuity of the PSD cable. Note: The PSD cable has one connector on one end, RIP Board, and two connectors on the other end, Cyan PSD Board and Yellow PSD Board. Is there continuity?

Yes
Go to step 2

No
Install the cable correctly

Go to step 3

Replace the RIP Board on page 4-10 Replace the PSD cable for the Cyan and Yellow PSD Assemblies

Replace the PSD Sensor Assembly on page 4-36. If this does not correct the problem, replace the RIP Board on page 4-10. Whenever the the PSD assembly is replaced it is necessary to perform all Printhead Adjustments on page 4-1.

Tray 1 Paper Size Sensing Service Check

The printer does not sense the size of the media installed in Tray 1. Note: If there is a problem when installing Tray 1, Tray 1 is difficult to remove or does not stay locked in position, go to Tray 1 Service Check on page 2-105.

Step

Action and Questions

Check to make sure Tray 1 is installed and seated correctly in the printer. Is the tray correctly installed in the printer?

Yes
Go to step 2

No
Install Tray 1 correctly. If there is still a problem, go to Tray 1 Service Check on page 2-105 Go to step 4 Go to step 7

2 3

Is another 500 Sheet Tray available? Try another 500 Sheet Tray in place of the internal Tray 1 paper tray. Does this fix the problem?

Go to step 3 Go to step 4

2-104 Service Manual

5060-XXX

Step

Action and Questions

Check the following parts in Tray 1 for any signs of broken parts, especially the teeth on the Back Restraint. Is the Back Restraint broken or any of the teeth broken or missing? Check the following parts to make sure they are installed correctly and they are not damaged or broken. * Size Sensing Gear Cover * Size Sensing Gear * Size Sensing Barrel Cam Note: Make sure the Size Sensing Barrel Cam is correctly installed. The position of the Cam tab can be observed through the size sensing gear cover. The cam position can be observed through the cover by moving the back restraint and observing the cam detent. In the A5 media position the detent should be visible through the opening in the gear cover. Are all the parts installed correctly, and not broken or missing? Is the answer to Step 3 "Yes" Check the following parts in the printer to make sure they are operating correctly. Check for any signs of broken or missing parts. * Size Sensing Springs * Size Sensing Links * Size Sensing Bracket Is there any sign of broken or missing parts? Check Paper Size Sensing assembly in the printer to make sure that the Size Sensing Links correctly actuate the paper size switches on the Engine Board. Does Tray 1 correctly actuate the paper size switches on the Engine Board?

Yes
Replace the Back Restraint

No
Go to step 5

Go to step 6

Repair or replace parts as necessary

6 7

Replace Tray 1 Repair or replace parts as necessary

Go to step 7 Go to step 8

Replace the Engine Board on page 4-14

Repair or replace parts as necessary

Tray 1 Service Check

Tray 1 does not stay seated or fit correctly in the printer, the media fails to feed correctly from Tray 1 or Tray 1 is difficult to install
Note: The Tray 1 Feed Test in the CE Diagnostics can be used to help isolate problems with paper feeding from Tray 1.

Step

Action and Questions

Check the following parts in Tray 1 for any signs of Broken or missing parts. Tray Bias Spring loose or missing Tray Bias Bellcrank Are any parts broken, loose or missing?

Yes
Repair or replace parts as necessary

No
Go to step 2

Diagnostic Information 2-105

5060-XXX

Step

Action and Questions

Check to make sure the autocompensator has fully retracted to its upper position. Does the Autocompensator retract correctly?

Yes
Go to step 3

No
Go to the Autocompe nsator Service Check on page 2-106 Go to the Autocompe nsator Service Check on page 2-106 Go to the Autocompe nsator Service Check on page 2-106

Check for any signs of damage to the Paper Tray Guide. Is the paper tray guide damaged, loose or missing?

Replace the Paper Tray Guide.

Check the following parts for any signs of wear, damaged or missing parts. Wear Strips Restraint Pads Wear Clip Side Restraint Back Restraint and Back Restraint Latch Are any of the parts broken, worn or missing?

Repair or replace parts as necessary

Autocompensator Service Check

If the paper fails to feed from Tray 1, go to Step A on page 2-107. If the autcompensator fails to lower when Tray 1 is installed, go to Step B on page 2-107. If the autocompentator fails to retract when you attempt to remove Tray 1, go to Step C on page 2-107. If there is no indication that the media is out or low, go to Step D on page 2-108. If the printer fails to detect transparencies and 203 Paper Jam displays, go to Step E on page 2-109. Note: When feeding paper through the printer to check for autocompensator problems use the Tray 1 Feed test in the CE Diagnostics as a printed copy is not required.

2-106 Service Manual

5060-XXX

Step A
Step Action and Questions
Use the Tray 1 feed test to feed paper from Tray 1. Check to see if the Pick Rolls are turning? Note: You can observe the pick rolls by opening the Lower Jam access door assembly. Do the Pick Rolls Turn? Check the Autocompensator Pick Rolls for any signs of contamination or damage to the rolls. Is there any excessive contamination or damage to the Pick Rolls?

Yes
Go to step 2

No
Go to step 3

Replace the Pick Rolls. Always replace both pick rolls at the same time. Replace the Autocompensator Assembly

Go to step 3

Check the voltages at J73 on the Engine Board. Are the voltages correct?

Replace the Engine Board on page 4-14

Step B
Step Action and Questions
Check Tray 1 for any signs of damage to the Pick Arm Lift Bellcrank activation tabs on the rear of the tray. Is there any damage to the tray? Check the following parts for any signs of damaged, loose or missing parts. Pick Arm Lift Bellcrank Bellcrank Lift Spring Tray interlock bellcrank Are any of the parts broken, loose or missing?

Yes
Replace Tray 1

No
Go to step 2

Repair or replace parts as necessary

Replace the Autocompensator Assembly

Step C
Step Action and Questions
Can you remove Tray 1 from the printer? Open the Lower Jam Access door and carefully lift the autocompensator assembly until it is in it's upper most position, and carefully try to remove Tray 1. Can you remove Tray 1?

Yes
Go to step 3 Go to step 3

No
Go to step 2 Determine what is causing the tray to stay in a locked position. Repair as necessary

1 2

Diagnostic Information 2-107

5060-XXX

Step

Action and Questions

Check Tray 1 for any signs of damage to the Pick Arm Lift Bellcrank activation tabs on the rear of the tray. Is there any damage to the tray? Check for any loose or broken parts on the autocompensator assembly. Are any loose or broken parts found? Check the following parts for any signs of damaged or broken parts. Pick Arm Lift Bellcrank Pick Arm Bellcrank Lift Spring Are there any damaged or broken parts?

Yes
Replace Tray 1

No
Go to step 4

Replace the Autocompensator Assembly Repair or replace parts as necessary

Go to step 5

Determine what is causing the Autocompensator to stay in the down position. Repair as necessary.

Step D

Step

Action and Questions

Enter the diagnostic mode and select the Tray 1 Sensor Test from the Input Tray Tests menu. You can activate the Paper Level Sensor inside the printer. The Paper Level Sensor is a dual sensor and checks the following levels for Tray 1. Does the Sensor Test pass? Note: The Tray 1 Level Sensor is a Dual Sensor assembly that senses when Tray 1 is empty, nearly empty or partially empty. Paper Level Sensing Assembly - Check to make sure the assembly is not loose or damaged. Check to make sure the arm is not broken. Are any parts loose or broken? Check the Paper Level Sensing Cable for correct installation at J69 on the Engine Board and to the Paper Level Sensing Dual Sensor Assembly. Is the cable connected correctly? Check the Paper Level Sensing Assembly Flag for correct installation and the Flag is not broken or damaged. Is the Paper Level Sensing assembly installed correctly and the flag not broken or damaged?

Yes
Call your next level support

No
Go to step 2

Repair or replace parts as necessary Go to step 4

Go to step 3

Install the cable correctly

Go to step 5

Install correctly or replace the flag if damaged or broken

2-108 Service Manual

5060-XXX

Step

Action and Questions

Check continuity of the Paper Level Sensing cable. Is there continuity? Check the voltage at J69-1. The voltage measures approximately +5V dc. Is the voltage correct?

Yes
Go to step 6

No
Replace the Level Sensing Cable Replace the Engine Board on page 4-14

Replace the Level Sensing Assembly

Step E
Step Action and Questions
Check the make sure that the transparency material installed in Tray 1 meets machine requirements. Does the media meet requirements? Check the following for correct installation and any signs of broken or damaged parts: Transparency Lift Arm Transparency Lift Link Is the Transparency Sensor Assembly installed correctly, not damaged or broken? Check continuity of the Paper Level Sensing cable. Is there continuity? Note: This cable is used for both the Paper Level Sensing Assembly and the Transparency Sensor Assembly.

Yes
Go to step 2

No
Inform the customer Repair or replace parts as necessary

Go to step 3

Replace the Transparency Assembly, If this does not correct the problem, replace theEngine Board on page 4-14

Replace the cable

Multipurpose Feeder (MPF) Service Check

200 Paper Jam displayed when using MPF - Media does not feed from MPF
Note: A 200 Paper Jam indicates that the printer is unable to feed a sheet from the MPF paper tray or is jammed before at or over the input sensor.

Step

Action and Questions

Does media feed correctly from Tray 1?

Yes
Go to step 2

No
Go to Tray 1 Service Check on page 2-105

Diagnostic Information 2-109

5060-XXX

Step

Action and Questions

Access the CE Diagnostic Test Menu. Select Input Tray Tests, Select MPF Feed Test, Select MP Feeder, Select Single. Note: The MPF Drive parts can be observed by opening the Lower Left Jam Cover. Observe the MFP Drive Gear located in the base printer. Does the Gear Turn when feeding media from the MPF? Does the MPF Drive Gear in the Autocompensator Assembly Turn when feeding media from the MFP?

Yes
Go to step 5

No
Go to step 3

Go to step 4

Go to the Autocompe nsator Service Check on page 2-106 Go to step 5

Check the following parts for any sign of broken, damaged or missing parts. MPF Bracket Assembly MPF Drive Gear MPF Drive Gear Bushing MPF Drive Gear Shaft Are any of the parts broken, damaged or missing? Manually turn the MPF Drive Gear in the MPF assembly. Does the MPF Pick Roll turn? Check to make sure the MFP Drive Gear in the printer is matching up properly with the MPF Drive Gear in the MPF Tray assembly. Do the gears match up correctly?

Repair or replace parts as necessary

Go to step 6

Repair or replace parts as necessary Determine what is causing the two gears not to match up and repair as necessary

Call your next level support

250 Paper Jam displayed when using MPF

Note: A 250 Paper Jam indicates that the MPF tried to feed a sheet of media from the MPF tray. A 250 Paper Jam may occur when there is no paper in the MPF, MPF has been selected as the paper source, or the MFP sensor is malfunctioning. If media is in the MFP it may feed normally with no 250 Paper Jam even though the sensor is malfunctioning.

Step

Action and Questions

Enter the CE Diagnostic Tests. Select Input Tray Tests, Sensor Test, Multipurpose Feeder. Manually actuate the MP Sensor by moving the paper flag in the MPF. Does the test pass?

Yes
Go to step 6

No
Go to step 2

2-110 Service Manual

5060-XXX

Step

Action and Questions

Check to make sure that the MP sensor cable from the Engine Board is correctly installed at J70 on the Engine Board. Is the cable correctly installed? Check the cable connection between the MP Sensor Cable and the Sensor. Is the connection good between the two cables? Disconnect the Sensor Cable from J70 on the Engine Board. Measure the following voltages on J70, being careful not to short any adjacent pins in the connector. All voltages are approximate values. J70-1: +5 V dc J70-2: +5 V dc J70-3: +5 V dc J70-4: 0 V dc Are the voltages correct? Check continuity of the Sensor Cable that is between the Engine board and MPF assembly. Is the continuity? Check the following parts for any signs of excessive wear, damaged, broken or missing parts. MPF Autocompensator Assembly Rib Housing Friction Buckler Buckler Housing Are any of the parts worn, damaged, broken or missing? Does the paper jam prior to the Input Sensor?

Yes
Go to step 3

No
Install the cable correctly

Go to step 4

Install the cable correctly Replace the Engine Board on page 4-14

Go to step 5

Replace the Sensor Assembly Repair or replace parts as necessary

Replace the Sensor Cable Assembly Go to step 7

Determine what is causing the paper to jam prior to the input sensor. If unable to determine what is causing the problem, call your next level support.

Go to the Paper Path Service Check on page 2-112

Diagnostic Information 2-111

5060-XXX

Paper Path Service Check

Note: A 250 Paper Jam only displays when using a Multpurpose Feeder. Go to the Multipurpose Feeder (MPF) Service Check on page 2-109.

250 Paper Jam Displayed - Unable to clear the message from the display

Step

Action and Questions

Check the Input Sensor S2 Is Sensor S2 operating correctly? Note: It may not be possible to run the base sensor test if the message cannot be cleared from the CE Diagnostic Tests screen. Check for any obstructions, such as pieces of media, in the area of the input deflector. You may have to remove the print cartridges and ITU assembly to gain access to the inside of the printer and Sensor S2. Are there any obstructions in the paper path in the are of Sensor S2? Check for any cables, broken or loose parts that might cause the paper to jam in the input area of the printer. Were any problems found inside the printer? Check to make sure the Transfer Plate is correctly installed. Is the Transfer Plate correctly installed? Check to make sure the Transfer is not broken and the ground brush is installed. Is there any problem with the Transfer Plate Assembly?

Yes
Go to Step 2

No
Repair or replace parts as necessary

Clear the area of the obstruction

Go to Step 3

Repair or replace parts as necessary Go to Step 5

Go to Step 4

Install the Transfer Plate correctly Call your next level support

Replace the Transfer Plate Assembly

201 Paper Jam Displayed - Unable to clear the message from the display

Step

Action and Questions

Check the paper path in the vicinity of the Fuser Transfer Plate, the Vacuum Transport Assembly or input to the Fuser Assembly for any signs of obstructions such as pieces of media that may be jammed in the machine. Are there any pieces of media jammed in the printer?

Yes
Remove the obstruction

No
Go to Step 2

2-112 Service Manual

5060-XXX

Step

Action and Questions

Check the Vacuum Transport assembly to make sure the belts are moving. Are the Vacuum Transport belts moving during printing? Note: You can observe the belts through the front paper jam door. Remove all the print cartridges. Remove the vacuum transport assembly and check for any signs of pieces of media in the belts. Is there any signs of media in the belts? Check for any sings of torn belts, excessive toner buildup or damage to the transport assembly especially to the transport drive gear. Are there any signs of broken or damaged parts in the Vacuum Transport Assembly? Check to make sure that the Vacuum Transport Assembly drive gear meshes correctly with drive gear on the fuser drive assembly. Do the gears mesh correctly?

Yes
Go to Step 3

No
Go to Step 5

Remove the media from the belts Replace the Vacuum Transport Assembly Go to Step 6

Go to Step 4

Go to Step 5

Check both the Fuser Drive Assembly and Vacuum Transport Assembly to make sure they are installed correctly Replace the Fuser Assembly on page 4-16 Replace the Vacuum Transport Assembly

Check to make sure that the fuser drive assembly drive gear to the vacuum transport is operating correctly. Is the Fuser Drive assembly drive gear for the vacuum transport operating correctly? Check to see if the paper is laying flat on the vacuum transport belts. Is the paper laying flat on the vacuum transport belts as it passes through the printer?

Go to Step 7

Contact your next level support

Diagnostic Information 2-113

5060-XXX

202 Paper Jam Displayed - Unable to clear the message from the display
Step Action and Questions
Check the Vacuum Transport for correct operation. Is the Vacuum Transport operating correctly?

Yes
Go to step 2

No
Replace the Vacuum Transport Assembly Go to Step 4 Replace the Fuser Assembly on page 4-16 Go to step 5

2 3

Does the media jam at the entry to the fuser assembly. Check the fuser drive assembly for correct operation. Is the fuser drive assembly operating correctly?

Go to step 3 Replace the Fuser Assembly on page 4-16 Replace the Fuser Assembly on page 4-16 Go to step 6

Does the media jam inside the fuser assembly?

Is the media jamming in the Redrive Assembly?

Replace the Fuser Assembly on page 4-16 Go to step 7 Call your next level support

6 7

Check the Redrive assembly for correct operation. Is the Redrive assembly operating correctly? Check the Redrive Belt. Is the redrive Belt driving the Redrive assembly?

Call your next level support Replace the Redrive Assembly on page 4-37

Close Door/HVPS/Printhead Interlock Switch Service Check

Note: There are two separate cables that contain two microswitches and a cable. These cable/switches provide separate interlocks for the Printhead and HVPS. One switch in each cable is mounted in the Front Access Door Support and the other switch in each cable is mounted on the ITU Light Shield Assembly. The HVPS/Cover Open cable is connected to J86 on the Engine board and the Printhead/Cover Open cable is connected to J12 on the RIP board.

POR incomplete, Close Door constantly displays

This symptom is usually associated with the lower switch mounted on the Front Access Door Support and with the switch mounted in the ITU Light Shield. Note: When the printer is left powered on for some time with this symptom displayed the printer may then display a 902 Service Error.

2-114 Service Manual

5060-XXX

Step

Action and Questions

Check to make sure that the ITU Light Shield is not out of position. Is the ITU Light Shield out of position? Check to make sure that the ITU Light Shield is not out of position. Is the ITU Light Shield out of position? Check the ITU assembly interlock switch actuator to make sure it is not damaged or broken and actuates the switches correctly. Is the actuator damaged or broken? Front Cover Assembly Does the front cover close correctly?

Yes
Properly align the ITU Light Shield Go to step 3

No
Go to step 2

Properly align the ITU Light Shield Go to step 4

Replace the ITU Assembly on page 4-41 Go to step 5

Install the front cover correctly or repair as necessary Go to step 6

Front Cover Assembly Check to make sure the front cover flag is not broken or damaged and actuates the switches correctly. Is the flag broken or damaged? Printhead/Cover Open Interlock Cable assembly Check to make sure that the Cable is correctly connected to J12 on the RIP board. Is the cable connected correctly? Make sure the Front Cover is closed and the ITU is correctly installed. Disconnect J12 from the RIP Board and check for continuity between Pins J12-1 and J12-3. Do you measure continuity?

Replace the Front Cover Assembly on page 4-22 Go to step 7

Install the cable correctly

Replace the RIP Board on page 4-10

Replace the Printhead Interlock Cable/Switch Assembly

POR complete, printer feeds blank page

This symptom is usually associated with the Upper switch mounted on the Front Access Door Support and with the right switch mounted in the ITU Light Shield.

Step

Action and Questions

Check to make sure that the ITU Light Shield is not broken. Is the ITU Light Shield broken? Check to make sure that the ITU Light Shield is not out of position. Is the ITU Light Shield out of position?

Yes
Replace the ITU Light Shield Properly align ITU Light Shield

No
Go to step 2

Go to step 3

Diagnostic Information 2-115

5060-XXX

Step

Action and Questions

Check the ITU assembly interlock switch actuator to make sure it is not damaged or broken and actuates the switches correctly. Is the actuator damaged or broken? Front Cover Assembly Does the front cover close correctly?

Yes
Replace the ITU Assembly on page 4-41 Go to step 5

No
Go to step 4

Install the front cover correctly or repair as necessary Go to step 6

Front Cover Assembly Check to make sure the front cover flag is not broken or damaged and actuates the switches correctly. Is the flag broken or damaged? HVPS/Cover Open Interlock Cable Assembly to Engine Board - Check to make sure that the cable is correctly connected to J86 on the engine board. Is the cable connected correctly? HVPS/Cover Open Interlock Cable Assembly - Make sure the Front Cover is closed and the ITU is correctly installed. Disconnect the switch cable from J86 on the engine board. Check for continuity between J86-1 and J86-2 on the cable connector. Is there continuity?

Replace the Front Cover Assembly on page 4-22 Go to step 7

Install the cable correctly

Replace the Engine Board on page 4-14

Replace the HVPS/Cover Open Interlock Switch/Cable Assembly

500 Sheet Drawer Option Service Check

Whenever the 500 Paper Tray has to be removed, use caution as the autocompensator may be in its down position which could result in damage to the autocompensator assembly. For Service Error 990 Tray X, X=Tray 1, 2, 3, 4 or 5. This is the tray that has a problem or needs service. The Tray Empty Sensor, Paper Low Sensor and Pass Thru Sensor for any installed Tray X (1 thru 4) can be checked using the Input Tray Sensor Test (500-Sheet Trays) on page 3-13.

2-116 Service Manual

5060-XXX

The base printer does not recognize that Tray X is installed.

Step Action and Questions
Is Tray x the only paper input option that is not recognized? Check to make sure that the printer and any option above Tray x is installed correctly. Is the printer and any options installed correctly? Check for correction installation of the Lower Options Autoconnect cable to Engine Board connector J5. Is the cable to J5 installed correctly? Autoconnect Cables - Check the autoconnect from the printer or option above Tray X. Check for any signs of cuts, pinched wiring or damage to the contacts in the connector. Are there any problems with the autoconnect cables? Tray X Autoconnect Cable - Check the Tray X autoconnect cable(s) for correct installation at the Tray X System board. Are the Tray X autoconnect cable(s) connected correctly? Tray X Autoconnect Cable Continuity - Check the continuity of the Tray X Autoconnect cable(s). Is there continuity?

Yes
Go to step 5 Go to step 3

No
Go to step 2 Install the option correctly and recheck Install the cable correctly and recheck Go to step 5

1 2

Go to step 4

Repair or replace as necessary Go to step 6

Install the cables correctly and recheck Replace Electronic Size Sensing Assembly (Includes the System Board) Replace the Engine Board

Go to step 7

Disconnect J5 from the engine board and check the voltages on connector J5 on the engine board. The voltages should measure as follows: J5-1: +24 V dc J5-3: +5 V dc J5-5: +5 V dc J5-6: +5 V dc J5-8: +5 V dc All voltages are approximate values. Are the voltages correct?

