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LexmarkTMC750 5060-XXX
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
5060-XXX
5060-XXX
Table of Contents
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Laser Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv-ix Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv-xii
iii
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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
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
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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
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Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
viii
5060-XXX
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.
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.
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.
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.
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
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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.
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.
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Service Manual
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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:
Preface xv
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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
General Information
1-1
5060-XXX
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
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.
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
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
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)
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.
5060-XXX
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
General Information
1-7
5060-XXX
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
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.
5060-XXX
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
500Sheet Input
Multipurpose Tray
2,000Sheet Drawer
Duplex
Standard Output
5-Bin Mailbox
Output Expander
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)
5060-XXX
500Sheet Input
Multipurpose Tray
2,000Sheet Drawer
Duplex
Standard Output
5-Bin Mailbox
Output Expander
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
500Sheet Input
Multipurpose Tray
2,000Sheet Drawer
Duplex
Standard Output
5-Bin Mailbox
Output Expander
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.
5060-XXX
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)
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)
5060-XXX
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.
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
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
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.
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.
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.
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.
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.
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.
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
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
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.
5060-XXX
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.
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
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.
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
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.
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.
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.
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.
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
145 Motor
146 Motor 147 Motor 148 Motor 149 Motor 150 Motor
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
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.
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.
5060-XXX
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
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
5060-XXX
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
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
5060-XXX
Description
Diagnostic Information
2-23
5060-XXX
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
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
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.
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
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
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
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
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.
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
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
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.
5060-XXX
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.
Diagnostic Information
2-29
5060-XXX
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.
5060-XXX
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
Setup Required
A Alignment =X.X*
Diagnostic Information
2-31
5060-XXX
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.
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.
5060-XXX
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.
Close Door
Diagnostic Information
2-33
5060-XXX
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.
5060-XXX
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
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
5060-XXX
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
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
5060-XXX
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.
Diagnostic Information
2-39
5060-XXX
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
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.
5060-XXX
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
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
5060-XXX
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.
Diagnostic Information
2-43
5060-XXX
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.
5060-XXX
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.
61 Defective Disk
Diagnostic Information
2-45
5060-XXX
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
5060-XXX
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.
Diagnostic Information
2-47
5060-XXX
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.
Step
Yes
Go to step 2
No
Problem solved
2 3
5060-XXX
Step
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
Diagnostic Information
2-49
5060-XXX
Yes
Go to Step 2
No
Problem Solved
Problem Solved
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
5060-XXX
Yes
Go to step 2
No
Problem Solved
Problem Solved
Step
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?
Diagnostic Information
2-51
5060-XXX
Yes
Go to step 2
No
Problem Solved
Problem Solved
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?
5060-XXX
Yes
Go to step 2
No
Problem Solved
Problem Solved
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?
Diagnostic Information
2-53
5060-XXX
Step
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
Table 1
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
5060-XXX
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
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
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
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
Step
Yes
Go to the AC Power Service Check on page 2-56
No
Go to the DC Power Service Check on page 2-57
Step
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
5060-XXX
Step
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
Step
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?
Diagnostic Information
2-57
5060-XXX
Step
Yes
Problem Solved
No
Replace the LVPS on page 4-15
Step
Yes
Replace the Second Transfer Roll on page 4-43 Call your next level support
No
Go to Step 2
Go to Step 3
5060-XXX
Step
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.
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
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
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
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
Printer does not recognize that one or more output options as being installed.
Step
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?
Diagnostic Information
2-61
5060-XXX
Step
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.
Step
Yes
Repair or replace as necessary
No
Go to Step 2
5060-XXX
Remove paper - Output Bin X is displayed, POST is incomplete unable to clear the message.
Step
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.
Yes
Go to Step 2
No
Repair or replace as necessary Reseat the cable
Go to Step 3
Go to Step 34
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
Yes
Go to Step 2
No
Install the cable correctly
Go to step 3
5060-XXX
Step
Yes
Go to step 2
No
Install the cable correctly Call your next level support Replace the Control Board
Go to step 3
Step
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
Diagnostic Information
2-65
5060-XXX
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
Go to Step 4
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
Go to Step 7
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
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
Yes
Go to Step 2
No
Check the autoconnect system in base printer
Diagnostic Information
2-67
5060-XXX
Step
Yes
Replace the Autoconnect cable
No
Go to Step 3
Go to Step 4
Go to Step 5
Step
Yes
Fix or replace the flag
No
Go to Step 2
Go to Step 3
Go to Step 4
5060-XXX
Step
Yes
Repair as necessary
No
Go to Step 2
Go to Step 3
Go to Step 4
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
Yes
Go to Step 2
No
Install the sensor correctly Install the sensor cable correctly Go to Step 4
Go to Step 3
Diagnostic Information
2-69
5060-XXX
Step
Yes
Go to Step 2
No
Install the sensor correctly Install the sensor cable correctly Go to Step 4
Go to Step 3
Step
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
Yes
Replace parts or repairs necessary
No
Go to Step 2
Go to Step 3
5060-XXX
Step
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
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
Diagnostic Information
2-71
5060-XXX
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
Yes
Replace the Cartridge
No
Call your next level support
Go to Step 3
5060-XXX
Step
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
The entire page is mostly all one color. Some printing may appear in other colors. This applies to Black, Cyan, Magenta and Yellow.