Replace Electronic Size Sensing Assembly (Includes the System Board)

Diagnostic Information 2-117

5060-XXX

Tray x autocompensator fails to retract, stays in down position.

Step Action and Questions
Use care when trying to remove a tray assembly when the autocompensator is in its down position. Remove the tray and manually reset the autocompensator to its up most position by actuating the Pick Arm Lift Bellcrank. Does the autocompensator assembly stay in the up position? Carefully replace the tray and recheck to see if the autocompensator operates correctly. Does the autocompensator assembly operate correctly? Check the autocompensator Pick Arm Lift Bellcrank to make sure it is installed correctly. Is the Pick Arm Lift Bellcrank installed correctly? Check the following for loose, broken or missing parts. Bellcrank Lift Spring Tray interlock Bellcrank Any any of these parts loose, broken or missing?

Yes
Go to step 2

No
Go to step 3

Problem Solved Go to step 4

Go to step 3

Install the bellcrank correctly Go to step 5

Repair or replace as necessary

The printer does not detect paper low in Tray x when adequate paper is installed in the tray.
Step Action and Questions
Run Tray x sensor test from the diagnostic menu. Does the test pass for sensor L2? Check the cable connection for the Paper Low/Out sensor to Tray x System Board. Is the cable correctly installed? Check the Paper Level Sensing assembly for correct installation, check the following for any signs of damaged or broken parts: Check the Paper Level Sensing Flag. Check the Paper Level Sensing Flag spring. Is the Paper Level Sensing assembly installed correctly? Is the Paper Level Sensing assembly damaged or broken?

Yes
Go to step 3 Go to step 3

No
Go to step 2 Install the cable correctly Install the Paper Level Sensing Assembly correctly

1 2

Go to step 4

Replace the Paper Level Sensing Assembly

2-118 Service Manual

5060-XXX

The printer does not detect paper out in Tray x when adequate paper is installed in the tray.
Step Action and Questions
Run Tray x sensor test from the diagnostic menu. Does the test pass for Sensor L1? Check the cable connection for the Paper Level Sensing Assembly to Tray x System Board. Is the cable correctly installed? Check the Paper Level Sensing Assembly for correct installation. Is the Paper Level Sensing Assembly installed correctly? Check continuity of the Paper Level Sensing Assembly Cable. Do you measure continuity? Check the Paper Level Sensing Assembly for correct installation. Check the following for any signs of damaged or broken parts: Check the Paper Level Sensing Flag. Check the Paper Level Sensing Flag spring. Is the Paper Level Sensing Assembly installed correctly? Check the Paper Level Sensing Assembly arm to make sure it goes all the way to the bottom of tray x. Does the arm extend all the way down to the bottom of the tray?

Yes
Go to step 5 Go to step 3

No
Go to step 2 Install the cable correctly Reinstall the assembly if not installed correctly Replace the cable Go to step 6

1 2

Go to step 4

Go to step 5

Replace the Paper Level Sensing Assembly

Recheck the arm. If the problem continues, replace the Paper Leveling Sensing Assembly. If this does not fix the problem, replace the Tray x System Board.

Check to see why the arm is not extending all the way to the bottom of the tray. Repair as necessary.

Diagnostic Information 2-119

5060-XXX

24x Error Code displayed, media does not reach the Pass Thru Sensor
Step Action and Questions
Is Tray X a HCIT 2000 Sheet Option?

Yes
Go toHCIT 2000 Sheet Option Service Check on page 2-126 Go to step 3

No
Go to step 2

Check the media installed in the tray to make sure it meets specifications. Does the media meet specifications?

Inform the customer that media loaded in Tray x does not meet specification Load the media correctly Go to step 5

Check to make sure that the media is loaded correctly, check the side and back restraints to make sure they are located and seated properly. Is the media loaded correctly? Check to see if the paper is trying to feed from the tray. Note: You can observe the autocompensator feed rolls and the paper thru the tray access door. You run the Tray x feed test from the diagnostic menu to help diagnose a feed problem. Is the media leaving the tray? Are the autocompensator pick arm rolls turning? Check the autocompensator pick arm rolls for any sign of wear or contamination. Are the autocompensator pick arm rolls worn or contaminated?

Go to step 4

Go to step 8

5 6

Go to step 6 Replace the Pick Arm Rolls. It is best to replace both rolls at the same time. Replace the wear strips Check for any obstructions that might catch the media and create a paper jam

Go to step 10 Go to step 7

Check paper tray wear strips for any signs of wear or contamination. Are the wear strips worn or contaminated? Check the pass thru sensor for correct operation by running the Tray x Sensor test from the diagnostic menu. Does the Pass Thru Sensor operate correctly?

Go to step 8

Go to step 9

2-120 Service Manual

5060-XXX

Step

Action and Questions

Check to make sure that the Pass Thru Sensor is correctly connected to the Tray X system board. Is the sensor cable connected correctly?

Yes
Replace the FRU's in the following order:
1. Pass Thru Sensor Assembly 2. Electronics/ Size Sensing Assembly

No
Install the cable correctly

10

Check the Autocompensator cable for correct installation to Tray x System board. Is the cable connected correctly? Check the base door assembly, paper guide, wall support plate and door spring for any signs of damaged parts, warped parts or obstructions that might cause the paper to jam over the pass thru sensor. Did you find any problems with these parts?

Go to step 11

Install the cable correctly Replace the Autocompensator Assembly

11

Repair or replace parts as necessary

The printer does not detect transparencies loaded in Tray x.

Step

Action and Questions

Check the transparency material to make sure it meets specifications. Does the transparency material meet specifications?

Yes
Go to step 2

No
Inform the customer that the transparency media in tray x does not meet specification Install the Transparency Assembly correctly Install the cable correctly

Check the Transparency Sensing Assembly for correct installation. Is the Transparency Sensing Assembly correctly installed? Check the Transparency Sensing Assembly cable to make sure the in-line connector is correctly installed to Tray x System board cable. Is the cable correctly installed? Check the Transparency Sensing Assembly cable to correct installation to Tray x System board. Is the cable connected correctly?

Go to step 3

Go to step 4

Replace the FRU's in the following order:

1. Transparency Sensor Assembly 2. Electronics/ Size Sensing Assembly

Install the cable correctly

Diagnostic Information 2-121

5060-XXX

Tray x does not detect size media is installed.

Step Action and Questions
Is the tray set for the size paper loaded in the Tray? Are there any signs of damaged or broken size sensing gears or size sensing barrel cam in the tray assembly? Check the Paper Size Sensing Assembly for any signs of damaged or broken parts. Are any signs of broken or damaged parts?

Yes
Go to step 2 Repair or replace defective parts Replace the Paper Size Sensing Assembly

No
Set the correct size Go to step 3

1 2

Replace the Electronics/ Size Sensing Assembly

990 Error Code displayed for Tray x

Step Action and Questions
Check to make sure the autocompensator cable is correctly installed at the tray System board. Is the cable correctly installed? Check to make sure the drive assembly cable is connected correctly to the tray system board. Is the cable correctly installed? Check for any signs of worn or broken parts in the Autocompensator and drive assemblies. Are any parts worn, broken or damaged?

Yes
Go to step 2

No
Install the cable correctly Install the cable correctly Replace the FRU's in the following order:
1. Electronic/ Size Sensing Assembly 2. Autocompensator Assembly 3. Drive Assembly

Go to step 3

Replace the assembly that has the defective parts

2-122 Service Manual

5060-XXX

Duplex Option Service Check

Do the following steps before proceeding with this service check:

1. Check for any pieces of media or obstructions in the duplex paper path that might 2. 3.
cause a paper jam. Check for correct installation of the Front Duplex Jam Tray and Right Side Clearance Tray. Check the Duplex for any signs of loose, damaged, contaminated or warped parts that might cause the media to jam.

Duplex not recognized as being installed

Step

Action and Questions

Is Duplex the only option installed beneath the base printer? Except for the Duplex Option remove any other paper options installed beneath the base printer. Does the printer recognize the Duplex Option as being installed?

Yes
Go to step 3 The problem is in 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 4

No
Go to step 2 Go to step 3

1 2

Check to make sure that the Duplex Option is correctly installed. Is the Duplex Option installed correctly? Check to make sure that the bottom option cable connector is snapped firmly into the bottom of the base machine. Is the cable connector mounted correctly? Check to make sure that the Options Option Cable is installed correctly to Engine Board connector J5. Is the cable installed correctly? Check the voltages on the on connector J5 on the engine board. The voltages are with the printer in standby mode. J5-1 measures approximately +24 V dc J5-3 measures approximately +5 V dc J5-5 measures approximately +5 V dc J5-6 measures approximately +5 V dc J5-8 measures approximately +5 V dc Are the voltages correct?

Install the Duplex Option correctly Install the cable correctly Install the cable correctly Replace the Engine Board

Go to step 5

Go to step 6

Go to step 7

Diagnostic Information 2-123

5060-XXX

Step

Action and Questions

Check the voltages on the Bottom Options cable connector. The voltages are with the printer in standby mode. J5-1 measures approximately +24 V dc J5-3 measures approximately +5 V dc J5-5 measures approximately +5 V dc J5-6 measures approximately +5 V dc J5-8 measures approximately +5 V dc Are the voltages correct? Check the upper options cable in the Duplex Option to make sure that it is installed correctly in the duplex frame. Is the cable installed correctly?

Yes
Go to step 8

No
Replace the Bottom Options Cable in the printer

Go to step 9

Correctly install the cable. If the connector is damaged, replace the cable assembly. Install the cable correctly

Check the Upper Options Cable in the duplex option to make sure it is connected correctly to J11 on the Duplex options board. Is the cable connected correctly? Check continuity of the Upper Duplex Options Cable. Is there continuity?

Go to step 10

10

Replace the Duplex Options Board

Install the cable correctly

230 Error Code is displayed.

Use the Sub Error Codes to help isolate a problem in the Duplex Option. Make sure that the Chassis Ground Spring is correctly installed and not missing or bent.

Step

Action and Questions

Paper Input Sensor and Paper Exit Sensor - Check for correct sensor operation by performing the Duplex Sensor Test on page 3-9. Do the sensors pass the test? Did the Paper Input Sensor Fail the test? Check to make sure that the Paper Input Sensor is connected correctly to the Duplex System Board at connector J5. Is the cable correctly attached?

Yes
Go to step 5

No
Go to step 2

2 3

Go to step 3 Replace the FRUs in the following order:

1. Paper Input Sensor 2. Duplex System Board

Go to step 4 Attach the cable correctly

2-124 Service Manual

5060-XXX

Step

Action and Questions

Check to make sure that the Paper Exit Sensor is correctly attached to the Duplex System board at connector J8. Is the cable correctly attached?

Yes
Replace the FRUs in the following order:
1. Paper Exit Sensor 2. Duplex System Board

No
Attach the cable correctly

230 Error Code is displayed, paper slipping or paper is skewing.

Use the Sub Error Code Table on page 2-19 to help diagnose 230 Paper Jams in the Duplex option.

Step

Action and Questions

Check the Duplex Shaft Assembly for any signs of worn, broken or damaged parts. Is the Duplex Shaft Assembly worn or broken? Check the Duplex 40T Shaft Drive F/R Gear for any broken teeth or other damage to the gear. Is the gear broken? Check the three Duplex Shaft Assembly bearings for any signs of missing, worn or broken parts. Are any of the bearings missing, worn or broken? Check the F/R Shaft Assembly for signs of damaged or contaminated rollers or shaft separation. Is the F/R Shaft Assembly damaged or separated?

Yes
Replace the Duplex Shaft Assembly Replace the Shaft Drive Gear Replace the defective bearing(s) Replace the F/R Shaft Assembly

No
Go to step 2

Go to step 3

Go to step 4

Check the duplex paper path for any broken, damaged or warped parts that might catch the paper

Top margin on duplexed copy set incorrectly

Go to Duplex Quick Test on page 3-8 to adjust the top margin on the back of the duplexed page.

Diagnostic Information 2-125

5060-XXX

HCIT 2000 Sheet Option Service Check

Printer does not recognize that the HCIT 2000 Sheet Option is installed.
Step Action and Questions
Is the HCIT 2000 Sheet Option the only paper input option that is not recognized? Check to make sure that the printer and any option above the HCIT 2000 Sheet Option is installed correctly. Is the printer and any options installed correctly?

Yes
Go to step 5 Go to step 3

No
Go to step 2 Install the options correctly and recheck performance Install the cable correctly and recheck performance Replace the Engine Board

1 2

Check for correction installation of the Lower Options Autoconnect cable to Engine Board connector J5. Is the cable to J5 installed correctly? Disconnect J5 from the engine board and check the voltages on connector J5 on the engine board. The voltages measure as follows: J5-1: +24 V dc J5-3: +5 V dc J5-5: +5 V dc J5-6: +5 V dc J5-8: +5 V dc All voltages are approximate values. Are the voltages correct? Autoconnect Cables - Check the autoconnect from the printer or option above the HCIT 2000 Sheet Option. Check for any signs of cuts, pinched wiring or damage to the contacts in the connector. Are there any problems with the autoconnect cables? HCIT Autoconnect Cable - Check the HCIT autoconnect cable for correct installation at the HCIT System board. Is the cable installed correctly? HCIT Autoconnect Cable Continuity - Check the continuity of the HCIT Autoconnect cable(s). Is there continuity?

Go to step 4

Go to step 5

Repair or replace as necessary

Go to step 6

Go to step 7

Install the cable correctly Replace the HCIT Autoconnect Cable

Replace HCIT System Board

2-126 Service Manual

5060-XXX

HCIT inoperative
Before proceeding with this service check make sure the 2000 Sheet Tray Option is properly connected to AC Power. If a Finisher is installed:

The AC jumper should go from the HCIT to the Finisher. The Finisher AC power cord
should attach to the AC voltage source. The base printer power cord should plug into the AC output connector on the HCIT. If a Finisher is not installed:

The printer power cord plugs into the HCIT AC outlet and the power cord from the
HCIT plugs into the AC voltage source. Note: Check to make sure that the wall outlet is working properly and all power cords are plugged in correctly. Check to make sure that the slide switch on the LVPS is toward the right. The System Board status LED can be observed by removing the rear cover. The LED is mounted on the HCIT system board.

Step

Action and Questions

Does the printer power up and work normally when plugged into the AC outlet on the HCIT? Check the system board LED to see if it is On solid or blinking. LED On solid means that the HCIT has detected the front door or side door open. LED Blinking means that the system is operating. Is the LED On solid or Blinking?

Yes
Go to step 2 If the LED is On solid, check the front and side doors. If the LED is blinking, replace the HCIT System Board Replace the HCIT System Board Replace the HCIT System Board Replace the HCIT LVPS

No
Go to step 5 Go to step 3

1 2

Measure the voltage at TP3 (+5 V dc test point) on the HCIT system board. The voltage should measure approximately +5 V dc. Is the voltage correct? Measure the voltage at CN2 pin 2 on the HCIT system board, the voltage measures approximately +5 V dc. Is the voltage correct? Check the AC line voltage at the input to the LVPS. Is the voltage correct?

Go to step 4

Go to step 5

Go to step 6

Diagnostic Information 2-127

5060-XXX

Step

Action and Questions

Check the AC cable from the HCIT AC inlet to the LVPS. Are the cables good?

Yes
Determine where the AC Line voltage is being lost to the HCIT. Repair as necessary.

No
Replace the cables

The HCIT 2000 Sheet Option does not recognize the size paper selected.
Step Action and Questions
Check to make sure that media loaded in the tray meets specifications. Is the media loaded properly and meet specifications?

Yes
Go to step 2

No
Load the media properly or inform the customer that the media does not meet specifications Reinstall the guide if installed incorrectly Install the cable correctly. Go to step 5

Check the Paper Tray Guide for correct installation. Is the Paper Tray Guide installed correctly for the selected paper size. Paper Size Sensor Cable - Check for correct installation of the Paper Size Sensor Cable to the HCIT System Board at CN7. Is the cable installed correctly? Check for loose or broken, loose or missing paper size sensor flag spring. Is a sensor flag spring broken, loose or missing?

Go to step 3

Go to step 4

Reconnect the spring if it is loose. Replace the spring if broken or missing. Replace the Paper Size Flag Replace the sensor. If this does not fix the problem, replace the HCIT System Board.

Check the paper size sensor flag for any signs of sticking or broken parts. Is the paper size sensor flag sticking or broken? Check continuity of the sensor cable. Do you measure continuity?

Go to step 6

Replace the sensor cable

2-128 Service Manual

5060-XXX

24x Paper Jams in HCIT

Use the HCIT Standalone Test Mode on page 3-24 inside the HCIT to help isolate paper jams. Run the Standalone Feeding Operation to observe paper feeding from the tray and through the feed assembly. Use the HCIT System Board LED Error Code Table on page 2-22 to further isolate paper jam or sensor problem. Before proceeding with this service check make sure the HCIT is installed correctly.

Step

Action and Questions

Check for pieces of paper or other obstructions in the feed assembly. Are any pieces of paper or obstructions found in the feed assembly? Check the media loaded in the paper tray to make sure it meets printer supplies specifications. Does the media meet specifications?

Yes
Remove any paper or obstructions Go to step 3

No
Go to step 2

Inform the customer that media in the paper tray does not meet specifications Go to step 4

Use the Standalone Feeding operation to observe paper feeding from the tray. Does the paper feed from the paper tray? Using the Standalone Feeding Operation Test, observe the Registration Motor (the registration motor is the motor at the top of the feed assembly). Does the Motor turn? Does the Pick Motor, the lower motor in the Feed Unit Assembly, turn? Check the Registration Motor Cable to HCIT System Board cable connected to CN3 for correct installation. Is the cable connected correctly?

Go to step 14

Go to step 5

Go to step 6

5 6

Go to step 8 Replace the following FRU's in the order shown:

1. HCIT System Board 2. Feed Unit Assembly

Go to step 7 Install the cable correctly

Check the Pick Motor cable to HCIT System Board cable connected to CN4 for correct installation. Is the cable connected correctly?

Replace the following FRU's in the order shown:

1. HCIT System Board 2. Feed Unit Assembly

Install the cable correctly

Use the HCIT System Board LED Error Code Table on page 2-22. Does the LED flash 7 times?

Go to step 9

Go to step 11

Diagnostic Information 2-129

5060-XXX

Step

Action and Questions

Check the Registration Home Sensor cable to make sure it is installed correctly to the sensor and to CN6 on the System board. Is the cable connected correctly? Is the Registration Home Sensor operating correctly?

Yes
Go to step 10

No
Install the cable correctly

10

Replace the following FRU's in the order shown:

1. HCIT System Board 2. Feed Unit Assembly

Replace the following FRU's in the order shown:

1. Registration Sensor 2. HCIT System Board

11

Use the HCIT System Board LED Error Code Table on page 2-22. Does the LED flash 8 times? Check the Pick Home Sensor cable to make sure it is installed correctly to the sensor and to CN6 on the System Board. Is the cable connected correctly? Is the Registration Home Sensor operating correctly?

Go to step 12

Go to step 14

12

Go to step 13

Install the cable correctly

13

Replace the following FRUs in the order shown:

1. HCIT System Board 2. Feed Unit Assembly

Replace the following FRU's 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 Error Code Table on page 2-22 to help isolate problems in the Feed Unit Assembly. Are you able to determine where the failure is occurring?

Repair or replace parts as necessary

Replace the Feed Unit Assembly

2-130 Service Manual

5060-XXX

Finisher Service Check

Use the HCOF Error Code Table on page 2-23 to help isolate problems in the finisher. These codes can be particularly helpful in diagnosing 280 Paper Jam problems in the finisher.

Check Finisher displayed, unable to clear display

Step Action and Questions
Check for correct printer and finisher installation. Make sure the magnetic bracket is mounted on the printer. Is the magnetic bracket mounted on the printer? Is the pin on the magnetic bracket actuating the joint switch in the finisher?

Yes
Go to step 2

No
If not installed, install the bracket Find out why the pin is not actuating the switch and repair as necessary Install the cable correctly Go to step 5

Go to step 3

Check the joint switch cable connection to CN19 on the finisher system board. Is the cable installed correctly? Check the joint switch activating spring for any signs of damage. Is the switch activating spring broken? Check the joint switch for correct operation. The switch can be checked by measuring continuity while actuating the switch. Is the switch operating correctly? Continuity Check - Check continuity of the joint switch cable. Is there continuity?

Go to step 4

Replace the joint switch assembly Go to step 6

Replace the joint switch assembly Replace the cable

Replace the finisher system board

The Finisher is totally inoperative, no motor movement, no LEDS On

This problem can be caused by a problem with the autoconnect system between the finisher and the printer. It also can be caused by a problem with the power system in the finisher.

Step

Action and Questions

Check the AC line cord to the finisher to make sure the options and printer are connected properly. Are the printer and options AC line cords connected properly?

Yes
Go to step 2

No
Connect the printer and options correctly

Diagnostic Information 2-131

5060-XXX

Step

Action and Questions

Check the communications cable from the finisher to the printer to make sure it is installed correctly at the output options autoconnect on the printer. Is the cable installed correctly? Disconnect the autoconnect cable from J7 on the engine board. Check the resistance between J7-6 and J7-7 on the cable connector. The resistance measures between 45 ohms and 50 ohms. Is the resistance correct? Check the communications cable to make sure it is connected properly to CN3 on the LVPS Relay board. Is the cable installed correctly? Note: The relay on the relay board is connected to +5 V dc from the printer through the communications cable. When the printer is powered on +5V DC is sent to the finisher relay board's relay coil which energizes the relay and connects primary AC line voltage to the LVPS. Check the resistance of the relay coil by measuring between CN3-1 and CN3-2 on the relay board. The resistance measures between 45 ohms and 50 ohms. Is the resistance correct? Check the voltage on the Output Options Autoconnect connector Pin 2 located on the top right rear of the printer. The voltage measures approximately +5 V dc. Is the voltage correct? Check the AC Line Voltage between CN2-1 and CN2-3 on the relay board. The line voltage should be within specifications for the AC power source the printer is connected to. Is there line voltage at CN2? Check the AC Line Voltage between CN1-1 and CN1-5 on the relay board. The line voltage should be within specifications for the AC power source the printer is connected to. Is there line voltage at CN1? Check continuity of the AC line cord. Is there continuity? Check the voltage at J7-5 on the engine board, the voltage measures approximately +5 V dc. Is the voltage correct?

Yes
Go to step 3

No
Install the cable correctly

Go to step 6

Go to step 4

Go to step 5

Install the cable correctly

Replace the communication cable Go to step 7

Replace the relay board/ LVPS assembly Go to step 10

Replace the LVPS assembly

Go to step 8

Replace the relay board assembly

Go to step 9

9 10

Go to step 10 Replace the top options cable

Replace the line cord Replace the engine board

2-132 Service Manual

5060-XXX

Font Door is open, no indication on display

Step Action and Questions
Check the front door to make sure it is activating the cover switch. Is the door activating the cover switch? Check Door - Door Switch activating tab (broken or missing). Is the front door and door activating tab damaged, broken or missing? Check the front door magnetic latches to make sure the front door closes correctly. Are the magnetic latches functioning properly? Check the front door switch cable connection to CN11 on the finisher system board. Is the cable connected correctly? Check the continuity of the front switch as the switch is activated. Do you measure continuity? Check continuity of the front door switch cable. Do you measure continuity?

Yes
Go to step 2

No
Repair or replace the door assembly Go to step 3

Replace the front door assembly Go to step 4

Replace the magnetic latches Install the cable correctly Replace the front door switch Replace the front door switch cable D1

Go to step 5

Go to step 6

Replace the finisher system board

Fan in Finisher inoperative

Step Action and Questions
Check to make sure the fan cable, H6, is correctly connected to CN21 on the finisher system board. Is the cable connected correctly? Check the cable H6 connection to the Fan assembly. Is the cable connected correctly? Check the voltage between CN21-1 and CN21-2, the voltage measures approximately +24 V dc. Is the voltage correct? Check continuity of the fan cable H6. Do you measure continuity?

Yes
Go to step 2

No
Install the cable correctly Install the cable correctly Replace the finisher system board Replace cable H6

2 3

Go to step 3 Go to step 4

Replace the fan assembly

Diagnostic Information 2-133

5060-XXX

No indication that the Chad Box is Full, No message on operator panel

Use the HCOF Error Code Table on page 2-23 to help diagnose the problem.

Step

Action and Questions

Check to make sure the Chad Box is correctly installed in the finisher. Is the Chad box correctly installed. Check to make sure the chad box cable S5 is properly connected to CN5 on the finisher system board. Is the cable properly connected? Check to make sure the chad box cable is properly connected to the chad box sensor located above the chad box. Is the cable properly connected to the sensor? The chad box sensor can be checked with a voltmeter. Empty the chad box. Check the voltages on CN5. The voltages read the following approximate values with chad box empty: CN5 Pin Voltage 1 +5 V dc +5 V dc supply 2 +5 V dc (sensor signal) 3 0 V dc Ground Are the voltages correct? Check the sensor by placing the chad box or a piece of paper in front of the sensor. As the chad box or piece of paper is moved away from the front of the sensor the voltage on CN5-2 should change from +5 V dc to 0 V dc. Does the voltage change?

Yes
Go to step 2

No
Install the chad box correctly Install the cable correctly Install the cable correctly

Go to step 3

Go to step 4

Go to step 5

Replace the finisher system board

Go to step 6

Replace the chad box sensor.

Chad Box Full is displayed when chad box is not full

Step Action and Questions
Check to make sure the chad box is correctly installed in the finisher. Is the chad box correctly installed? The chad box sensor can be checked with a voltmeter. Empty any material that is in the Chad Box. Measure the voltage on CN5-2. The voltage changes from approximately +5 V dc to 0 V dc as the sensor is activated. Does the voltage change?

Yes
Go to step 2

No
Install the chad box correctly Replace the finisher system board

The sensor is working correctly

2-134 Service Manual

5060-XXX

3. Diagnostic Aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. There are different test menus that can be accessed to identify problems with the printer.

Configuration Menu
The Configuration Menu contains a set of menus, settings and operations which are infrequently used by a user. Generally, the options made available in this menu are used to configure a printer for operation. To gain access to the Configuration Menu: Turn the printer off, press and hold the Select and Return buttons while you turn the printer on and wait unit "Performing Self Test" appears on the display. Release the buttons. The following are available from the Configuration Menu: Black and White Lock Fuser Cnt Value Reset Fuser Cnt Print Quality Pages Note: This is not displayed if in DEMO mode. Color Trapping Size Sensing Type Sensing Sensed Trans Sensed Paper Calibrate Trays Panel Menus PPDS Emulation - This only displays if the PPDS interpreter is available. Download Emuls - This only displays if at least one Downloaded Emulator is installed. Demo Mode Factory Defaults Energy Conserve ITU Alignment Auto Color Adjust Exit Config Menu - Pressing Select exists the CONFIG MENU and reboots the printer. Note: An asterisk(*) in the value list indicates the default value.

Diagnostic Aids 3-1

5060-XXX

Black and White Lock

Enter the Configuration Menu and Select Black and White Lock from the Menu. Value List: =On =Off

Fuser Count Value

Enter the Configuration Menu and Select Fuser Count Value. You can not reset this value. It only displays if the Maintenance Warning and Intervention function is enabled in the printer's Configuration ID. The value can be viewed by pressing SELECT.

Reset Fuser Count

This only displays if the Maintenance Warning and Intervention function is enabled in the Printer's Configuration ID. The fuser maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. The counter can be used to track printer usage. When the counter reaches 150,000, the printer posts a fuser maintenance message on the operator panel.

1. Enter the Configuration Menu and Select Reset Fuser Count to view the page count. 2. Press RETURN to return to the previous menu or Press SELECT to reset the
maintenance page counter back to zero.

Print Quality Pages

The Print Quality Test consists of 5 pages of printer information, settings, various color blacks, color grayscales and color gradients. Use this test to identify print quality problems. The Test Pages must be printed on A4, Legal or Letter paper. Enter the Configuration Menu. Pressing SELECT will select the pages to be printed.

Color Trapping
Enter the Configuration Menu and select Color Trapping from the menu. The values are: =Off =1.5(2*)

3-2 Service Manual

5060-XXX

Size Sensing
Only paper sources that support Auto Size Sensing are displayed.

1. Enter the Configuration Menu and Select Size Sensing. 2. One of the following is displayed:
Tray 1 Sensing Tray 2 Sensing Tray 3 Sensing Tray 4 Sensing =Auto* =Off Select the value you want from the list above.

Type Sensing
Only paper sources that support Auto Type Sensing are displayed. Enter the configuration Menu and select Type Sensing. One of the following is displayed: Tray 1 Tray 2 Tray 3 Tray 4 =Transparency* =Custom Type 5 Select the value you want from the above list.

Sensed Paper
Only paper sources that support Auto Type Sensing are displayed. The factory default paper type or each tray is determined by the value of Configuration ID. This value is as follows: Tray 1 factory default paper type = Plain Paper Tray 2 factory default paper type = Plain Paper or Custom Type 2 Tray 3 factory default paper type = Plain Paper or Custom Type 3 Tray 4 factory default paper type = Plain Paper or Custom Type 4 The following media can be sensed by Tray 1, Tray 2, Tray 3 and Tray 4: Plain Paper, Glossy Paper, Card Stock, Labels, Bond, Letterhead, Preprinted, colored paper, Custom Type 1, Custom Type 2, Custom Type 3, Custom Type 4 or Custom Type 6

Diagnostic Aids 3-3

5060-XXX

Calibrate Trays
Only Trays that support transparency sensing are displayed. The following are displayed whenever a tray has been detected that is not calibrated. Tray X Not Calibrated This message usually indicates a user-correctable NVRAM problem. The tray may not have been calibrated or the NVRAM variable for tray calibration may be missing. To calibrate the tray:

1. Select Calibrate Trays from the Configuration Menu. 2. Select the desired Tray from the menu.
You will be prompted to load paper into the selected tray (not transparencies). Load <input source> Plain Paper Press GO to initiate calibration. Press RETURN to abort the calibration and return to the previous menu.

3. 4.

Panel Menus
Select Panel Menus from the Configuration Menu. =Disable =Enable*

PPDS Emulation
This only displays if the PPDS interpreter is available. Select PPDS Emulation from the Configuration Menu. =Activate =Deactivate

Download Emuls
This only displays if at least one Downloaded Emulator is installed. Select Download Emuls from the Configuration. Menu. =Disable

3-4 Service Manual

5060-XXX

Demo Mode
Select Demo Mode from the Configuration Menu. =Activate =Deactivate*

Factory Defaults
Select Factory Defaults from the Configuration Menu. =Restore Base =Restore Network Note: Restore Network is only listed on models that have integrated network support.

Energy Conserve
This setting only affects the values that are displayed in the Power Saver Menu. Select Energy Conserve from the Configuration Menu. =On =Off

ITU Alignment
This alignment is required anytime you replace the ITU Assembly.

1. 2. 3. 4.

Enter the Configuration Menu Group by pressing Select and Return at POST. Select ITU Alignment from the Configuration Menu Group. A test page is printed after ITU Alignment is selected. After the test page prints, enter alignment values for each alignment setting.

Example: A Alignment =1.5* The alignment values range from -7 to + 7 in 0.5 increments (0*).

5. Press Select to continue to the next alignment value. 6. To cancel the alignment procedure press Go or Return.

Auto Color Adjust

Select Auto Color Adjust from the Configuration Menu. =Off =100.1000(in increments of 50) (500*)

Diagnostic Aids 3-5

5060-XXX

Exit Configuration Menu

Press Select to exit the Configuration Menu and reboot the printer.

Diagnostic Mode
To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. To enter the Diagnostic Mode:

1. 2. 3. 4.

Turn the printer off. Press and hold the Go and Return buttons. Turn the printer on. Release the buttons when "Performing Self Test" is displayed.

The tests display on the operator panel in the order shown:

Print Registration Alignment Top Fine Margin Adjustment Miscellaneous Tests Print Tests Hardware Tests Duplex Tests (if installed) Input Tray Tests (500-Sheet Trays) Input Tray Tests (2000-Sheet Trays) Output Bin Tests Finisher Tests (if installed) Base Sensor Test Device Tests (if optional flash or disk installed) Printer Setup EP Setup Error Log

Exiting the Diagnostics Mode

Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode.

3-6 Service Manual

5060-XXX

Device Tests Quick Disk Test

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

1. Select the Quick Disk Test from the Device Tests menu. The power indicator blinks while the test is in progress. Quick Disk Test/Test Passed message displays if the test passes and the power
indicator turns on solid.

Quick Disk Test/Test Failed message displays if the test failed and the power 2.
indicator turns on solid. Press Go, Return, or Stop to return to the Device Tests menu.

Disk Test/Clean
WARNING: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1 1/2 hours depending on the disk size. To run the Disk Test/Clean Test:

1. Select Disk Test/Clean from the Device Tests menu. "Files will be lost/Go or Stop?" message displays to warn the user that all contents
on the disk will be lost.

2. To exit the test immediately and return to the Device Tests menu, press Return/Stop. 3. 4.
To continue with the test, press Go. If Go is selected, "Disk Test/Clean/BAD:000000 00%" message displays. The screen updates periodically indicating the percentage of test completed and the number of bad blocks found. The power indicator blinks during the test. The test can be canceled anytime during the test by pressing Return/Stop. Once the test is complete, the power indicator turns on solid and a message displays. xxxx Bad Blocks/yyyyyy Usable message displays if fewer than 2000 bad blocks are detected. xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks. xxxx Bad Blocks/Replace Disk message displays if more than 2000 bad blocks are detected. The disk cannot be recovered because too many bad blocks exist on the disk. Press Go or Return/Stop to return to the Device Tests menu.

Diagnostic Aids 3-7

5060-XXX

Flash Test
This test causes the file system to write and read data on the flash to test the flash. WARNING: This test destroys all data on the flash because the flash is reformatted at the end of the test. To run the Flash Test:

1. Select Flash Test from the Device Tests menu. The power indicator blinks while the test is running. Flash Test/Test Passed message displays if the test passes and the power 2.
indicator turns on solid. Flash Test/Test Failed message displays if the test fails and the power indicator turns on solid. Press Go or Return/Stop to return to the Device Tests menu.

Duplex Tests Duplex Quick Test

This test verifies if the Duplex Unit Top Margin is set correctly. This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the backside of the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages (Continues) until Return/Stop is pressed. You must use either Letter or A4 paper. To run the Duplex Quick Test:

1. Select Duplex Quick Test from the menu. 2. Select Single or Continuous. The single Duplex Quick test cannot be canceled.
The printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports envelopes, then the page is printed from Tray 1. Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet. If adjustment is necessary, the Top Margin Offset must be adjusted first. The range of the adjustment is -25 to +25. The Duplex Top Margin Offset range is -20 to +20. Adjustment of this setting lets you shift up or down the position of the Top Margin. Changing this parameter by 1 unit moves the margin 1/100 inch. A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin.

3. Press Return/Stop to exit the test.

Check the Top Margin Offset of the base printer.

3-8 Service Manual

5060-XXX

Duplex Sensor Test

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

Error Log Viewing the Error Log

The error log provides a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive positions in the log are entered. All 2xx and 9xx error messages are stored in the error log. To view the Error Log:

1. Select Display Log from the Error Log menu. The Error log displays on three screens as only four entries display at a time. 2. To move to the next screen press Menu> to move forward or <Menu to move 3.
backward. Press Return/Stop to exit the Error Log.

Clearing the Error Log

To clear the Error Log:

1. 2. 3.

Select Clear Log from the Error Log menu. Select "YES" to clear the Error Log or "NO" to exit the Clear Log menu. If "YES" is selected, the Empty Error Log displays on the screen. Press Return/Stop to exit the Clear Log menu.

Diagnostic Aids 3-9

5060-XXX

Hardware Tests
The following Hardware Tests can be selected from this menu: LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 2 Wrap (if available) Serial 3 Wrap (if available)

LCD Test
To run the LCD Test:

1. Select LCD Test from the Diagnostic menu. The LCD test continually executes the LCD display test. 2. Press Return/Stop to cancel the test.

Button Test
To run the Button Test:

1. Select Button Test from the Diagnostic menu. With no buttons pressed, several OP (Open) appear on the display. 2. Press each button one at a time and a CL (Closed) displays in place of an OP. The
proper operation of each button can be checked.

3. Press Return/Stop to cancel the test.

SDRAM Memory Test

This test checks the validity of SDRAM, both standard and optional. The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly. To run the SDRAM Memory Test:

1. Select SDRAM Memory Test from the menu. The power indicator blinks indicating the test is in progress. 2. Press Return/Stop to exit the test.
P:###### represents the number of times the memory test has passed and finished successfully. Initially 000000 displays with the maximum pass count being 999,999. F:##### represents the of time the memory test has failed and finished with errors. Initially 00000 displays with the maximum fail count being 99,999.

3-10 Service Manual

5060-XXX

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

ROM Memory Test

The ROM Memory Test is used to check the validity of the controller board code and fonts. To run the ROM Memory Test:

1. Select ROM Memory Test from the menu. P and F represent the same numbers for 2.
DRAM. The power indicator blinks indicating the test is in progress. The test runs continuously. Press Return/Stop to exit the test.

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 messages displays for approximately three seconds: ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached, the test stops with the power indicator on solid. The final results display on the screen.

Parallel Wrap Test

Use this test with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested. To run the Parallel Wrap Test:

1. Disconnect the parallel interface cable and install the wrap plug (P/N 1319128). 2. Select the Parallel Wrap Test from the menu. The power indicator blinks indicating the test is in progress. The test runs
continuously until canceled. Each time the test finishes, the screen updates. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately three seconds: Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error

Diagnostic Aids 3-11

5060-XXX

RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops. The power indicator goes on solid and the final results display. Press Return/Stop to exit the test.

Serial Wrap Test

Use this test to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. To run the Serial Wrap Test:

1. Disconnect the serial interface cable and install the wrap plug. 2. Select the appropriate Serial Wrap Test from the menu: Serial Wrap, Serial 1 Wrap,
Serial 2 Wrap or Serial 3 Wrap. P and F represent the same numbers for DRAM.

The power indicator blinks indicating the test is running. 3. This test runs continuously unless canceled by pressing Return/Stop.
Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following failure messages displays for approximately three seconds and the Fail Count increases by 1: Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error

3-12 Service Manual

5060-XXX

Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached the test stops. The power indicator goes on solid and the final results display. Press Return/Stop to exit the test.

Input Tray Tests Input Tray Feed Test

This test lets you observe the paper path as media is feeding through the printer. The upper front door, used to access the print cartridge, cannot be opened during the feed test. To observe the paper path, you must open the lower front door, used to access the envelope feeder or MPF. No information is printed on the feed test pages since the laser isn't engaged during this test. Note: This test can be run using any of the paper or envelope sizes supported by the printer. The pages are placed in the default output bin, however, the Feed Test menu lets you to select the input source. To run the Input Tray Feed Test:

1. Select Input Tray Feed Test from the menu. 2. Select the input source from the sources displayed on the Feed Test Menu. All 3. 4.
installed sources are displayed. Select either Single (feeds one sheet of media from the selected source) or Continuous (continues to feed from the selected source until Return/Stop is pressed). Press Return/Stop to exit test.

Input Tray Sensor Test (500-Sheet Trays)

Use this test to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test 500-Sheet Trays:

1. Select the Sensor Test from the Input Tray Test menu. Sensor L1=Input Tray level/empty Sensor 1 Sensor L2=Input Tray level/empty Sensor 2

Diagnostic Aids 3-13

5060-XXX

Sensor P=Input Tray Pass Thru Sensor 2. Once this message displays, you can manually actuate each sensor. The tray empty
sensor can be actuated by hand, however a sheet of paper can be used to cover the pass through sensor. When the sensor is closed, CL displays, when the sensor is open, OP displays. Press Return/Stop to exit the test.

3.

Tray sensors are supported by the following sources:

Source
Tray 1 Tray 2 Tray 3 Tray 4 Multi Purpose Feeder

L1
Yes Yes Yes Yes Yes

L2
Yes Yes Yes Yes No

Pass thru sensor

No Yes Yes Yes No

Input Tray Tests (2000-Sheet Tray)

Use this test to determine if the 2000-Sheet Tray sensors are working correctly. Select Sensor Test from the menu for the tray you want to test. The following is displayed: <input tray> EM=OP NE=OP LE=OP SC=OP The selected tray is displayed on line 1 <input tray> either Tray 1, 2, 3, or 4. EM=trays empty sensor NE=trays near empty sensor LE=trays paper level sensor SC=input trays side cover sensor Manually actuate the bin sensor by moving the flag in and out of the sensor. The display indicates OP (Open) when the flag is out of the sensor or CL (Closed) when the flag is in the sensor.

3-14 Service Manual

5060-XXX

Output Bin Test - Standard Bin

This test verifies if the standard bin sensor is working correctly. To run the Standard Bin Sensor Test:

1. 2. 3.

Select Output Bin Tests from the Diagnostic Menu. Select Output Bin Tests - Sensor Tests. Select Sensor Tests - Standard Bin. Standard Bin/Full=CL message displays.

Manually actuate the bin sensor by moving the flag in and out of the sensor. The display indicates OP (open) when the flag is out of the sensor and CL (closed) when the flag is in the sensor.

4. Press Return/Stop to exit the test.

Output Bin 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. This test verifies that media can be fed to a specific output bin. No information is printed on the media because the printhead is not turned on during this test. To run the Output Bin Feed Test:

1. Select Feed Test from the Output Bin Test menu. 2. Select the output bin you want the paper to exit into. All output bins installed on the 3. 4.
printer are shown on the feed test menu. Select either Single (one sheet of media feeds to the selected output bin) or Continuous (media continues feeding to the selected output bin) until Return/Stop is pressed. Press Return/Stop to exit the test.

Output Bin Sensor Test

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

1. Select Output Bin Sensor Test from the menu. 2. Select the Bin you want to test. If Standard Bin is selected the following is displayed.
Standard Bin

Diagnostic Aids 3-15

5060-XXX

3. 4.

F=OP F=Standard Bin Output Bin Full Sensor If Output Expander is selected the following is displayed. <output bin> P=OP F=OP NF=OP P=Output Expander Pass Thru Sensor. F=Output Expander Full Sensor NF=Output Expander Near Full Sensor. If 5-Bin Mailbox is selected the following is displayed. <output bin> P1=OP P2=OP L=NL P1=5-Bin Mailbox first Pass Thru Sensor. P2=5-Bin Mailbox second Pass Thru Sensor. L=5-Bin Mailbox output level sensor where: L=EM indicates the bin is empty. L=NL indicates the bin contains media but the bin is not near full nor full. L=NF indicates the bin is near full. L=FL indicates the bin is full. Once the screen is displayed you can manually actuate the sensor you want to test. When the sensor is closed (CL) displays, and when the sensor is open (OP) displays. To exit the test press Return or Stop.

Output Bin X Sensor Test

Output Expander To run the Output Bin x Sensor tests:

1. 2. 3. 4.

Select Output Bin Tests from the menu. Select Output Bin Tests - Sensor Tests. Select Sensor Tests - Output Bin x. Press Return/Stop to exit the test.

The following is displayed: Output Bin x P=OP F=OP NF=CL P = Pass Thru Sensor F = Bin Full Sensor (lower part of dual sensor) NF = Near Full Sensor (upper part of dual sensor) Once the message displays, you can manually actuate each of the output bin sensors. For all the sensors except the output level sensor, when the sensor is closed CL displays and when the sensor is open, OP displays. If the 5-Bin mailbox is selected the following is displayed:

3-16 Service Manual

5060-XXX

<output bin> (output bin displayed on line 1 = output bin 1, output bin2, output bin3, output bin4 or output bin 5 for the bin selector) P1 = 5-Bin mailbox first pass thru sensor P2 = 5-Bin mailbox second pass thru sensor L = EM 5-Bin x empty L = NL bin contains media but the bin is not near full or full L = NF bin is near full L = FL bin is full

Base Sensor Test

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

1. Select Base Printer Sensor Test from the menu. The operator panel displays OP for open and CL for closed. 2. Manually toggle the sensors by hand to verify that each sensor switches from open
to closed.

5-Bin Mailbox 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 test checks all of the diverters installed on the printer. When the test is selected from the diagnostic menu the following is displayed: Diverter Test Running This is a single test. The test terminates upon completion.

Diagnostic Aids 3-17

5060-XXX

Finisher Tests Staple Test

This test verifies the operation of the staple mechanism in the finisher. To run the Staple Test:

1. Select Staple Test from the test menu. 2. Select a destination bin.
The printer feeds eight pieces of media to the finisher and accumulates all eight pieces in the accumulator. After the last sheet is accumulated, the pack is stapled.

3. When the test is complete, the printer returns to the original screen.

Finisher Feed Test

This test verifies that media can be fed to a Finisher output bin and then stapled. To run the Finisher Feed Test:

1. Select Finisher Feed Test from the menu. 2. Select a destination bin.
The printer feeds eight pieces of media to the selected finisher output bin where they are stapled. Note: No information is printed on the fed sheets as the laser is not engaged during this test.

3. This test cannot be canceled or terminated once the test has begun. When the test
is complete the printer returns to the original screen.

Finisher Sensor Test

This test determines if the Finisher sensors are working correctly. To run the Finisher Sensor Test, select Finisher Sensor Test from the Finisher Test menu. If you Select Media 1 from the menu the following will be displayed and the sensors polled: Media Path 1 testing............

3-18 Service Manual

5060-XXX

Once the sensors have been polled the following will be displayed and the sensors are ready to test: Media Path 1 S1=CL S2=CL S1=Punch Timing Sensor A S2=Punch Timing Sensor B Once this screen is displayed you can manually actuate each of the sensors. When the sensor is closed CL is displayed, when the sensor is open OP will be displayed. If you select Media 2 from the menu the following will be displayed and the sensors polled: Media Path 2 Testing............ Once the sensors have been polled the following will be displayed and the sensors are ready to test. Media Path 2 S3=CL S4=CL S3=Inverter Jam Sensor S4=Drop Timing Sensor Once the screen is displayed you can manually actuate each of the sensors. When the sensor is closed CL is displayed, when the sensor is open OP will be displayed. If you select Media 3 from the menu the following will be displayed and the sensors polled: Media Path 3 testing.......... Once the sensors have been polled the following will be displayed and the sensors are ready to test: Media Path 3 S5=CL S5=Exit Timing Sensor Once the screen is displayed you can manually actuate the sensor. When the sensor is closed CL is displayed, when the sensor is open OP will be displayed. If you select Media Level from the menu the following will be displayed and the sensors polled: Media Level testing...........

Diagnostic Aids 3-19

5060-XXX

Once the sensors have been polled the following will be displayed and the sensors are ready to test: Media Level S1=CL S2=CL S1=Paper Surface Sensor 1 (upper) S2=Paper Surface Sensor 2 (lower) Once the screen is displayed you can manually actuate the sensor. When the sensor is closed CL is displayed, when the sensor is open OP will be displayed. To exit the sensor test, press RETURN or STOP.

Hole Punch Test

Use this test to verify that media can be fed to the Finisher output bin and hole punched. Letter or A4 size media must be used in the source tray for this test. No information is printed on the feed test pages since the laser is not energized during this test. Eight sheets of paper are fed and holes punched with a three hole pattern. Enter the Diagnostic mode.

4. Select Finisher Tests from the menu. 5. Select Hole Punch Test.
Press Return after the test is complete to exit the test.

Miscellaneous Tests Automated Motor Detection

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

1. 2. 3. 4.

Select Misc. Tests from the menu. Select Motor Detect from the menu. Remove all the print cartridges from the printer. Press Go.

The following screen is displayed: Motor Detection in progress The test lasts approximately ten seconds. No buttons are active during detection and the test completes automatically.

3-20 Service Manual

5060-XXX

Print Tests
The Print Tests consist of the following tests: Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) MP Feeder Print Quality Pages Print Line Len Pages

Print Tests (input source)

This test determines if the printer can print on media from any of the paper input sources. Each of the installed sources is available within the Print Tests menu. The content of the test page will vary depending on the media installed in the selected input source. If a source is selected that contains paper, then a page similar to the Quick Test Page is printed and will not contain the Print Registration diamonds. If a source is selected which contains envelopes then an Envelope Print Test pattern is printed. This pattern only contains text, which consists of continuous prints of each character in the selected symbol set. If continuous is selected, all sources printing with paper sizes will print the same page continuously until the test is stopped. If continuous is selected from a source which contains envelopes then the envelope print test pattern is printed on the first envelope and the rest are blank. The Print Test page always prints single sided, regardless of the Duplex setting or the presence of the Duplex unit. To run the Print Test:

1. Select Print Test from the menu. 2. Select the paper source from the menu. 3. Select either Single or Continuous from the menu.
Note: If Single is selected, no buttons are active while the Print Test Page is printing. If Continuous is selected, Return or Stop can be pressed to cancel the test. The following screen is displayed while printing. <input source> Printing <media width> <input source>=Tray 1,Tray 2, Tray 3, Tray 4, Tray 5, MP Feeder, or Env Feeder <media width>=N for Narrow Width Media =W for Wide Width Media

4. Press Return or Stop at the end of the test to return to the original screen.

Diagnostic Aids 3-21

5060-XXX

Print Quality Test Pages

The print quality test has five pages of settings, various color blocks, color array scales, and color gradients. This test may be printed from either Configuration Menu or the Diagnostic Test Menu. When printed from the Configuration Menu, the toner cartridge lockout function is enabled, which means these pages cannot be printed unless a cartridge is installed with a Machine Class ID which matches the Machine Class ID stored in the printer NVRAM. When printed from the Diagnostic Test Menu the toner cartridge lockout function is disabled. To run the Print Quality Test page from the Diagnostic menu, select Print Quality Test Pages from the menu. Once the test is started it cannot be cancelled. When the test pages print the printer returns to the original screen.

Print Line Length Page

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

Print Registration
The print registration range is as follows: Bottom Margin: -25 to +25 Top Margin: -25 to +25 Left Margin: -12 to +12 Right Margin: -12 to +12 To set Print Registration:

1. Select Registration from the Diagnostic menu. 2. The Top margin sign/value pair blinks. This indicates it is the margin value being
changed.

3. To select the margin value to change, press Select until the margin value pair you 4.
want to change is blinking. To change the margin value press Menu. When the value you want is displayed, press Select to save the value.To exit the Registration menu, press Return.

To verify the margin values are correct you must print the "Quick Test Page" from the registration screen. Press Go to print the test page. While printing the Quick Test Printing message displays. Once printing is complete, the Registration screen displays. The "Quick Test Page" should be printed on letter or A4 paper.

3-22 Service Manual

5060-XXX

Setting Printer Alignment

1. Enter the Diagnostic Mode. 2. Select Alignment for Cyan, Yellow, or Magenta.
The following screen is displayed: T=sxx* R=sxx* L=sxx* Z=sxx* T=Top Margin Offset (-128 to +127) L=Left Margin Offset (-300 to +300) R=Right Margin Offset (-300 to +300) Z=Theta Offset (Skew compensation) (-16 to +16) s=sign for negative values (this space is blank for positive values) xx=margin value. *=Default Value

3. Run an Alignment Test Page before changing any of the settings. 4. When the alignment screen is displayed the Top Margin sign/value pair flashes. To
Change the value, press Menu. Once the desired value is displayed, press Select to save the value and move to the next value. The margin values blink in the following order: Top, Left, Right and Theta. To skip a margin value, because its value is correct, press Select. The default value remains the same. 5. If Return is selected and you exit the alignment menu after a margin value has been changed but not saved, then the default value is not changed. However, if the Alignment Test page is requested after a margin value has been changed but not saved, then the default value is changed and the Alignment Test Page is printed using the new value. 6. To verify that the margin values are correct, you must print the Alignment Test Pages. Press Go from the Alignment Test screen that displays each of the margin values. Pressing Go serves as a hot key to the Alignment Test Pages. Buttons are not active when the Alignment Test Pages are printing. Note: The Alignment Test Pages consist of all three color alignment pages. The Alignment Test Page should be printed on A4 or Letter paper. The printer tries to print the test page from the default paper source, however if the default source only supports envelopes, then the page,prints from Tray 1.

7. Complete a Line Length Calibration from the Print Tests in the Diagnostics Menu. 8. To exit the Alignment Test press Return.

Diagnostic Aids 3-23

5060-XXX

HCIT Standalone Test Mode

This test lets you check out and test the HCIT without removing any option or the base printer mounted above the optional HCIT. Note: During normal operation, the red LED on the HCIT system board blinks or flashes on for one second and off for one second.

Dip Switch Settings

Do the following steps to set and run the Test/Diagnostic:

1. Use the Dip Switch Settings Table to determine the settings (DSW1 thru DSW4) on
the HCIT Control Board for the test you want to run.

2. Turn the HCIT power off by moving the LVPS slide switch to the left position. 3. Press and hold the Push Button Switch PBSW1 while moving the LVPS slide switch
to the right position. The red LED on the HCIT Control board comes on.

4. Press PBSW1 to feed paper. 5. Press PBSW1 to stop feeding paper.

Dip Switch Settings Table

DSW1
Off Off Off Off On On On On

DSW2
Off Off On On Off Off On On

DSW3
Off On Off On Off On Off On

DSW4
N/A N/A N/A N/A N/A N/A N/A N/A

Mode
Set for shipping The adjustment for the Mirror Reflection Sensors must be performed anytime the sensors are replaced. EEPROM Initialize Not used Paperless Operation Mode Self Operation Mode Standalone Feeding Operation Mode Not used

3-24 Service Manual

5060-XXX

4. Repair Information
WARNING: Read the following before handling electronic parts.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:

Keep the ESD-sensitive part in its original shipping container (a special ESD bag)
until you are ready to install the part into the machine.

Make the least-possible movements with your body to prevent an increase of static
electricity from clothing fibers, carpets, and furniture. Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges any static electricity 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-sensitive part on the machine cover or on a metal table; if you need to put down the ESD-sensitive part for any reason, first put it into its special bag. Machine covers and metal tables are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESDsensitive part. (Large metal objects can be discharge paths without being grounded.) Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table. If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case). Be extra careful in working with ESD-sensitive parts when cold-weather heating is used because low humidity increases static electricity.

Printhead Adjustments
Whenever a printhead is removed, it is necessary to perform the Printhead Manual Adjustment on page 4-1 and Printhead Electronic Alignment on page 4-4.

Printhead Manual Adjustment

1. Draw a scribe line on the frame next to the front (A) and rear (B) of the printhead to
provide reference points before adjusting or removing a printhead. Note: When you adjust or replace the printhead, tighten the three mounting screws friction tight so the printhead does not wobble but can be adjusted left and right.

Repair Information

4-1

5060-XXX

2. Position the printhead along the front (A) and rear (B) scribe lines.

3. Run an Alignment Test Page from Setting Printer Alignment on page 3-23.

4-2 Service Manual

5060-XXX

4. Move the rear of the printhead to a position that allows the color of the printhead
being adjusted to align over the black target on the left side of the Alignment Test Page. Tighten the right rear mounting screw (A).

5. Run an Alignment Test Page to verify the printhead rear adjustment. 6. Move the front of the printhead to a position that allows the printhead color to align
over the black target on the right side of the Alignment Test Page. Tighten the front mounting screw.

7. Run an Alignment Test Page to verify the printhead front adjustment.

Note: You may be required to make both front and rear printhead adjustments several times to obtain correct manual alignment on both sides of the Alignment Test Page.

8. After you obtain correct front and rear printhead adjustments, tighten the left rear
printhead mounting screw.

Repair Information

4-3

5060-XXX

Printhead Electronic Alignment

1. Perform Setting Printer Alignment on page 3-23.

Screw Identification Table

The following table contains screw types, locations, and quantities necessary to service the printer. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly.

Reference number
002

Screw type
4-40 Machine

Location
Parallel Connector to Shield

Purpose
Attach

Qty
2

102

M3.5x8mm Thread Cutting

Cartridge Guides to Upper Frame Upper Front Cover to Cartridge Guides Front Cover Pivot to Front Upper Cover Front Left Light Shield to Upper Front Cover

Attach Attach Attach Attach Mounting Attach Attach

8 4 2 1 7 1 4

121

M3.5x6mm Machine

LVPS to Lower Frame Right Rear Cover to LVPS HVPS standoffs to Upper Frame

4-4 Service Manual

5060-XXX

Reference number
232

Screw type
M3x6mm Taptite Metal Thread Forming

Location
Ground Cable to Right Front Cover Support and Upper Frame. Ground Cable to Bottom Support Plate and Engine Card Shield Back Lamp Brackets to Fuser Frame Front Lamp Brackets to Fuser Frame Blank INA Covers to RIP Shield RIP Card Ground Shield to RIP Shield RIP Shield to Engine Shield RIP Card to RIP Shield Engine Card to Engine Shield RIP Shield Cover to RIP Shield V-Block Plates to Upper Frame Ground Cable Strap to RIP Ground Shield

Purpose
Attach

Qty
2

Attach

Attach Attach Mounting Mounting Mounting Mounting Mounting Mounting Mounting Attach

2 2 2 5 4 12 6 8 2 1

Repair Information

4-5

5060-XXX

Reference number
312

Screw type
M2.9x6mm Plastite

Location
Front Access Door Assembly Door Handle to Cover Detent Housing to Cover ITU Switch Housing to Light Shield Duplex Baffle to Lower Right Door Front and Rear Latches to Lower Right Door Bias Latch Cover to Door MPF Asm To MPF Door Support Bracket to MPF Door MPF Cable Cover to Door Asm MPF Latch Support Brackets to Upper Frame Voltage Cable to Terminal (BOR/ITU) Black Voltage Cable to Terminal (BOR/ITU) Cyan Voltage Cable to Terminal (BOR/ITU) Magenta Voltage Cable to Terminal (BOR/ITU) Yellow

Purpose
Mounting Mounting Mounting Attach Attach Mounting Attach Attach Attach Mounting Attach Attach Attach Attach Attach

Qty
3 2 1 1 4 2 1 6 4 1 2 1 1 1 1

4-6 Service Manual

5060-XXX

Reference number
323

Screw type
M3.5x1.35mm Plastite 6 long

Location
Frame Support Back Plate to Lower Frame Door Latch Catch to Frame Transfer HVPS to Lower Frame Fuser Top Duct to Lower Frame Right Front Cover Support to Lower Frame Front Lower Left Cover to Lower Frame Front Left Handle Cover Asm to Lower Frame Front Lower Right Cover to Lower Frame Front Right Handle Cover Asm to Lower Frame Right Front Cover to Lower Frame Left Lower Cover to Lower Frame Left Upper Cover Asm to Lower Frame Left Upper Cover Asm to Upper Frame Left Lower Pivot to Lower Frame Left Upper Pivot to Left Lower Cover Rear Cover to Lower Frame, Left Cover Rear Fan Cover to Lower Frame and Top Cover

Purpose
Attach Attach Mounting Attach Attach Attach Attach Attach Attach Attach Attach Attach Attach Attach Attach Attach Attach

Qty
2 2 1 1 1 1 4 1 4 2 2 2 1 2 1 6 4

Repair Information

4-7

5060-XXX

Reference number
323

Screw type
M3.5x8mm Plastite Thread Forming

Location
Top Cover Asm to Upper Front Cover Top Cover Asm to RIP Shield ITU Light Shield Asm to Upper Front Guide ITU Ribs to Upper Redrive Door Upper Door Hinges to Upper Frame (Redrive) Inner Redrive Asm to Upper Frame (Redrive) Developer HVPS to Cartridge Contact Asm Engine Card Shield to Frame BOR Drive Asm to Upper Frame ITU Drive Asm to Lower Frame Fuser Drive Asm to Lower Frame Vacuum Top Duct to Lower Frame Toner Shield to Lower Frame Upper Deflector To Lower Frame (PF XPORT) VTB Asm to Lower Frame (PF XPORT) Inner Deflector to VTB Assembly (PF XPORT) Jam Access Spring to VTB Asm (PF XPORT) 500 Pick Assembly to Lower Frame Paper Size Sensing Assembly to Lower Frame Paper Level Sensing Assembly to Lower Frame

Purpose
Attach Attach Attach Mounting Mounting Mounting Mounting Mounting Mounting Mounting Mounting Mounting Attach Mounting Mounting Attach Attach Mounting Mounting Mounting

Qty
3 1 1 5 2 2 4 5 1 3 4 2 4 2 2 1 1 3 1 3

4-8 Service Manual

5060-XXX

Reference number
324

Screw type
M3.5x10mm Plastite Thread Forming

Location
Transfer HVPS/RIP Fan Asm to RIP Shield Front Left Light Shield to Left Upper Cover Asm and Top Cover Front Right Light Shield to Right Front Cover Support and Top Cover Cartridge Drive Assemblies to Upper Frame Upper Door Hinges to Upper Frame (Redrive) Inner Redrive Assembly to Upper Frame

Purpose
Attach Attach

Qty
1 1

Attach

Mounting Attach Mounting Attach

12 2 2 1

412

2.9x5.2mm Plastite

Hinge Restraint to Door (MPF) SEMS

423

M3.5x9 Plastite

Tray Bias Bellcrank to Tray

Mounting

484

M3.5x14 Machine Panhead

Printhead to Upper Frame

Mounting

12

Repair Information

4-9

5060-XXX

Removal Procedures
CAUTION: Remove the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The printer weighs 47.7 kg (105 lb) and requires at least two people to lift it safely. Make sure your fingers are not under the printer when you lift or set the printer down. Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.

Outer EMC Shield

1. Loosen screw type 232 on page 4-5 (A) and lift the outer EMC shield from the
printer.

RIP Board
Go to RIP Board Assembly - Network, Model 5060-002 on page 7-25 or RIP Board Assembly, Non-Network, Model 5060-001 on page 7-25 for part number. Improper RIP board replacement can result in incorrect printer function and significant additional service time due to loss of data. Also if both the RIP and engine boards are being replaced, DO NOT replace both at once. Replace one board at a time, following appropriate procedures for each.

4-10 Service Manual

5060-XXX

1. 2. 3. 4. 5. 6.

Remove the Outer EMC Shield on page 4-10. Remove the Rear Cover on page 4-12. Remove the USB connector screw type 232 on page 4-5 (A). Remove the RIP board screw type 232 on page 4-5 (B). Remove the parallel connector (C). Disconnect all cables from the RIP board and remove the board.

Perform the following steps to install the replacement RIP board:

1. 2. 3. 4. 5. 6.

Power Off the printer. Install the replacement RIP board. Power On the printer. When the operator panel prompts NV Rip to Eng, choose STOP. This prevents transfer of data from the RIP board to the engine board. When the operator panel prompts NV Eng to Rip, choose GO. This transfers data from the engine board to the RIP board. The printer restarts at this point. At the READY prompt print a MENU page and look for the correct printer name and equivalent/updated RIP code level. The MENU page should print with acceptable print quality indicating calibration data has been properly preserved.

Repair Information

4-11

5060-XXX

Rear Cover
Go to Rear Cover on page 7-5 for part number.

1. Remove the rear cover screw type 323 on page 4-7 (A). 2. Open the MPF, remove the rear cover screw type 323 on page 4-7 (B), and
remove the rear cover.

HVPS Transfer Board

1. Remove the Rear Cover on page 4-12. 2. Remove the HVPS transfer board screw type 324 on page 4-9 and 312 on 3. 4. 5.
page 4-6 (A). Disconnect the five spade terminals (B) from the transformers. Disconnect the control cable (C). Remove the HVPS transfer board.

4-12 Service Manual

5060-XXX

Rear Fan Cover

Go to Rear Fan Cover on page 7-5 for part number.

1. Remove the Rear Cover on page 4-12. 2. Remove the rear fan cover screw type 323 on page 4-7 (A) and remove the rear
fan cover.

Repair Information

4-13

5060-XXX

Fuser Fan
Go to Fuser Fan on page 7-29 for part number.

1. Remove the Rear Fan Cover on page 4-13. 2. Disconnect the fuser fan cable from connector J2 (B) on the engine board. 3. Remove the fuser fan screws (A), part number 12G6529 and remove the fan.

Engine Board
Go to Engine Board on page 7-28 for part number.

1. 2. 3. 4. 5.

Remove the Rear Fan Cover on page 4-13. Remove the Rear Cover on page 4-12. Disconnect all cables from the engine board. Remove the engine board screw type 323 on page 4-7 (A) and remove the engine board. Remove the engine board. Be careful not to damage the paper size switches and actuators (B).

4-14 Service Manual

5060-XXX

LVPS
Go to LVPS, 115V on page 7-23 or LVPS, 220V on page 7-23 for part number.

1. Remove the Rear Fan Cover on page 4-13. 2. Remove the Fuser Assembly on page 4-16. 3. Remove the LVPS screw type 121 on page 4-4 (A) from the rear of the printer.

Repair Information

4-15

5060-XXX

4. Remove the right rear cover screw type 121 on page 4-4 (A).

5. Open the redrive cover and remove the screw type 121 on page 4-4 (A) from the
top of the LVPS and remove the LVPS from the printer. Note: Be sure to reinstall the ground strap when you replace the LVPS.

Fuser Assembly
CAUTION: Be sure the fuser assembly has cooled before you remove it. Go to Fuser Assembly 115V 500W on page 7-6 or Fuser Assembly 220V 500W on page 7-6 for part numbers.

1. Open the lower right door assembly. 2. Unlatch the two fuser latches (A). 3. Remove the fuser assembly.

4-16 Service Manual

5060-XXX

Fuser Drive Assembly

Go to Fuser Drive Assembly on page 7-7 for part number.

1. Remove the Fuser Assembly on page 4-16. 2. Remove the fuser drive assembly screw type 323 on page 4-7 (A) and remove the
assembly.

Repair Information

4-17

5060-XXX

Lower Right Door Assembly

Go to Lower Right Door Assembly on page 7-3 for part number.

1. Open the lower right door assembly. 2. Carefully flex the lower right door assembly to free the hinges from the mounting
posts.

3. Remove the lower right door assembly.

Fuser Top Duct

Go to Fuser Top Duct on page 7-5 for part number.

1. Remove the Rear Fan Cover on page 4-13. 2. Remove the fuser top duct screw type 323 on page 4-7 (A) and remove the top
duct.

4-18 Service Manual

5060-XXX

Fuser Bottom Duct

Go to Fuser Bottom Duct on page 7-5 for part number.

1. Remove the Fuser Top Duct on page 4-18. 2. Remove the Fuser Fan on page 4-14. 3. Press the fuser bottom duct latches (A) to release the duct, lift up and remove the
duct.

Fuser Web Oiler Motor Assembly

Go to Fuser Assembly, WEB Oiler 115V 500W on page 7-6 or Fuser Assembly, WEB Oiler 220V 500W on page 7-6 for part number.

1. Remove the Fuser Assembly on page 4-16. 2. Remove the paper path access door cover right mounting screw.

Repair Information

4-19

5060-XXX

3. Remove the Front Right Handle Cover Assembly on page 4-30. 4. Disconnect the web oiler motor assembly cable.

5. Remove the fuser web oiler motor assembly mounting screws and remove the
assembly. Note: When you reinstall the web oiler motor assembly, pull the excess cable, twist, install a cable tie, and route the cable down into the printer.

4-20 Service Manual

5060-XXX

Note: Make sure the motor cable (A) is routed away from gears (B).

Redrive Door
Go to Redrive Door on page 7-11 for part number.

1. Open the redrive door. 2. Loosen the redrive door upper hinge screw type 324 on page 4-9 (A). 3. Lift the redrive door from the hinge (B) and remove the redrive door.

Repair Information

4-21

5060-XXX

Front Cover Assembly

Go to Front Cover Assembly on page 7-3 for part number.

1. 2. 3. 4.

Open the front cover assembly. Remove the detent post tension spring (B). Flex the front cover assembly to free the hinge from the mounting post (A). Remove the front cover assembly.

Top Cover Assembly

Go to Top Cover Assembly on page 7-3 for part number.

1. Remove the Front Cover Assembly on page 4-22. 2. Remove the Redrive Door on page 4-21. 3. Remove the redrive cap.

4-22 Service Manual

5060-XXX

4. Remove the light shield screw type 324 on page 4-9 and 323 on page 4-7 (A). 5. Remove the shield.

Repair Information

4-23

5060-XXX

6. Remove the front upper pivot cover screw type 102 on page 4-4 (A) and remove
the pivot cover.

7. Open the MPF and remove the top cover screw type 323 on page 4-8 (B) from the
left side of the printer.

8. Remove the top cover screw type 323 on page 4-8 (A) from the rear of the printer.

4-24 Service Manual

5060-XXX

9. Remove the top cover mounting screws (A) from the front of the printer.

10. Remove the operator panel bezel.

11. Open the redrive door and loosen the redrive assembly screw type
323 on page 4-7 (A).

Repair Information

4-25

5060-XXX

12. Lift the top cover and disconnect the operator panel cable.

13. Remove the bin full sensor (C), flag (A), and upper options auto connect (B) from the
top cover.

14. Remove the top cover.

Operator Panel
Go to Operator Panel Assembly, Low Volt on page 7-3 or Operator Panel Assembly, High Volt on page 7-3 for part number.

1. Remove the Front Cover Assembly on page 4-22. 2. Remove the operator panel bezel.

4-26 Service Manual

5060-XXX

3. Unlatch the operator panel latches (A).

4. Disconnect the operator panel cable from the operator panel and remove the
operator panel.

Repair Information

4-27

5060-XXX

Cartridge Drive Assembly (Yellow)

Go to Cartridge Drive Assembly, Yellow on page 7-31 for part number.

1. 2. 3. 4.

Remove the Rear Fan Cover on page 4-13. Remove the cartridge drive assembly mounting screws (A). Disconnect the cable from the cartridge drive assembly. Remove the cartridge drive assembly.

Cartridge Drive Assembly (Cyan, Magenta, Black)

Go to Cartridge Drive Assembly, Cyan/Magenta/Black on page 7-31 for part number.

1. 2. 3. 4.

Remove the RIP Board Shield Assembly on page 4-38. Remove the Engine Board on page 4-14. Remove the cartridge drive assembly mounting screws (A). Disconnect the cable (B) from the cartridge drive assembly.

4-28 Service Manual

5060-XXX

5. Remove the cartridge drive assembly.

Repair Information

4-29

5060-XXX

Front Right Handle Cover Assembly

Go to Front Right Handle Cover Assembly on page 7-3 for part number.

1. Open the front cover. 2. Remove the light shield screw type 324 on page 4-9 and 323 on page 4-7 (A). 3. Remove the light shield.

4. Remove the Paper Path Access Door Cover/Front Lower Left Cover on
page 4-32.

5. Remove the front right handle cover assembly screw type 323 on page 4-7 (A)
and remove the assembly.

4-30 Service Manual

5060-XXX

Front Left Handle Cover Assembly

Go to Front Left Handle Cover Assembly on page 7-3 for part number.

1. Open the front cover. 2. Remove the front left handle cover assembly screw type 323 on page 4-7 (A)
and remove the assembly.

Lower Jam Access Door Assembly

Go to Lower Jam Access Door Assembly on page 7-5 for part number.

1. Remove the Front Left Handle Cover Assembly on page 4-31. 2. Remove the lower jam access door assembly screw type 323 on page 4-7 (A) and
remove the door.

Repair Information

4-31

5060-XXX

Paper Path Access Door Cover/Front Lower Left Cover

Go to Paper Path Access Door on page 7-3 and Front Lower Left Cover on page 7-3 for part numbers.

1. Remove the Front Left Handle Cover Assembly on page 4-31 (B). 2. Open the paper path access door, remove screw type 323 on page 4-7 (A),
and remove the door.

3. Separate the paper path access door cover from the front lower left cover (C). Be
careful not to lose the door spring (D).

4-32 Service Manual

5060-XXX

Multipurpose Feeder (MPF)

Go to Multipurpose Feeder (MPF) on page 7-13 for part numbers.

1. 2. 3. 4.

Open the MPF. Remove the MPF strap screw type 412 on page 4-9 (A). Disconnect the MPF switch cable from the engine board at connector J10. Release the MPF latch (B) and remove the MPF.

Waste Container Door

Go to Waste Container Door on page 7-5 for part number.

1. Open the waste container door. 2. Flex the door and remove it from the hinges (A).

Repair Information

4-33

5060-XXX

Left Lower Cover

1. Remove the Lower Jam Access Door Assembly on page 4-31. 2. Remove the left lower cover screw type 323 on page 4-7 (A)
and remove the cover.

Printheads
Go to Printhead Assembly on page 7-9 for part numbers. Whenever a printhead is removed, it is necessary to perform the Printhead Manual Adjustment on page 4-1 and Printhead Electronic Alignment on page 4-4.

1. Remove the Top Cover Assembly on page 4-22. 2. Draw a scribe line on the frame next to the front (A) and rear (B) of the printhead to
provide reference points before removing a printhead. When you replace the printhead, tighten the three mounting screws friction tight so the printhead does not wobble but can be adjusted left and right.

4-34 Service Manual

5060-XXX

3. Remove the printhead screw type 484 on page 4-9 (B) through the holes (A) in
the top of the rear printer frame.

4. 5. 6. 7.

Remove the printhead mounting screw (A) from the front of the printhead assembly. Disconnect the printhead video cable (B) from the printhead. Disconnect the mirror motor/hysnc cable (C) from the RIP board at connector J2. Remove the printhead.

Repair Information

4-35

5060-XXX

PSD Sensor Assembly

Go to PSD Assembly on page 7-9 for part number.

1. Remove Printheads on page 4-34. Draw a scribe line on the frame next to the
front (A) and rear (B) of the printhead to provide reference points before removing a printhead.

2. Remove the PSD sensor assembly mounting screws. 3. Lift the PSD sensor assembly and disconnect the cable. 4. Remove the PSD sensor assembly.
Note: Be careful not to lose shim (A) under the PSD sensor assembly. When you reinstall the assembly, pull forward on tab (B) and install the front mounting screw first.

4-36 Service Manual

5060-XXX

RIP Fan
Go to RIP Fan on page 7-29 for part number.

1. 2. 3. 4.

Remove the Top Cover Assembly on page 4-22. Remove the rip fan screw type 324 on page 4-9 (A). Disconnect the rip fan cable from the engine board at connector J53. Remove the rip fan.

Redrive Assembly
Go to Redrive Assembly on page 7-11 for part number.

1. Open the redrive door. 2. Remove the redrive assembly screw type 323 on page 4-7 (A).

Repair Information

4-37

5060-XXX

3. Remove the drive belt (B) from the lower redrive pulley. 4. Remove the redrive assembly.
Note: When you reinstall the redrive assembly be sure to align the notch in the redrive assembly with tab (A).

RIP Board Shield Assembly

Go to RIP Board Shield Assembly on page 7-25 for part number.

1. 2. 3. 4. 5. 6. 7.

Remove the Top Cover Assembly on page 4-22. Remove the Rear Fan Cover on page 4-13. Remove the Rear Cover on page 4-12. Remove the RIP Board on page 4-10. Remove the HVPS Transfer Board on page 4-12. Remove the RIP board shield assembly mounting screws (A) through the holes in the shield. Remove the RIP board shield assembly.

4-38 Service Manual

5060-XXX

HVPS Developer Board

1. Remove the RIP Board Shield Assembly on page 4-38. 2. Remove the HVPS developer board mounting screws. 3. Disconnect the HVPS developer board cables (A)(B)(C) and remove the board.

VTB Fan
Go to VTB Fan on page 7-29 for part number.

1. Remove the RIP Board Shield Assembly on page 4-38. 2. Remove the VTB fan with a flatblade screwdriver.

Repair Information

4-39

5060-XXX

ITU Drive Motor

1. Remove the RIP Board Shield Assembly on page 4-38. 2. Remove the Engine Board Shield on page 4-41. 3. Remove the ITU drive motor mounting screws (B), disconnect cable (A), and remove
the assembly.

ITU Drive Assembly

1. 2. 3. 4.
Remove the RIP Board Shield Assembly on page 4-38. Remove the Engine Board Shield on page 4-41. Remove the ITU drive assembly mounting screws (A) and disconnect the cable. Move the bottom of the ITU drive assembly toward you as you rotate the top of the assembly out of the printer. Be careful not to damage the large drive gear as you remove the ITU drive assembly.

4-40 Service Manual

5060-XXX

ITU Assembly
Go to ITU Assembly on page 7-17 for part number.

1. 2. 3. 4.

Open the front cover. Remove the toner cartridges. Open the MPF. Raise the ITU release lever (A) and slide the ITU from the printer.

Engine Board Shield

Go to Engine Board Shield on page 7-28 for part number.

1. Remove the RIP Board Shield Assembly on page 4-38. 2. Remove the Engine Board on page 4-14. 3. Remove the engine board shield screw type 323 on page 4-7 (A),
screw type 232 on page 4-5 (B), and remove the shield.

Repair Information

4-41

5060-XXX

Waste Container Latch

Go to Waste Container Latch on page 7-30 for part number.

1. Remove the Paper Size Sensing Assembly on page 4-42. 2. Use a flatblade screwdriver to release the waste container latch from the paper size
sensing assembly.

Paper Size Sensing Assembly

Go to Paper Size Sensing Bracket on page 7-30 for part numbers. Note: The paper size sensing assembly contains components that easily fall apart as you remove the assembly. Be careful not to lose any of the components.

1. 2. 3. 4. 5. 6.

Remove the Rear Cover on page 4-12. Remove the Rear Fan Cover on page 4-13. Remove the Engine Board Shield on page 4-41. Open the waste toner container door and slide the container out. Remove the paper size sensing assembly screw type 323 on page 4-7 (A). Remove the assembly.

4-42 Service Manual

5060-XXX

Second Transfer Roll

Go to Second Transfer Roll on page 7-8 for part number.

1. Remove the ITU Assembly on page 4-41. 2. Lift the transfer roll from the front bearing and remove the transfer roll.

BOR Drive Assembly

Open the front cover. Remove the yellow toner cartridge. Remove the front right light shield cover. Remove the BOR housing assembly screw type 323 on page 4-7 (A) and remove the assembly. Note: Gear (B) can easily fall from the assembly. Be careful not to lose the gear.

1. 2. 3. 4.

Repair Information

4-43

5060-XXX

Cartridge Contact Assembly

Go to Cartridge Contact Assembly on page 7-20 for part numbers.

1. 2. 3. 4. 5. 6.

Remove the Cartridge Drive Assembly (Cyan, Magenta, Black) on page 4-28. Open the front cover. Remove the toner cartridges. Remove the cartridge rail front and rear mounting screws and remove the rail. Disconnect the cable from the HVPS developer board. Press the cartridge contact assembly retaining tabs (A) and remove the assembly.

4-44 Service Manual

5060-XXX

5. Connector Locations
Engine Board
Connector
J2 Main Fan

Pin No.
1 2 3 4

Signal
FAN1 Stall IN Ground FAN1 PWM Out +24 V dc Left Side Oiler PHA OUT + Oiler PHB OUT + Oiler PHA OUT Oiler PHB OUT FAN2 Stall IN Ground FAN2 PWM Out +24 V dc Left Side +24 V dc (options) Ground RXD1_OPTS_IN Ground STAG_ENC +5 V dc (options) Ground -TXD1_OUT +24 V dc (options) Ground RXD1_OPTS_IN Ground +5 V dc (options) Ground (-TXD1_OUT)

J3 Oiler Stepper Motor

1 2 3 4

J4 VTB Fan

1 2 3 4

J5 Options Conn. Trays

1 2 3 4 5 6 7 8

J7 Options Conn. Stacker

1 2 3 4 5 6 7

Connector Locations 5-1

5060-XXX

Connector
J8 Yellow Drive Motor Fuser Drive Motor

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Signal
Y ON OUT FUSER ON OUT +5 V dc +5 V dc Y DIR OUT FUSER DIR OUT +24 V dc +24 V dc Ground Ground Y CLK OUT FUSER CLK OUT Y HALL IN FUSER HALL IN Y LOCK IN FUSER LOCK IN +3.3 V dc +5 V dc +5 V dc +24 V dc +24 V dc Ground Ground Ground Ground Ground

J9 LVPS

1 2 3 4 5 6 7 8 9 10

5-2

Service Manual

5060-XXX

Connector
J10 Fuser

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12

Signal
EXIT SENSOR IN FUSER CAM1 IN FUSER CAM2 IN OILER ENC A IN OILER ENC B IN HR THERM IN BR THERM IN Ground +5 V dc switched ZERO Xing IN HR HEAT ON OUT BR HEAT ON OUT +5 V dc switched BIN FULL IN Ground LIFT PHA OUT LIFT PHA OUT +

J11 Bin Full

1 2 3

J12 BOR Motor

1 2

Connector Locations 5-3

5060-XXX

Connector
J20 HVPS - Developer

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Signal
(-CART METER K IN) K AC B EN OUT SC K CHIP DEV PWM OUT (-CART METER M IN) K CHG PWM OUT SC M CHIP CMY CHG PWM OUT (-CART METER C IN) CMY AC B EN OUT SC C CHIP M DEV PWM OUT (-CART METER K IN) C DEV PWM OUT SC Y CHIP Y DEV PWM OUT Ground +24 V dc switched

5-4

Service Manual

5060-XXX

Connector
J45 RIP Interface

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Signal
I2C DATA RIP I2C CLK RIP (-NOTIFY RIP) Ground (-VSYNC Y OUT) FPIRQ RIP (-VSYNC M OUT) (-VSYNC C OUT) Ground (-VSYNC K OUT) (-HSYNC Y IN) (-HSYNC C IN) (-HSYNC M IN) (-HSYNC K IN) (-RIP PRESENT OUT) Ground ITU ZONECLK OUT ITU HOMEZONE OUT ON OUT

Connector Locations 5-5

5060-XXX

Connector
J47 Cyan Cartridge Motor Magenta Cartridge Motor

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Signal
Not used C ON OUT +5 V dc +5 V dc M DIR OUT C DIR OUT +24 V dc M and C +24 V dc M and C Ground Ground M CLK OUT C CLK OUT M HALL IN C HALL IN M LOCK IN C LOCK IN CLR FULL IN Ground FAN3 STALL IN Ground FAN3 PWM OUT +24 V dc Right Side

J52 Waste CLNR Full

1 2

J53 RIP Fan

1 2 3 4

5-6

Service Manual

5060-XXX

Connector
J64 ITU Drive Motor Black Cartridge Drive Motor

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Signal
K ON OUT ITU ON OUT +5 V dc +5 V dc K DIR OUT ITU DIR OUT +24 V dc ITU and K +24 V dc ITU and K Ground Ground K CLK OUT ITU CLK OUT K HALL IN ITU HALL IN K LOCK IN ITU LOCK IN +5 V dc switched STAGING ENG OUT Ground Ground STAGING OUT 2 STAGING OUT 1

J67 Staging Motor

1 2 3 4 5 6

Connector Locations 5-7

5060-XXX

Connector
J68 S2/NM/Prism Media 1

Pin No.
1 2 3 4 5 6 7 8 9 10

Signal
Narrow Media IN +5 V dc switched Ground PPS2 IN +5 V dc switched Ground PRISM LED VOLT Ground PRISM SENSOR IN +5 V dc switched +5 V dc switched PAPER OUT IN PAPER LOW IN Ground LED VCC Ground +3.3 V dc XPAR TRAY 1 IN +5 V dc switched MPF FEED LOW IN MPF FEED OUT IN Ground

J69 Paper Out/Low XPAR Media 2

1 2 3 4 5 6 7 8

J70 MPF Media

1 2 3 4

5-8

Service Manual

5060-XXX

Connector
J71 HVPS- Transfer

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Signal
ITU TX ENA OUT ITU TX CUR PWM 0 ITU SERVO INTO ITU TX PWM OUT CMY TX ENA OUT K SERVO INTO K TX PWM OUT C SERVO INTO C TX PWM OUT Y SERVO INTO Y TX PWM OUT M SERVO INTO M TX PWM OUT Ground +24 V dc switched +5 V dc ITU DATA +3.3 V dc TPS GAIN OUT ITU TEMP BELT HOLE 1 Ground Ground ITU EEPROM CLK +24 V dc Right Side TPS LED ON OUT TONER PATCH OUT BELT HOLE 2 +5 V dc switched

J72 ITU Autoconnect

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Connector Locations 5-9

5060-XXX

Connector
J73 Autocompensator Motor1 (+5 V dc switched)

Pin No.
1 2 3 4 5 6

Signal

AUTOCOMP ENC IN Ground Ground AUTOCOMP OUT 2 AUTOCOMP OUT 1 +24 V dc to Cover SW +24 V dc switched

J86 Cover Interlock

1 2

Engine Board

5-10

Service Manual

5060-XXX

RIP Board
Connector
J1 Operator Panel Connector

Pin No.
1 2 3 4 5

Signal
OP I2CDATA +5 V dc OP I2CClk Ground OP I2RGround HSYNC-/SOS thermistor +5 V dc Hsync Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr NC NC laser en Ground laser adj Ground laser PWM +5 V dc head Ground video data video data +

J2 Printhead Yellow Connector

1 2 3 4 5 6 7 8 9 10

J3 Printhead Yellow Connector

1 2 3 4 5 6 7 8 9 10 11

Connector Locations

5-11

5060-XXX

Connector
J4 Printhead Yellow/Cyan Connector

Pin No.
1 2 3 4 5 6 7 8

Signal
Ground lexhsync/eos ALTHERM +5 V dc EOS card Ground lexhsync/eos ALTHERM +5 V dc EOS card Ground HSYNC-/SOS thermistor +5 V dc Hsync Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr NC NC laser en Ground laser adj Ground laser PWM +5 V dc head Ground video data video data +

J5 Printhead Cyan Connector

1 2 3 4 5 6 7 8 9 10

J6 Printhead CYAN Connector

1 2 3 4 5 6 7 8 9 10 11

5-12

Service Manual

5060-XXX

Connector
J7 Printhead Magenta Connector

Pin No.
1 2 3 4 5 6 7 8 9 10

Signal
Ground HSYNC-/SOS thermistor +5 V dc Hsync DC Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr NC NC laser en Ground laser adj Ground laser PWM +5 V dc head Ground video data video data +x Ground lexhsync/eos ALTHERM +5 V dc EOS card Ground lexhsync/eos ALTHERM +5 V dc EOS card

J8 Printhead Magenta Connector

1 2 3 4 5 6 7 8 9 10 11

J9 Printhead Magenta/Black Connector

1 2 3 4 5 6 7 8

Connector Locations

5-13

5060-XXX

Connector
J10 Printhead Black Connector

Pin No.
1 2 3 4 5 6 7 8 9 10

Signal
Ground HSYNC-/SOS thermistor +5 V dc Hsync DC Ground mm ref freq mm lock mm strt/en Ground +24 V dc mir mtr NC NC laser en Ground laser adj Ground laser PWM +5 V dc head Ground video data video data + +5 V dc Ground V Corx

J11 Printhead Black Connector

1 2 3 4 5 6 7 8 9 10 11

J12 Cover Open Switch Connector

1 2 3

J13 Parallel Port Connector J18 USB Port Connector 1 2 3 4 G1 G1 G2 G2 USB +5 V dc USB DUSB D+ Ground Ground Ground

5-14

Service Manual

5060-XXX

Connector
J19 Option DRAM Socket 2 J20 Option DRAM Socket 1 J21 Base DRAM Socket J23 Power Connector

Pin No.

Signal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Ground Ground Ground Ground Ground Ground Ground Ground +3 V dc Sense +3.3 V dc +3.3 V dc +3.3 V dc +5 V dc +5 V dc +5 V dc +24 V dc

Connector Locations

5-15

5060-XXX

Connector
J24 Engine to RIP Connector

Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Signal
ITU Zone CLk ITU Zone HB RIPPRES N Ground HSYNCN M TSYNCN K HSYNCN Y HSYNCN C Ground VSYNCN K VSYNCN M VSYNCN C VSYNCN Y VSYNCN OWL PIO NOTIFY R Ground OP I2DATA R OP I2CLK R

5-16

Service Manual

5060-XXX

RIP Board

Connector Locations

5-17

5060-XXX

LVPS Cable Connectors to Engine Board & RIP Board

Connector
RIP Board Power

Pin No. Signal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Ground Return +3.3 V dc rtn Ground Return +3.3 V dc rtn Ground Return +3.3 V dc rtn Ground Return +3.3 V dc rtn Ground Return +5 V dc Rtn Ground Return +5 V dc Rtn Ground Return +5 V dc Rtn Ground Return +24 V dc Rtn +3.3 V dc Sense +3.3 V dc +3.3 V dc +3.3 V dc +5 V dc +5 V dc +5 V dc +24 V dc +3.3 V dc +5 V dc +5 V dc +24 V dc +24 V dc Ground Ground Ground Ground Ground

Engine Board Power

1 2 3 4 5 6 7 8 9 10

5-18

Service Manual

5060-XXX

Connector
Engine Board Cable

Pin No. Signal

1 2 3 4 5 6 7 8 9 10 11 12 FusExitSen BURCam1 N/C WebEncoderA WebEncoderB HRThermistor BURThermistor Ground +5 V dc switched ZCSense Heat On #1 Heat On #2x

Connector Locations

5-19

5060-XXX

LVPS Fuser Connectors

Connector
LVPS AC Fuser Connector

Pin No. Signal

1 2 3 4 5 AC Load #1 AC Common Ground NC AC Load #2x FusExitSen BURCam1 N/C WebEncoderA WebEncoderB HRThermistor BURThermistor Return - Analog Ground +5 V dc switched N/Cx

LVPS DC Fuser Control Connector

1 2 3 4 5 6 7 8 9 10

5-20

Service Manual

5060-XXX

HCIT 2000-Sheet Board

Connector
CN1 I/F

Pin No.
1 2 3 4 5 6

Signal
Send PRI RXD PGND PERON SGND PRI TXD Poweron +5 V dc SGND PGND PGND PGND +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc REG A REG A REG B REG B No Connection +24 V dc +24 V dc PICK A *PICK A PICK B *PICK B

CN2 LVPS

1 2 3 4 5 6 7 8 9

CN3 REG Motor

1 2 3 4 5 6 7

CN4 PICK Motor

1 2 3 4 5 6

Connector Locations

5-21

5060-XXX

Connector
CN5 LIFT Motor

Pin No.
1 2

Signal
+24 V dc LHOT +5 V dc GND SIDE +5 V dc GND LEVEL +5 V dc GND EMPTY +5 V dc GND RHOME +5 V dc GND PHOME +5 V dc GND SIZE 0 +5 V dc GND SIZE 1 +5 V dc GND SIZE 2 +5 V dc GND NE EMP

CN6 Sensors Side Door/Level/Empty/ Registration Home/Pick Home

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CN7 Size Sensors/Near Empty

1 2 3 4 5 6 7 8 9 10 11 12

5-22

Service Manual

5060-XXX

Connector
CN8 S1(Pick Sensor) S2(Registration Sensor)

Pin No.
1 2 3 4 5 6

Signal
+5 V dc S2 GND +5 V dc S1 GND

Connector Locations

5-23

5060-XXX

HVPS
Connector
CN1 HVPS Input Connector

Pin No Signal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +24 V dc +24 V dc Return M-Txpwm M-Srvo out Y -Txpwm Y-Srvo out C-Txpwm C-Srvo out K-Txpwm K-Srvo out KCYM-Txenable I-Txpwm I-Srvo out I-Txcurpwm I-Txenable HV Transformer output to 2nd Transfer Roll Cable HV Transformer Output Terminal to Black Transfer Cable HV Transformer Output Terminal to Cyan Transfer Cable HV Transformer Output Terminal to Yellow Transfer Cable HV Transformer Output Terminal to Magenta Transfer Cable

T102 Transformer HV Terminal I (ITU) T201 Transformer HV Terminal K Black T301 Transformer HV Terminal C Cyan T401 Transformer HV Terminal Y Yellow T501 Transformer HV Terminal M Magenta

1 1 1 1 1

5-24

Service Manual

5060-XXX

HVPS Board

Connector Locations

5-25

5060-XXX

HVPS Developer Board

Connector
CN1 Developer HVPS Input

Pin No Signal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Ground +24 V dc return +24 V dc Y-Ctsense Y-Devpwm Y-TnrSense C-Devpwm C-CtSense M-Devpwm C-TnrSense CYM-Acenable M-CtSense CYM-Chgpwm M-TnrSense K-Chgpwm K-CtSense K-Devpwm K-TnrSense K-Acenable K-CtSense K-TnrSense (Gnd Return) M-CtSense M-TnrSense (Gnd Return) C-CtSense C-TnrSense (Gnd Return) Y-CtSense Y-TnrSense (Gnd Return) Cleaner Bias Terminal

CN2 Smart Cartridge Black

1 2

CN3 Smart Cartridge Magenta

1 2

CN4 Smart Cartridge Cyan

1 2

CN5 Smart Cartridge Yellow

1 2

CB Terminal

5-26

Service Manual

5060-XXX

HVPS Developer Board

Connector Locations

5-27

5060-XXX

HCOF Finisher HCOF SUB LVPS Relay Board

Connector
CN1 AC Input

Pin No
1 2 3 4 5

Signal
AC In Not used Not used Not used AC In AC Out to LVPS Not used AC Out to LVPS +5 V dc Gound

CN2 LVPS

1 2 3

CN3 Relay Board +5 V dc Switched

1 2

5-28

Service Manual

5060-XXX

HCOF LVPS Board

Connector
CN2 LVPS Out

Pin No
1 2 3 4 5 6 7 8

Signal
+24 V dc +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground AC In from Relay Not Used Not Used Not Used AC In from Relay

CN1

1 2 3 4 5

Connector Locations

5-29

5060-XXX

HCOF System Board

Connector
CN1 Drop Solenoid

Pin No
1 2

Signal
SOL+ SOLMTRMTRN.C. MTR+ MTR+ N.C. No Cartridge Low Staple Home Position Unit Check Ground +5 V dc Jog A Jog *A Jog B Jog *B Bun A Bun *A Bun B Bun *B +5 V dc Jog Home Pos Sensor Ground +5 V dc Bundle Belt Home Pos Sensor Ground

CN2 Stapler Assembly

1 2 3 4 5 6 7 8 9 10 11 12

CN3 Jogger Motor/ Bundle Motor

1 2 3 4 5 6 7 8

CN4 Stapler Sensor

1 2 3 4 5 6

5-30

Service Manual

5060-XXX

Connector
CN5 Chad Box Full

Pin No
1 2 3

Signal
+5 V dc Chad Box Sensor Ground Tray Limit SW Ground +5 V dc Tray Near Full Sensor Ground +5 V dc Tray Offset Posit Sensor Ground MTR + MTR +5 V dc Exit Timing Sensor Ground +5 V dc Paper Surface Upper Sensor Ground +5 V dc Paper Surface Lower Sensor Ground A+ AB+ B+SOL -SOL +5 V dc Inverter Jam Sensor Ground

CN6 Tray Sensors Tray Limit/ Near Full/Offset Position

1 2 3 4 5 6 7 8

CN7 Tray Motor

1 2

CN8 Tray Sensors Exit Timing/ Paper Surface Upper/Paper Surface Lower

1 2 3 4 5 6 7 8 9

CN9 Feed

1 2 3 4

CN10 Inverter Jam

1 2 3 4 5

Connector Locations

5-31

5060-XXX

Connector
CN11 Door Switch

Pin No
1 2

Signal
Switch + Switch MTR + MTR A+ AB+ BN.C. +24 V dc +24 V dc P-Ground P-Ground A+ AB+ BN.C. +5 V dc Drop Timing Sensor Ground +5 V dc Punch Home Sensor Ground +5 V dc Punch Timing A Sensor Ground +5 V dc Punch Timing B Sensor Ground

CN12 Tray Lift

1 2

CN13 Feed Motor

1 2 3 4 5

CN14 Power

1 2 3 4

CN15 Feed Motor

1 2 3 4 5

CN16 Punch

1 2 3 4 5 6 7 8 9 10 11 12

5-32

Service Manual

5060-XXX

Connector
CN17 Feed

Pin No
1 2

Signal
SOL+ SOL TxD SG RxD SG FG Switch - PTR Joint N.C. Ground

CN18 Communications

1 2 3 4 5

CN19 Joint

1 2 3

CN20 CPU Prog

1 20

Connector Locations

5-33

5060-XXX

HCOF System Board

5-34

Service Manual

5060-XXX

6. Preventive Maintenance
This chapter describes procedures for printer preventive maintenance. Following these recommendations can 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

Lubrication Specifications
Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure. Some unauthorized lubricants may chemically attack polycarbonate parts. Use IBM no. 10 oil, P/N 1280443 (Approved equivalents: Mobil DTE27, Shell Tellus 100, Fuchs Renolin MR30), IBM no. 23 grease (Approved equivalent Shell Darina 1), and grease, P/N 99A0394 to lubricate appropriate areas.

Preventive Maintenance

6-1

5060-XXX

Scheduled Maintenance
The operator panel displays "80 Fuser Maintenance" and "83 ITU Maintenance" for scheduled maintenance. "80 Fuser Maintenance" is displayed at each 150K copies when the fuser assembly needs to be replaced to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers:

12G6496, Maintenance Kit 115V 12G6497, Maintenance Kit 220V 12G6498, Maintenance Kit 100V
"83 ITU Maintenance" is displayed at each 105K 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 kit with the following part number:

12G6304, ITU Maintenance Kit

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 100K copies when the Web Oiler Assembly is nearly exhausted. Go to WEB Oiler Assembly on page 7-7 for part number.

6-2 Service Manual

5060-XXX

7. Parts Catalog
How to Use This Parts Catalog
SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they
are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. PP: (Parts Packet) in the Description column indicates the part is contained in a parts packet.

The Lexmark C750 (5060-XXX) laser printer is available in two models: 5060-001 5060-002 The parts catalog uses these designations to identify model specific FRUs.

Parts Catalog

7-1

5060-XXX

Assembly 1: Covers

7-2 Service Manual

5060-XXX

Assembly 1.0: Covers

AsmIndex Part number Units Description

1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 NS NS NS NS

12G6410 12G6507 12G6506 12G6319 12G6409 12G6389 12G6396 12G6356 12G6393 12G6405 12G6411 12G6394 12G6357 12G6391 12G6388 12G6412 12G6404 12G6402 12G6344 12G6345 12G6399 12G6397 56P0170 12G6380 12G6491 12G6347

1 1 1 1 1 1 1 1 1 1 3 1 2 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1

Top Cover Assembly 250 Output Flag Bin Full Sensor Cable, Options - Stacker Redrive Cap Cover Assembly Top Front Support Bracket Right Rear Cover Screw, PP 12G6530 Lower Right Door Assembly Right Front Cover Screw, PP 12G6309 Front Right Light Shield Cover Screw, PP 12G6530 Front Right Handle Cover Assembly Front Lower Right Cover Front Cover Assembly Paper Path Access Door Screw, PP 12G6309 Front Lower Left Cover Front Left Handle Cover Assembly Left Front Light Shield Cover Operator Panel Bezel with Logos Operator Panel Assembly, Low Volt Operator Panel Assembly, High Volt Front Upper Pivot Cover Screw, PP 12G6532 Front Access Door Support Paper Tray Guide Machine Pad Jam Access Door Spring Front Hold Down Bellcrank

Parts Catalog

7-3

5060-XXX

Assembly 1.1: Covers

7-4 Service Manual

5060-XXX

Assembly 1.1: Covers

AsmIndex Part number Units Description

1.1-1 2 3 4 5 6 7 8 9 10 11 NS NS NS NS NS NS NS NS NS

12G6408 12G6392 12G6398 12G6395 12G6400 12G6390 12G6401 12G6340 12G6358 12G6360 12G6339 12G6510 12G6511 12G6485 12G6386 12G6387 12G6383 12G6384 12G6385

1 11 1 1 1 1 1 1 1 1 1 1 6 2 1 1 2 2 2 1

Left Upper Cover Assembly Screw, PP 12G6309 Left Upper Pivot Cover Left Lower Pivot Cover Lower Jam Access Door Assembly Waste Container Door Rear Cover Rear Fan Cover Fuser Top Duct Fuser Bottom Duct Fuser Wall Duct Blank, TLI/SN Label Cable Tie Cable Mount Lower Access Jam Door Assembly Duplex Actuator Arm Ground Cable Fuser Latch Slide Fuser Latch Slide Spring #58 Gear

Parts Catalog

7-5

5060-XXX

Assembly 2: Fuser

AsmIndex

Part Number

Units

Description

2-1 1 NS NS 2 2 3 3

12G6301 12G6302 12G6514 12G6515 12G6337 12G6341 12G6338 12G6342

1 1 1 1 1 1 1 1

Fuser Assembly 115V 500W Fuser Assembly 220V 500W Fuser Assembly, WEB Oiler 115V 500W Fuser Assembly, WEB Oiler 220V 500W Fuser Lamp, 115V 500W Hot Roll Fuser Lamp, 220V 500W Hot Roll Fuser Lamp, 115V 400W Backup Roll Fuser Lamp, 220V 400W Backup Roll

7-6 Service Manual

5060-XXX

Assembly 2.1: Fuser

AsmIndex

Part Number

Units

Description

2.1-1 2 NS

12G6414 12G6545

1 4 1

Fuser Drive Assembly Screws PP 12G6309 WEB Oiler Assembly

Parts Catalog

7-7

5060-XXX

Assembly 3: Vacuum Belt Transport Assembly

AsmIndex

Part Number

Units

Description

3-1 2 3

12G6489 12G6488 12G6428

1 1 1

Vacuum Belt Transport Assembly Transfer Plate Assembly Second Transfer Roll

7-8 Service Manual

5060-XXX

Assembly 4: Printheads

AsmIndex

Part Number

Units

Description

4-1 2 3 4 NS NS

12G6322 4 12 12 12G6523 12G6535 12G6536 4 4 4

Printhead Assembly Screw, PP 12G6534 Screw, PP 12G6539 PSD Assembly Guide Assembly, Cartridge Left Side Guide Assembly, Cartridge Right Side

Parts Catalog

7-9

5060-XXX

Assembly 5: Paper Feed Output (Redrive)

7-10 Service Manual

5060-XXX

Assembly 5: Paper Feed Output (Redrive)

AsmIndex Part number Units Description

5-1 2 3 4 5 6 7 8 9

56P0107 12G6493 12G6492 12G6355 12G6513 12G6512 12G6485

1 2 2 1 1 1 1 2 1

Anchor, Bracket Mounting Upper Door Hinge Screw, PP 12G6533 Redrive Assembly Redrive Door Lower Rear Door Latch Lower Front Door Latch Screw, PP 12G6530 Door Assembly, Jam Access

Parts Catalog

7-11

5060-XXX

Assembly 6: Multipurpose Feeder (MPF)

7-12 Service Manual

5060-XXX

Assembly 6: Multipurpose Feeder (MPF)

AsmIndex Part number Units Description

6-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 NS NS

12G6452 12G6460 12G6453 12G6455 12G6454 12G6457 12G6456 12G6461 12G6458 12G6459 12G6462 12G6463 12G6465 12G6464 12G6451 12G6354 12G6447 12G6346 12G6450 12G6449 12G6448

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

MP Feeder Door Cover Door Hinge Restraint Screw, PP 12G6533 Frame Bias Latch Frame Bias Latch Cover Screw, PP 12G6533 Frame Bias Spring MPD Support Bracket Cover Sensor Mount Bracket Paper Out/Low Sensor MPF Support Bracket Spring MPF Support Bracket MPF Bracket Assembly MPF Drive Gear MPF Drive Gear Bushing MPF Drive Gear Shaft MPF Autocompensator Pick Assembly Rib Housing Friction Buckler Buckler Housing MPF Door Assembly MPF Cable Cover MPF Cable

Parts Catalog

7-13

5060-XXX

Assembly 7: 500-Sheet Integrated Tray

7-14 Service Manual

5060-XXX

Assembly 7: 500-Sheet Integrated Tray

AsmIndex Part number Units Description

7-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

12G6416 12G6419 12G6418 12G6424 12G6423 12G6422 12G6538 12G6425 12G6426 12G6568 12G6421 12G6420 12G6417 99A0120

1 1 1 1 3 1 10 1 1 1 1 1 1 1 2

500-Sheet Tray Assembly Back Restraint Latch Back Restraint Size Sensing Gear Cover Size Sensing Gear Size Sensing Barrel Cam Screw, M 3x5mm Tray Bias Bellcrank Assembly Screw, PP 12G6533 Tray Bias Spring Reflector Label Wear Strip Tray Wear Clip Side Restraint Restraint Pad

Parts Catalog

7-15

5060-XXX

Assembly 8: Autocompensator Assembly

AsmIndex

Part Number

Units

Description

8-1 2 3 4 5 6 7 8 NS NS NS NS NS NS

12G6474 12G6471 12G6558 12G6557 12G6427 99A0070 12G6475 12G6473 12G6476 12G6461 12G6478 56P0551 56P0552 12G6472

1 1 1 1 1 2 1 1 1 1 1 1 1 1

Transparency Sensor Tray Interlock Bellcrank Pick Arm Lift Bellcrank Bellcrank Lift Spring Pick Assembly 500-Tray Pick Rolls Transparency Lift Arm Transparency Lift Link Paper Level Sensing Assembly Sensor, Paper Out/Low Flag, Paper Out/Low Cable, Paper Media Low/Out Cable, Pick Motor Extension Tray Interlock Bracket

7-16 Service Manual

5060-XXX

Assembly 9: ITU Assembly

AsmIndex

Part Number

Units

Description

9-1 2 3 4 NS NS

12G6300 12G6518 56P0568 12G6443 12G6413

1 1 1 1 2 1

ITU Assembly ITU Motor Drive Assembly Screw, PP 12G6309 ITU Drive Motor ITU Bias Spring ITU Light Shield Assembly

Parts Catalog

7-17

5060-XXX

Assembly 9.1: ITU Assembly

7-18 Service Manual

5060-XXX

Assembly 9.1: ITU Assembly

AsmIndex Part number Units Description

9.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

12G6446 12G6442 56P0180 12G6353 12G6434 12G6444 12G6438 12G6437 12G6435 56P0172 56P0171 56P0173 56P0182 12G6436 12G6445 56P0181 12G6439 12G6440 12G6441

1 4 4 4 8 3 3 2 3 3 2 2 2 1 1 1 1 1 1 1

Yellow Terminal Contact Assembly Terminal, Contact Spring Screw PP 12G6533 FTR Spring Cartridge Support Roller Rear V Block Guide Rear Transfer Bellcrank BOR Spring, Yellow Front Transfer Bellcrank Front V Block Guide BOR Spring, Cyan BOR Spring, Magenta BOR Spring, Black Front V Block Guide, Black ITU Black Transfer Front Bellcrank TFR Rear Bellcrank, Black Rear V Block Guide, Black Black Terminal Contact Assembly Magenta Terminal Contact Assembly Cyan Terminal Contact Assembly

Parts Catalog

7-19

5060-XXX

Assembly 10: Cartridge Contact Assembly

7-20 Service Manual

5060-XXX

Assembly 10: Cartridge Contact Assembly

AsmIndex Part number Units Description

10-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

56P0310 12G6374 12G6372 12G6375 12G6362 12G6371 12G6363 12G6378 12G6367 12G6366 12G6368 12G6370 12G6369 12G6365 12G6379 12G6364 12G6373 12G6377 12G6376

1 8 1 1 1 6 1 1 1 1 1 1 1 1 1 1 2 4 1 1

Cartridge Contact Assembly, Complete Developer Pin Spring Plug Spring Toner Level Spring Spring Toner Plug Contact Pin Housing, Cartridge Contacts Cartridge Support Roller TAR Contact Developer Roll Contact Doctor Blade Contact Charge Roll Contact PC Drum Contact Cap, Developer Contacts Smart Chip Cable Assembly Cleaner Contacts Cap Screw, PP 12G6309 Cleaner Pin Spring Rear Hold Down Bellcrank Rear Hold Down Spring

Parts Catalog

7-21

5060-XXX

Assembly 11: Electronics

7-22 Service Manual

5060-XXX

Assembly 11.0: Electronics

AsmIndex Part number Units Description

11-1

11A9095

Power Cord Set U.S., Canada (LV), Brazil (LV), Colombia (LV), Costa Rica (LV), Dominican Republic (LV), Equador (LV), El Salvador (LV), Guatemala (LV), Honduras (LV), Nicaragua (LV), Panama (LV), Venezuela (LV), Puerto Rico (LV), Virgin Islands (LV) Mexico (LV), Asia Pacific (english) LV, Japan (LV), Taiwan (LV), Saudi Arabia (LV), Power Cord Set PRC (HV) Power Cord Set Bolivia (HV), Peru (HV) Power Cord Set Kuwait (HV), Bahrein (HV), Qatar (HV), UAE (HV), OMAN (HV) Pakistan (HV), Yemen (HV), Iraq (HV), Libya (HV), Cyprus (HV), UK (HV), Ireland (HV) Power Cord Set Brazil (HV), Paraguay (HV), Uruguay (HV), African Countries Denmark (HV), Austria (HV), Czech (HV) Slovak countries (HV), Greece (HV), Hungary (HV), Finland (HV), Norway (HV), Sweden (HV), France (HV), Belgium (HV), Netherlands (HV), Germany (HV), Italy (HV), Lebanon (HV), Syria (HV), Egypt (HV), Jordan (HV), Iran (HV), Euro English (HV), Albania (HV), Bosnia (HV), Bulgaria (HV), Croatia (HV), Slovenia (HV), Macedonia (HV), Yugoslavia (Serbia and Montenegro) (HV), Romania (HV), Iceland (HV) Poland (HV), Russia (HV), Turkey (HV), CIS (HV), Spain (HV), Catalan (HV), Portugal (HV), Power Cord Set Israel (HV) Power Cord Set Switzerland HV (French/German and Italian) Power Cord Set South Africa (HV), Namibia (HV), Lesotho (HV), Botswana (HV) Power Cord Set Chile (HV) Power Cord Set Denmark, (HV) Power Cord Set Argentina (HV) LVPS, 115V LVPS, 220V Screw, PP 12G6540 Screw BOR Housing Assembly with motor WEB Oiler Index Drive Assembly

1 1 1

43H5544 1339517 1339519

1 1 1

1339520

1 1 1 1 1 1 2 2 3 4 5 6

1339521 1339522 1339523 1339524 1339525 1339544 12G6329 12G6330

1 1 1 1 1 1 1 1 8 2

12G6446 12G6543

1 1

Parts Catalog

7-23

5060-XXX

Assembly 11.1: Electronics

7-24 Service Manual

5060-XXX

Assembly 11.1: Electronics

AsmIndex Part number Units Description

11.1-1 2 3 4 5 6 7 7 8 9 10 11 12 13 NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS 12G6331 12G6325 12G6334 12G6326 12G6335 56P9910 12G6509 12G6324 99A1611 99A0408 99A2432 12G6333 12G6332 99A0426 12G6310 12G6311 12G6312 12G6313 12G6314 12G6315 12G6316 12G6317 12G6318 12G6319 12G6320 12G6321 12G6349 12G6350 12G6351 12G6379 12G6387 12G6448 12G6503 12G6504 56P0311 56P0554

22 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Screw, PP 12G6309 RIP Board Ground Shield RIP Board Assembly - Network, Model 5060-002 INA Riser Support Bracket Riser Card Assembly w/o Support Brackets Standoff, INA RIP Spacer SDRAM DIMM 128MB SDRAM DIMM 64MB RIP Board Assembly, Non-Network, Model 5060-001 Ethernet Blank Shield, use with Non-Network RIP Boards INA Blank Flat Shield, use when options are not installed Blank Parallel Shield, use with network RIP Boards RIP Board Shield Assembly RIP Board Cover Shield Screw, Parallel Connector Mounting Cable, Video Printhead - Y Cable, Video Printhead - C Cable, Video Printhead - M Cable, Video Printhead - K Cable, LEXPSD -YC Cable, LEXPSD - MK Cable, HVPS Control - Developer Cable, HVPS Control - Transfer Cable, RIP-Engine, Comm and CT. Cable, Options - Stacker Cable, Options - Bottom Cable, Operator Panel Cable, Fuser and Y Cartridge Motor Cable, C and M Cartridge Motor Cable, ITU and K Cartridge Motor Cable, Smart Chip Cable, Ground Cable, MPF Paper Level Cable, Printhead Interlock/Cover Open Cable, HVPS Interlock/Cover Open Cable, ITU/Machine Autoconnect Cable, Printhead Control, HSYNC/Mirror Motor

Parts Catalog

7-25

5060-XXX

Assembly 11.2: Electronics

7-26 Service Manual

5060-XXX

Assembly 11.2: Electronics

AsmIndex Part number Units Description

11.2-1 2 3 4 5 6 NS NS NS NS NS

12G6327

1 1 1

HVPS Transfer Board Screw, PP 12G6309 Screw, PP 12G6530 Standoff, High Voltage Power Supply - Developer Screw, PP 12G6540 HVPS Developer Board Contact Assembly, Black Terminal Contact Assembly, Magenta Terminal Contact Assembly, Cyan Terminal Contact Assembly, Yellow Terminal Terminal, Contact Spring

12G6541 12G6328 12G6339 12G6340 12G6341 12G6546 12G6442

4 4 1 1 1 1 1 1

Parts Catalog

7-27

5060-XXX

Assembly 11.3: Electronics

AsmIndex

Part Number

Units

Description

11.3-1 2 3 4 5

12G6336 12G6323 12G6387

1 12 1 1 14

Engine Board Shield Screw, PP 12G6531 Engine Board Ground Strap Screw, PP 12G6309

7-28 Service Manual

5060-XXX

Assembly 11.4: Electronics

AsmIndex

Part Number

Units

Description

11.4-1 2 3 4 5 6 NS

12G6343 12G6361 12G6479 12G6382 12G6529 12G6490

1 1 2 1 1 2 1

RIP Fan Duct RIP Fan Screws, PP 12G6530 VTB Fan Fuser Fan Screws, Fuser Fan Mounting VTB Fan Gap Cover

Parts Catalog

7-29

5060-XXX

Assembly 11.5: Electronics

AsmIndex

Part Number

Units

Description

11.5-1 2 3 4 5 6 7 NS NS

12G6494 12G6470 12G6469 12G6467 12G6468 12G6466 12G6472 12G6505

1 1 1 4 1 1 4 1 1

Waste Toner Container Waste Container Latch Spring Waste Container Latch Paper Size Sensing Spring Paper Size Sensing Bracket Screw, Paper Size Sensing Assembly Mounting PP 12G6531 Paper Size Sensing Link Bracket Tray Interlock Waste Toner Full Sensor

7-30 Service Manual

5060-XXX

Assembly 11.6: Electronics

AsmIndex

Part Number

Units

Description

11.6-1 2 3 4 5

12G6480

1 2 4

Registration Motor Assembly Screw, PP 12G6533 Screw, PP 12G6530 Cartridge Drive Assembly, Cyan/Magenta/Black Cartridge Drive Assembly, Yellow

12G6526 12G6527

3 1

Parts Catalog

7-31

5060-XXX

Assembly 12: Output Expander

7-32 Service Manual

5060-XXX

Assembly 12.0: Output Expander

AsmIndex Part number Units Description

12-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

99A0107 99A0104 99A0369 99A0052 56P0407 99A0915 56P0409 99A1817 99A1688 99A1689 99A0482 99A0481 99A1784 99A0415 56P0408 56P0402 56P0401 99A0409 99A1580 99A0414

1 1 1 1 1 1 9 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1

Deflector, Upper Redrive Also order 99A0104 Spring, Upper Diverter Shaft Assembly, Exit Also order PP 99A0572 Shaft Assembly, Lower Exit Also order PP 99A0572 Shield, Output Option Card Board, Output Expander DC motor Screw, PP 56P0167 Cover, Front Control Board Tray, Output Expander Diverter Arm Spring Clutch Assembly Spring, Output Tray Latch, Output Tray Shaft Bearing PP 99A0572 Bracket, Attach Spring, Swing Arm Output Expander Assembly, Mechanical Linkage Cover, Rear Support Rear Cover Level Sensor Bracket Flag, Output Paper Level Sensor, Dual Bin Full

Parts Catalog

7-33

5060-XXX

Assembly 12.1: Output Expander

7-34 Service Manual

5060-XXX

Assembly 12.1: Output Expander

AsmIndex Part number Units Description

12.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NS

56P0405 99A0368 99A0363 56P0410 56P0400 99A0361 99A0362 99A0364 99A0482 99A0481 99A0912 99A0351 99A0913 99A1744

1 1 3 2 11 1 1 1 1 1 1 1 1 3 1 1

Door Assembly, Right Jam Access Shaft Assembly, Lower Also order PP 99A0572 Pulley, Drive Bracket, Attach Screw, PP 56P0167 Cover, Front Belt, 160 Gear Arm Assembly, Belt Idler Spring, Belt Tensioner Spring, Output Tray Latch, Output Tray Frame Assembly Sensor, Output Expander Pass Thru Shaft Bearing PP 99A0572 Shaft Assembly, Middle 40T Also order PP 99A0572 Kit, Stacker Assembly

Parts Catalog

7-35

5060-XXX

Assembly 13: 5-Bin Mailbox

7-36 Service Manual

5060-XXX

Assembly 13.0: 5-Bin Mailbox

AsmIndex Part number Units Description

13-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

99A1512 99A1710 56P0416 56P0423 99A0104 56P0411 56P0422 56P0415 99A1723 99A1724 99A1708 99A1725 99A1742 99A1712 56P0420 99A1743 99A1713 99A1687 99A1735 56P0412 99A1736 99A1737 99A1718 99A1716 56P0417 99A1740 99A1726 99A1786 99A1719 56P0413

1 1 1 1 1 1 1 1 4 1 1 1 2 5 1 1 1 5 5 4 1 5 5 1 1 1 1 1 1 1 12 1

Cover, Redrive Cap Cover, Wire Cover, Top Bin Latch, Rear Access Door Spring, Upper Diverter Door, Front Latch, Access Door Front Cover, Right Shaft Asm, Drive Shaft Asm, Drive with Gear Cover, Right Side Packet, Drive Shaft Bushing Sensor, 5-Bin Mailbox Pass thru Tray, Paper Cap Bracket Asm, Bail Attach Kit, 5-Bin Mailbox Asm Bail, order 99A1743, 5-Bin Mailbox Asm Kit Support, Paper Tray Stop Asm, Paper Tray Flag, Bin Full Rear Structural Cover Cable, Dual Sensor Sensor, Dual Paper Height Cable Asm, Lower Auto Connect Drive Asm, Main DC Drive Flag, Bin Full Board Asm, 5-Bin Mailbox System Frame Asm, Left w/Clutch Asm Gear, Drive Cable Asm, Upper Auto Connect Screw, Board Mounting PP 99A0263 Cover, Left Side

Parts Catalog

7-37

5060-XXX

Assembly 13.1: 5-Bin Mailbox

7-38 Service Manual

5060-XXX

Assembly 13.1: 5-Bin Mailbox

AsmIndex Part number Units Description

13.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 NS NS NS NS NS NS NS

99A1741 99A1727 99A1728 99A1731 99A1729 99A1730 99A1789 56P0418 99A1732 99A1738 99A1722 99A1787 99A1721 99A1734 99A0462 99A1715 99A1717 99A1788 99A0450 56P0550

4 1 12 4 4 4 4 4 1 4 5 4 4 1 1 1 1 1 1 10 1

Spring, Diverter Frame Asm, Right Side Screw, Board Mounting PP 12G6309 Cam, Diverter Actuator Spring, Diverter Actuator Latch, Diverter Actuator Arbor, Diverter Actuator C-clip Bracket, Attach Front Solenoid, Diverter Deflector, Paper Exit w/Brush Deflector, Paper Deflector Deflector, Paper Top Bin Spring, Static Ground Grease Packet, IBM #23 Roller Asm, Rear Access Door Gear, Drive Retainer, R-Ring Retainer Cable, Tray Media Level Sensor

Parts Catalog

7-39

5060-XXX

Assembly 14: 500-Sheet Tray Option

7-40 Service Manual

5060-XXX

Assembly 14.0: 500-Sheet Tray Option

AsmIndex Part number Units Description

14-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 NS

56P0168 12G6550 12G6565 12G6471 12G6556 12G6553 12G6562 12G6559 12G6558 12G6566 12G6557 12G6560 12G6380 56P0169 12G6554 12G6563 12G6552 12G6561 12G6555 12G6567 12G6475 12G6473 12G6474 99A0070 12G6564 12G6510

1 1 1 1 1 1 1 1 1 1 1 1 1 7 1 1 1 1 1 1 1 1 1 1 2 1 4

Drive Assembly, 500 Option 2 Screw, PP 12G6309 500 Option Tray Pick Assembly Paper Level Sensing Assembly Tray Interlock Bellcrank Cover, Frame Pass Thru Sensor Hinge Electronics/Size Sensing Assembly with System Board Pick Arm Lift Bellcrank Paper Size Sensing Assembly Bellcrank Lift Spring 500 Base Assembly Machine Pad Plate, 500 Support Assembly Paper Guide Wall Support plate Base Door Assembly Spring 500 Option Deflector Grounding Spring Transparency Sensor Arm Transparency Lift Link Transparency Sensor Pick Arm Roll Assembly Transparency Sensing Assembly Cable Tie

Parts Catalog

7-41

5060-XXX

Assembly 14.1: 500-Sheet Tray Option

7-42 Service Manual

5060-XXX

Assembly 14.1: 500 Sheet Tray Option

AsmIndex Part number Units Description

14.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

12G6416 12G6419 12G6418 12G6424 12G6423 12G6422 12G6538 12G6425 12G6426 12G6568 12G6421 12G6420 12G6417 99A0120

1 1 1 1 3 1 10 1 1 1 1 1 1 1 2

500-Sheet Tray Assembly Back Restraint Latch Back Restraint Size Sensing Gear Cover Size Sensing Gear Size Sensing Barrel Cam Screw, M 3x5mm Tray Bias Bellcrank Assembly Screw, PP 12G6533 Tray Bias Spring Reflector Label Wear Strip Tray Wear Clip Side Restraint Restraint Pad

Parts Catalog

7-43

5060-XXX

Assembly 15: Duplex Unit

7-44 Service Manual

5060-XXX

Assembly 15.0: Duplex Unit

AsmIndex Part number Units Description

15-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 NS

56P0480 99A2540 56P0447 56P0434 56P0483 56P0432 56P0457 56P0455 56P0442 56P0435 56P0479 56P0444 56P0476 56P0473 56P0439 56P0454 56P0475 56P0472 56P0441 56P0468 56P0470 56P0466 56P0467 99A0267 56P0471 56P0474 56P0445 56P0449 56P0482

1 5 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1

Back Cover Redrive Bearing Duplex Entry Shaft Assembly Screw PP 12G6533 Right Side Front Tray Guide Deflector Actuator Assembly Duplex Front Jam Tray Assembly Duplex Support Bracket Sensor Mount Plate Duplex Exit Sensor Duplex Shaft Mount Front Decurl Assembly F/R Backup Shaft Assembly 5mm Bushing Brake Pad Duplex Paper Guide Wall Support Brake Spring Pass Thru Shaft Assembly Duplex Shaft Assembly Pass Thru Spring Aligner Arm Spring Spur Drive Gear 26T Duplex Gear Retainer Parts Packet 99A0267 Bellcrank Assembly Decurl BAC Assembly 40T Shaft Drive F/R Gear Support Decurl Guide Pulley Washer

Parts Catalog

7-45

5060-XXX

Assembly 15.1: Duplex Unit

7-46 Service Manual

5060-XXX

Assembly 15.1: Duplex Unit

AsmIndex Part number Units Description

15.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NS

56P0456 56P0462 56P0463 56P0464 56P0459 56P0430 56P0458 56P0433 99A1789 56P0478 99A0323 56P0465 56P0477 56P0451 99A1717 56P0452 56P0436 56P0437 99A0323

1 1 1 1 1 1 1 1 1 1 2 2 2 1 3 2 3 1 1 2

Duplex Support Plate Autoconnect Cable Assembly DC Forward/Reverse Motor Assembly DC Duplex Feed Motor Screw PP 12G6309 Back Support Duplex Card Assembly Chassis Ground Spring Right Jam Clearance Tray Assembly Retainer, C - Clip Aligner Spring Paper Guide Assembly Drive Alignment Shaft Assembly Reduction Gear Shaft Backup Spring Assembly 32PPM Drive Gear Backup Spring Assembly Upper RIB Assembly Duplex Output Sensor Paper Guide Assembly

Parts Catalog

7-47

5060-XXX

Assembly 16: HCIT

7-48 Service Manual

5060-XXX

Assembly 16.0: HCIT

AsmIndex Part number Units Description

16-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

56P0561 56P0519 56P0520 56P0518 56P0522 56P0516 56P0511 56P0494 56P0495 56P0513 56P0497 56P0498 56P0490 56P0524 56P0547 56P0549 56P0563 56P0548 56P0523 56P0525 56P0527 56P0533 56P0534 56P0562 56P0542 56P0529 56P0528 56P0530 56P0532 56P0544 56P0535 56P0526 56P0536 56P0540 56P0539

1 1 1 1 3 10 1 1 1 1 1 1 1 1 1 1 3 1 2 1 2 1 1 1 2 2 2 2 1 2 5 2 1 1 1

Paper Size Sensor Box Assembly Flag, Paper Size R Flag, Paper Size F Flag, Paper Size C Spring, Paper Size Flag Sensor, Photo Interrupter Paper Size Sensors Cable System Control Board Screws PP56P0565 LVPS Elevator Motor Assembly AC Power Outlet AC Power Inlet Jumper, AC Power Cord Paper Tray Guide Elevator Lift Belt Elevator Lift Ring 7, Elevator Lift Gear/Elevator Lift Elevator Lift Gear Paper Tray Arms Feed Unit, Complete Assembly Bushing Spring, Feed Unit Front Spring, Feed Unit Rear Feed Cover Separation/Torque Roller Feed Cam E-Clips PP 56P0531 Feed Roller Spring, Feed Unit Bushing, 060 Emitter Timing Wheel Clip, Plastic 5W Sensors, Special Optical Level Sensor Flag Spring, Extension Near Empty Sensor Flag

Parts Catalog

7-49

5060-XXX

Assembly 16.1: HCIT

7-50 Service Manual

5060-XXX

Assembly 16.1: HCIT

AsmIndex Part number Units Description

16.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 NS NS NS NS NS NS

56P0505 56P0503 56P0491 56P0493 56P0500 56P0501 56P0492 56P0504 56P0508 56P0507 56P0506 56P0514 56P0517 56P0509 56P0510 56P0512 56P0515 56P0541 56P0543

1 1 2 16 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1 9

Rear Cover Right Side Cover Caster, Movable Screws PP 56P0565 F Adjuster Front Cover Cover, Main CA Caster, Fixed Left Side Cover Upper Left Side Jam Cover Locating Pin, Options Front Right Locating Pin, Options Rear Left Options Autoconnect Cable Assembly Options Cable Mounting Plate Cable, Feed Unit Special Sensors Cable, Feed Unit Sensors Cable, Elevator Motor Magnetic Latch Tray Present Lever Cable Clamp

Parts Catalog

7-51

5060-XXX

Assembly 17: Finisher

7-52 Service Manual

5060-XXX

Assembly 17.0: Finisher

AsmIndex Part number Units Description

17-1 2 3 4 5 6 7 8 9 10 NS

56P0321 56P0569 56P0573 56P0574 56P0575 56P0576 56P0387 56P0577 56P0320 56P0566 56P0317

1 1 1 1 1 1 1 1 1 1 1

Top Cover Rear Cover Upper Right Side Cover Lower Tray Cover Bottom Kick Cover Front/Rear Lower Cover Bar Tip Unit Lower Right Side Cover Cover Front Door Finisher Install Kit Cartridge Staple

Parts Catalog

7-53

5060-XXX

Assembly 17.1: Finisher

7-54 Service Manual

5060-XXX

Assembly 17.1: Finisher

AsmIndex Part number Units Description

17.1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS

56P0324 56P0357 56P0339 56P0325 56P0334 56P0332 56P0315 56P0345 56P0318 56P0328 56P0383 56P0347 56P0342 56P0338 56P0333 56P0323 56P0386 56P0322 56P0326 56P0327 56P0329 56P0330 56P0331 56P0335 56P0336 56P0337 56P0340 56P0341 56P0343 56P0350 56P0351 56P0352 56P0353 56P0354 56P0356 56P0359 56P0360 56P0361 56P0362

1 1 1 1 1 1 1 1 1 1 1 4 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

Motor Assembly Elevator Tray Actuation Assembly HCOF Control Board Assembly Motor Assembly Paper Feed Belt 170P2M4 Belt 40S3M900 Punch Assembly Sensor GP1A73A Box Chad Belt 40S3M198 Solenoid Inverter Sensor EE-SX1235A-P2 Caster Low Voltage Power Supply Belt 60S6M1420 Gear Assembly Offset Motor and Gear Fan Assembly DC Motor Tray Paper Flag Paper Full Belt 40S3M888 Belt 40S3M225 Belt 40S3M279 Belt 40S3M80 Belt 40S2M264 Belt 40S2M176 Belt 40S2M176 Cable Communication Power Cord Sensor OJ-541-A5 Sensor EE-SX460-P1-CHN Switch Cover Open Switch Micro, SS-5FL-3T(10E) Switch Micro, K3-3 Bracket Finisher Alignment Pack Magnet, Strong and Weak and Door Latch Harness Cable Assembly H2 - Engine Board to Drop Solenoid Harness Cable Assembly H3 - Engine Board to Harness Cable Assembly H4/ Drop Timing Sensor/Punch Home Position Sensor/Inverter Timing Sensor Harness Cable Assembly H4 - Harness Cable H3 to Punch Timing Sensor Harness Cable Assembly H5 - Engine Board to Printer Docking Switch

Parts Catalog

7-55

5060-XXX

Assembly 17.2: Finisher

7-56 Service Manual

5060-XXX

Assembly 17.2: Finisher

AsmIndex Part number Units Description

17.2-1 2 3 4 5 6 7 8 9 10 11 12 13 14 NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS

56P0355 56P0385 56P0347 56P0384 56P0332 56P0319 56P0348 56P0349 56P0316 56P0358 99A2575 56P0346 56P0344 56P0330 56P0388 56P0363 56P0364 56P0365 56P0366 56P0367 56P0368 56P0369 56P0370 56P0371 56P0372 56P0373 56P0374 56P0375 56P0376 56P0377 56P0378 56P0379 56P0380 56P0381 56P0382

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Guide Vertical Paper Solenoid Drop Assembly EE-SX460-P1-CHN, Jogger Belt Staple Assembly Accumulator Belt Accumulator w/o Stapler Sensor OS-535223-601 Sensor OS-311D-A5 Staple Assembly Accumulator Slides Staple Cartridge Sensor EE-SPY415, Chad Box Full Sensor OJ511K-A5 Paper Feed-Input Belt Switch Assembly Harness Cable Assembly H6 - Engine Board to Fan Harness Cable Assembly S1 - Cable S2 to Stapler Assembly Harness Cable Assembly S2 - Engine Board to Cable S1 Harness Cable Assembly S3 - Engine Board to Jogger Home Position Sensor/ Bundle Belt Home Position Sensor Harness Cable Assembly S4 - Engine Board to Jogger Motor/Bundle Motor Harness Cable Assembly S5 - Engine Board to Chad Box Full Sensor Harness Cable Assembly E2 - Cable E5 to Exit Timing Sensor Harness Cable Assembly E3 - Cable E5 to Paper Surface Upper Sensor/Paper Surface Lower Sensor Harness Cable Assembly E5 - Engine Board to Cable E2/E3 Harness Cable Assembly E6 - Cable E8 to Upper Tray Limit Switch 1/Upper Tray Limit Switch 2 Harness Cable Assembly E7 - Cable E8 to Tray Offset Position Sensor Harness Cable Assembly E8 - Engine Board to E6/E7 Harness Cable Assembly E9 - Cable E10 to Tray Offset Motor Harness Cable Assembly E10 - Engine Board to Cable E9 Harness Cable Assembly E12 - Ground Harness Cable Assembly R1 - Engine Board to Inverter Solenoid/Inverter Jam Sensor Harness Cable Assembly D1 - Engine Board to Front Door Switch Harness Cable Assembly D2 - Engine Board to Low Voltage Power Supply Harness Cable Assembly D3 - Low Voltage Power Supply Relay Board to AC Input/Output Harness Cable Assembly D5 - Low Voltage Power Supply to Low Voltage Power Relay Board

Parts Catalog

7-57

5060-XXX

Assembly 18: Options

AsmIndex Part number Units Description

18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18

56P9908 56P9909 12G6509 56P9910 56P9911 56P9912 56P9913 56P9914 56P9917 56P9935 56P9936 56P0162 56P9938 56P9939 56P9926 56P9927 56P9928 56P9929 56P9930 56P9932 56P9942 56P9934 12G1695 12G1696 99A0545 99A0560 99A0629 99A0424 56P0161 99A0923 56P9906 56P9908 56P9909

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Card Assembly, Bar Code Card Assembly, Prescribe Card Assembly, 64MB SDRAM Card Assembly, 128MB SDRAM Card Assembly, 256MB SDRAM Card Assembly, 4MB Flash DIMM Card Assembly, 8MB Flash DIMM Card Assembly, 16MB Flash DIMM Card Assembly, 32MB Flash DIMM Card Assembly, Traditional Chinese Font DIMM Card Assembly, Simplified Chinese Font DIMM Adapter, Parallel 1284 C-B Hard Disk, 5GB or larger with/Adapter (formatted) Hard Disk, 5GB or larger ISP Hard Disk (unformatted) Forms Software Forms Director Software Lexmark Forms 4MB DIMM Lexmark Forms 8MB DIMM Lexmark Forms 16MBMB DIMM Lexmark Forms 64MB DIMM Hard Drive Mounting Kit MarkNet Token Ring Print Server MarkNet N2001e Ethernet 10/100BaseTX MarkNet N2002e Ethernet 10BaseT/2 External Serial Adapter Tri-Port Adapter - LocalTalk/Serial/Infrared Coax/Twinax Adapter for SCS Infrared Adapter RS-232-C Serial/Parallel 1284-C Adapter Parallel Port + USB INA Card Assembly Card Assembly IPDS/SCS/Tne Card Assembly, Barcode Card Assembly, Prescribe

7-58 Service Manual

5060-XXX

Assembly 19: Miscellaneous

AsmIndex Part number Units Description

19 19 19 19 19 19 19 19 19

1 1 1 1 1 1 1 1 1

Screw Type 323, PP 12G6309 Screw Type 324, PP 12G6530 Screw Type 232, PP 12G6531 Screw Type 102, PP 12G6532 Screw Type 312/322/412/423, PP 12G6533 Screw Type 484, PP 12G6534 Screw, 500-Sheet Tray, PP 12G6538 Screw Type 124, PP 12G6539 Screw Type 121, PP 12G6540

Parts Catalog

7-59

5060-XXX

7-60 Service Manual

5060-XXX

Index
A
Acronyms Diagnostics Error Code Table 2-7 Service Checks 2-48 Sub Error Code Table 2-19 Symptom Table - Base Printer 2-2 Symptom Table - Finisher Option 2-6 Symptom Table - HCIT 2000 Sheet Option 2-4 Symptom Table - Output Expander Option 2-5 Symptom Table - 5-Bin Mailbox Option 2-5 Symptom Table - 500 Sheet Drawer Option 2-4 System Board LED Error Code Table 2-22 User Attendance Message Table 2-28 2XX Paper Jam Message Table 2-24 Disk Test/Clean 3-7 Duplex Tests 3-8

1-17

B
Base Sensor Test 3-17 Button Test 3-10

C
Connector Locations Engine Board 5-1 Fuser Connectors 5-20 HCIT 2000 Sheet Board 5-21 HVPS 5-24 HVPS Developer Board 5-26 LVPS 5-18 RIP Board 5-11

E
Error Log 3-9 ESD-Sensitive Parts 4-1

D
Diagnostic Aids Device Tests 3-7 Disk Test/Clean 3-7 Flash Test 3-8 Quick Disk Test 3-7 Diagnostic Mode 3-6 Duplex Tests 3-8 Duplex Quick Test 3-8 Duplex Sensor Test 3-9 Error Log 3-9 Clearing the Error Log 3-9 Viewing the Error Log 3-9 Hardware Tests 3-10 Button Test 3-10 LCD Test 3-10 Parallel Wrap Test 3-11 ROM Memory Test 3-11 SDRAM Memory Test 3-10 Serial Wrap Test 3-12 Input Tray Tests 3-13 Input Tray Feed Test 3-13 Paper Feed Tests Base Sensor Test 3-17 Input Tray Sensor Test 3-13 Output Bin Feed Test 3-15 Output Bin Sensor Test 3-15 Output Bin Test - Standard Bin 3-15 Output Bin X Sensor Test 3-16 5-Bin Mailbox Diverter Test 3-17 Print Registration 3-22 Diagnostic Mode 3-6

F
Flash Test

3-8 3-10

H
Hardware Tests

I
Input Tray Feed Test 3-13 Input Tray Sensor Test 3-13

L
Laser Notices iv-ix LCD Test 3-10 Lubrication Specifications 6-1

M
Maintenance, Scheduled

6-2 iv-ix

N
Notices and Safety Information

O
Output Bin Feed Test 3-15 Output Bin Sensor Test 3-15 Output Bin Test - Standard Bin 3-15 Output Bin X Sensor Test 3-16

I-1

5060-XXX

P
Parallel Wrap Test 3-11 Parts Catalog Autocompensator Assembly 7-16 Cartridge Contact Assembly 7-20 Covers 7-2 Duplex Unit 7-44 Electronics 7-22 Finisher 7-52 Fuser 7-6 HCIT 7-48 ITU Assembly 7-17 Miscellaneous 7-59 Multipurpose Feeder (MPF) 7-12 Options 7-58 Output Expander 7-32 Paper Feed Output (Redrive) 7-10 Printheads 7-9 Vacuum Belt Transport Assembly 7-8 5-Bin Mailbox 7-36, 7-37 500-Sheet Integrated Tray 7-14 500-Sheet Tray Option 7-40 POR (Power On Reset) Sequence 2-1 Printhead Adjustment Procedures 4-1

Lower Right Door Assembly 4-18 LVPS 4-15 Multipurpose Feeder (MPF) 4-33 Operator Panel 4-26 Outer EMC Shield 4-10 Paper Path Access Door Cover/Front Lower Left Cover 4-32 Paper Size Sensing Assembly 4-42 Printheads 4-34 PSD Sensor Assembly 4-36 Rear Cover 4-12 Rear Fan Cover 4-13 Redrive Assembly 4-37 Redrive Door 4-21 RIP Board 4-10 RIP Board Shield Assembly 4-38 RIP Fan 4-37 Second Transfer Roll 4-43 Top Cover Assembly 4-22 VTB Fan 4-39 Waste Container Door 4-33 Waste Container Latch 4-42 ROM Memory Test 3-11

S
Safety Information iv-xii Safety Inspection Guide 6-1 Scheduled Maintenance 6-2 Screw Identification Table 4-4 SDRAM Memory Test 3-10 Serial Wrap Test 3-12 Service Checks 2-48 AC & DC Power 2-56 Autocompensator 2-106 Cartridge Drive Assembly 2-49 Close Door/HVPS/Printhead Interlock Switch

Q
Quick Disk Test

3-7

R
Removals BOR Housing Assembly 4-43 Cartridge Contact Assembly 4-44 Cartridge Drive Assembly (Cyan, Magenta, Black) 4-28 Cartridge Drive Assembly (Yellow) 4-28 Engine Board 4-14 Engine Board Shield 4-41 Front Cover Assembly 4-22 Front Left Handle Cover Assembly 4-31 Front Right Handle Cover Assembly 4-30 Fuser Assembly 4-16 Fuser Bottom Duct 4-19 Fuser Drive Assembly 4-17 Fuser Fan 4-14 Fuser Top Duct 4-18 Fuser Web Oiler Motor Assembly 4-19 HVPS Developer Board 4-39 HVPS Transfer Board 4-12 ITU Assembly 4-41 ITU Drive Assembly 4-40 ITU Drive Motor 4-40 Left Lower Cover 4-34 Lower Jam Access Door Assembly 4-31

2-114
Cover Open/HV Interlock Switch 2-102 Duplex Option 2-123 Fans 2-54 Finisher 2-131 Fuser 2-95 HCIT 2000 Sheet Option 2-126 ITU Drive Motor 2-89 Multipurpose Feeder (MPF) 2-109 Operator Panel LCD/Status LED/Buttons Output Expander Option 2-60 Paper Path 2-112 Print Quality 2-72 PSD 2-103 Second Transfer Roll 2-58 Tray 1 2-105 Tray 1 Paper Size Sensing 2-104 100 ITU Error 2-86

2-83

I-2 Service Manual

5060-XXX

5-Bin Mailbox Option 2-66 500 Sheet Drawer Option 2-116 900 Error Code 2-48

Part Numbers
11A9095 7-23 12G1695 7-58 12G1696 7-58 12G6300 7-17 12G6301 7-6 12G6302 7-6 12G6309 7-59 12G6310 7-25 12G6311 7-25 12G6312 7-25 12G6313 7-25 12G6314 7-25 12G6315 7-25 12G6316 7-25 12G6317 7-25 12G6318 7-25 12G6319 7-3, 7-25 12G6320 7-25 12G6321 7-25 12G6322 7-9 12G6323 7-28 12G6324 7-25 12G6325 7-25 12G6326 7-25 12G6327 7-27 12G6328 7-27 12G6329 7-23 12G6330 7-23 12G6331 7-25 12G6332 7-25 12G6333 7-25 12G6334 7-25 12G6335 7-25 12G6336 7-28 12G6337 7-6 12G6338 7-6 12G6339 7-5, 7-27 12G6340 7-5, 7-27 12G6341 7-6, 7-27 12G6342 7-6 12G6343 7-29 12G6344 7-3 12G6345 7-3 12G6346 7-13 12G6347 7-3 12G6349 7-25 12G6350 7-25 12G6351 7-25 12G6353 7-19

12G6354 12G6355 12G6356 12G6357 12G6358 12G6360 12G6361 12G6362 12G6363 12G6364 12G6365 12G6366 12G6367 12G6368 12G6369 12G6370 12G6371 12G6372 12G6373 12G6374 12G6375 12G6376 12G6377 12G6378 12G6379 12G6380 12G6382 12G6383 12G6384 12G6385 12G6386 12G6387 12G6388 12G6389 12G6390 12G6391 12G6392 12G6393 12G6394 12G6395 12G6396 12G6397 12G6398 12G6399 12G6400 12G6401 12G6402 12G6404 12G6405 12G6408 12G6409 12G6410 12G6411 12G6412

7-13 7-11 7-3 7-3 7-5 7-5 7-29 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21 7-21, 7-25 7-3, 7-41 7-29 7-5 7-5 7-5 7-5 7-5, 7-25, 7-28 7-3 7-3 7-5 7-3 7-5 7-3 7-3 7-5 7-3 7-3 7-5 7-3 7-5 7-5 7-3 7-3 7-3 7-5 7-3 7-3 7-3 7-3
I-3

5060-XXX

12G6413 12G6414 12G6416 12G6417 12G6418 12G6419 12G6420 12G6421 12G6422 12G6423 12G6424 12G6425 12G6426 12G6427 12G6428 12G6434 12G6435 12G6436 12G6437 12G6438 12G6439 12G6440 12G6441 12G6442 12G6443 12G6444 12G6445 12G6446 12G6447 12G6448 12G6449 12G6450 12G6451 12G6452 12G6453 12G6454 12G6455 12G6456 12G6457 12G6458 12G6459 12G6460 12G6461 12G6462 12G6463 12G6464 12G6465 12G6466 12G6467 12G6468 12G6469 12G6470 12G6471 12G6472

7-17 7-7 7-15, 7-43 7-15 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-15, 7-43 7-16 7-8 7-19 7-19 7-19 7-19 7-19 7-19 7-19 7-19 7-19, 7-27 7-17 7-19 7-19 7-19, 7-23 7-13 7-13, 7-25 7-13 7-13 7-13 7-13 7-13 7-13 7-13 7-13 7-13 7-13 7-13 7-13 7-13, 7-16 7-13 7-13 7-13 7-13 7-30 7-30 7-30 7-30 7-30 7-16, 7-41 7-16, 7-30

12G6473 12G6474 12G6475 12G6476 12G6478 12G6479 12G6480 12G6485 12G6488 12G6489 12G6490 12G6491 12G6492 12G6493 12G6494 12G6503 12G6504 12G6505 12G6506 12G6507 12G6509 12G6510 12G6511 12G6512 12G6513 12G6514 12G6515 12G6518 12G6523 12G6526 12G6527 12G6529 12G6530 12G6531 12G6532 12G6533 12G6534 12G6535 12G6536 12G6538 12G6539 12G6540 12G6541 12G6543 12G6545 12G6546 12G6550 12G6552 12G6553 12G6554 12G6555 12G6556 12G6557 12G6558

7-16, 7-41 7-16, 7-41 7-16, 7-41 7-16 7-16 7-29 7-31 7-5 7-8 7-8 7-29 7-3 7-11 7-11 7-30 7-25 7-25 7-30 7-3 7-3 7-25, 7-58 7-5, 7-41 7-5 7-11 7-11 7-6 7-6 7-17 7-9 7-31 7-31 7-29 7-59 7-59 7-59 7-59 7-59 7-9 7-9 7-15, 7-43, 7-59 7-59 7-59 7-27 7-23 7-7 7-27 7-41 7-41 7-41 7-41 7-41 7-41 7-16, 7-41 7-16, 7-41

I-4 Service Manual

5060-XXX

12G6559 7-41 12G6560 7-41 12G6561 7-41 12G6562 7-41 12G6563 7-41 12G6564 7-41 12G6565 7-41 12G6566 7-41 12G6567 7-41 12G6568 7-15 1339517 7-23 1339519 7-23 1339520 7-23 1339521 7-23 1339522 7-23 1339523 7-23 1339524 7-23 1339525 7-23 1339544 7-23 43H5544 7-23 56P0161 7-58 56P0168 7-41 56P0169 7-41 56P0170 7-3 56P0171 7-19 56P0172 7-19 56P0173 7-19 56P0180 7-19 56P0181 7-19 56P0182 7-19 56P0315 7-55 56P0316 7-57 56P0317 7-53 56P0318 7-55 56P0319 7-57 56P0320 7-53 56P0321 7-53 56P0322 7-55 56P0323 7-55 56P0324 7-55 56P0325 7-55 56P0326 7-55 56P0327 7-55 56P0328 7-55 56P0329 7-55 56P0330 7-55, 56P0331 7-55 56P0332 7-55, 56P0333 7-55 56P0334 7-55 56P0335 7-55 56P0336 7-55 56P0337 7-55 56P0338 7-55

7-57 7-57

56P0339 7-55 56P0340 7-55 56P0341 7-55 56P0342 7-55 56P0343 7-55 56P0344 7-57 56P0345 7-55 56P0346 7-57 56P0347 7-55, 56P0348 7-57 56P0349 7-57 56P0350 7-55 56P0351 7-55 56P0352 7-55 56P0353 7-55 56P0354 7-55 56P0355 7-57 56P0356 7-55 56P0357 7-55 56P0358 7-57 56P0359 7-55 56P0360 7-55 56P0361 7-55 56P0362 7-55 56P0363 7-57 56P0364 7-57 56P0365 7-57 56P0366 7-57 56P0367 7-57 56P0368 7-57 56P0369 7-57 56P0370 7-57 56P0371 7-57 56P0372 7-57 56P0373 7-57 56P0374 7-57 56P0375 7-57 56P0376 7-57 56P0377 7-57 56P0378 7-57 56P0379 7-57 56P0380 7-57 56P0381 7-57 56P0382 7-57 56P0383 7-55 56P0384 7-57 56P0385 7-57 56P0386 7-55 56P0387 7-53 56P0388 7-57 56P0400 7-35 56P0401 7-33 56P0402 7-33 56P0405 7-35

7-57

I-5

5060-XXX

56P0407 7-33 56P0408 7-33 56P0409 7-33 56P0410 7-35 56P0411 7-37 56P0412 7-37 56P0413 7-37 56P0415 7-37 56P0416 7-37 56P0417 7-37 56P0418 7-39 56P0420 7-37 56P0422 7-37 56P0423 7-37 56P0430 7-47 56P0432 7-45 56P0433 7-47 56P0434 7-45 56P0435 7-45 56P0436 7-47 56P0437 7-47 56P0439 7-45 56P0441 7-45 56P0442 7-45 56P0444 7-45 56P0445 7-45 56P0447 7-45 56P0449 7-45 56P0451 7-47 56P0452 7-47 56P0454 7-45 56P0455 7-45 56P0456 7-47 56P0457 7-45 56P0458 7-47 56P0459 7-47 56P0462 7-47 56P0463 7-47 56P0464 7-47 56P0465 7-47 56P0466 7-45 56P0467 7-45 56P0468 7-45 56P0470 7-45 56P0471 7-45 56P0472 7-45 56P0473 7-45 56P0474 7-45 56P0475 7-45 56P0476 7-45 56P0477 7-47 56P0478 7-47 56P0479 7-45 56P0480 7-45

56P0482 7-45 56P0483 7-45 56P0490 7-49 56P0491 7-51 56P0492 7-51 56P0493 7-51 56P0494 7-49 56P0495 7-49 56P0497 7-49 56P0498 7-49 56P0500 7-51 56P0501 7-51 56P0503 7-51 56P0504 7-51 56P0505 7-51 56P0506 7-51 56P0507 7-51 56P0508 7-51 56P0509 7-51 56P0510 7-51 56P0511 7-49 56P0512 7-51 56P0513 7-49 56P0514 7-51 56P0515 7-51 56P0516 7-49 56P0517 7-51 56P0518 7-49 56P0519 7-49 56P0520 7-49 56P0522 7-49 56P0523 7-49 56P0524 7-49 56P0525 7-49 56P0526 7-49 56P0527 7-49 56P0528 7-49 56P0529 7-49 56P0530 7-49 56P0532 7-49 56P0533 7-49 56P0534 7-49 56P0535 7-49 56P0536 7-49 56P0539 7-49 56P0540 7-49 56P0541 7-51 56P0542 7-49 56P0543 7-51 56P0544 7-49 56P0547 7-49 56P0548 7-49 56P0549 7-49 56P0550 7-39

I-6 Service Manual

5060-XXX

56P0551 7-16 56P0552 7-16 56P0554 7-25 56P0561 7-49 56P0562 7-49 56P0563 7-49 56P0566 7-53 56P0569 7-53 56P0573 7-53 56P0574 7-53 56P0575 7-53 56P0576 7-53 56P0577 7-53 56P9906 7-58 56P9908 7-58 56P9909 7-58 56P9910 7-25, 56P9911 7-58 56P9912 7-58 56P9913 7-58 56P9914 7-58 56P9917 7-58 56P9926 7-58 56P9927 7-58 56P9928 7-58 56P9929 7-58 56P9930 7-58 56P9932 7-58 56P9934 7-58 56P9935 7-58 56P9936 7-58 56P9938 7-58 56P9939 7-58 56P9942 7-58 99A0052 7-33 99A0070 7-16, 99A0104 7-33, 99A0107 7-33 99A0120 7-15 99A0267 7-45 99A0323 7-47 99A0351 7-35 99A0361 7-35 99A0362 7-35 99A0363 7-35 99A0364 7-35 99A0368 7-35 99A0369 7-33 99A0408 7-25 99A0409 7-33 99A0414 7-33 99A0415 7-33 99A0424 7-58 99A0426 7-25

7-58

7-41 7-37

99A0450 7-39 99A0462 7-39 99A0481 7-33, 99A0482 7-33, 99A0545 7-58 99A0560 7-58 99A0629 7-58 99A0912 7-35 99A0913 7-35 99A0915 7-33 99A0923 7-58 99A1512 7-37 99A1580 7-33 99A1611 7-25 99A1687 7-37 99A1688 7-33 99A1689 7-33 99A1708 7-37 99A1710 7-37 99A1712 7-37 99A1713 7-37 99A1715 7-39 99A1716 7-37 99A1717 7-39, 99A1718 7-37 99A1719 7-37 99A1721 7-39 99A1722 7-39 99A1723 7-37 99A1724 7-37 99A1725 7-37 99A1726 7-37 99A1727 7-39 99A1728 7-39 99A1729 7-39 99A1730 7-39 99A1731 7-39 99A1732 7-39 99A1734 7-39 99A1735 7-37 99A1736 7-37 99A1737 7-37 99A1738 7-39 99A1740 7-37 99A1741 7-39 99A1742 7-37 99A1743 7-37 99A1744 7-35 99A1784 7-33 99A1786 7-37 99A1787 7-39 99A1788 7-39 99A1789 7-39, 99A1817 7-33

7-35 7-35

7-47

7-47

I-7

5060-XXX

99A2432 7-25 99A2540 7-45 99A2575 7-57

I-8 Service Manual