Step
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
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
Yes
Problem Solved
No
Go to Step 2
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
5060-XXX
Step B
Step
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
Step
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?
Go to Step 4
Go to Step 5
Repair the HV contact Block Assembly. Replace the HVPS Developer Board on page 4-39
Diagnostic Information
2-75
5060-XXX
Step
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
Step A
Step
Yes
Replace the print cartridge. Replace the Cartridge Drive Assembly.
No
Go to step 2 No problem found
1 2
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.
Step A
Step
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
Yes
Set Color Calibration on
No
Go to step 2
Diagnostic Information
2-77
5060-XXX
Step
Yes
Problem Solved
No
Replace the HVPS Transfer Board on page 4-12
Step
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.
Step
Yes
Go to Step 2
No
Inform the customer Go to Step 4
Go to Step 3
5060-XXX
Step
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?
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
Yes
Problem Solved
No
Go to Step 2
Diagnostic Information
2-79
5060-XXX
Step
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
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
Yes
Problem Solved
No
Go to Step 2
Go to Step 3
5060-XXX
Step
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
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
Yes
Problem Solved
No
Go to Step 2
Problem Solved
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
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?
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
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?
5060-XXX
Step
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 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
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
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?
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?
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
5060-XXX
Step
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
14
Go to the Operator Panel on page 4-26 and replace the operator panel cable
Diagnostic Information
2-85
5060-XXX
Step
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 5
Go to step 9
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
5060-XXX
Step
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
Diagnostic Information
2-87
5060-XXX
Step
Yes
Go to step 10
No
Go to step 10
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
12
13
Go to step 14
Install the connector/ cable correctly Replace the ITU Autoconnect cable
14
5060-XXX
Step
Yes
Call your next level support
No
Problem Solved
Step
Yes
Go to step 2
No
Install the cable correctly
Go to step 3
Go to step 4
Diagnostic Information
2-89
5060-XXX
Step
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?
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?
5060-XXX
Step
Yes
Go to step 2
No
Remove the packing material from the printer
Go to step 3
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
Step
Yes
Go to step 2
No
Remove the packing material from the printer
Go to step 3
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
5060-XXX
Step
Yes
Go to step 2
No
Remove the packing material from the printer
Go to step 3
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
Step
Yes
Go to step 2
No
Remove the packing material from the printer
Go to step 3
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
5060-XXX
Yes
Install the correct voltage hot roll lamp Install the correct voltage back up roll lamp
No
Go to step 2
Go to step 3
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:
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
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
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
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
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
5060-XXX
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
Yes
Call your next level support
No
Problem Solved
Diagnostic Information
2-99
5060-XXX
Yes
Go to step 2
No
Correctly install the cable Replace the Fuser Assembly on page 4-16
Yes
Go to step 2
No
Correctly install the Fuser Drive Assembly on page 4-17. Replace the Fuser Assembly on page 4-16
Yes
Go to step 2
No
Install the cable correctly
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
Problem Solved
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?
Step
Yes
Go to step 2
No
Install the cable correctly
5060-XXX
Step
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
Problem Solved
Step
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?
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?
5060-XXX
Step
Yes
Replace the Engine Board on page 4-14
No
Replace the Front Cover/ HV Interlock Switch/Cable Assembly
Step
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.
5060-XXX
Step
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.
Step
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
5060-XXX
Step
Yes
Replace the Back Restraint
No
Go to step 5
Go to step 6
6 7
Go to step 7 Go to step 8
Step
Yes
Repair or replace parts as necessary
No
Go to step 2
5060-XXX
Step
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?
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?
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?
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
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
5060-XXX
Step
Yes
Replace Tray 1
No
Go to step 4
Go to step 5
Determine what is causing the Autocompensator to stay in the down position. Repair as necessary.
Step D
Step
Yes
Call your next level support
No
Go to step 2
Go to step 3
Go to step 5
5060-XXX
Step
Yes
Go to step 6
No
Replace the Level Sensing Cable Replace the Engine Board on page 4-14
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
Step
Yes
Go to step 2
No
Go to Tray 1 Service Check on page 2-105
5060-XXX
Step
Yes
Go to step 5
No
Go to step 3
Go to step 4
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?
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
Step
Yes
Go to step 6
No
Go to step 2
5060-XXX
Step
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
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.
5060-XXX
250 Paper Jam Displayed - Unable to clear the message from the display
Step
Yes
Go to Step 2
No
Repair or replace parts as necessary
Go to Step 3
Go to Step 4
Install the Transfer Plate correctly Call your next level support
201 Paper Jam Displayed - Unable to clear the message from the display
Step
Yes
Remove the obstruction
No
Go to Step 2
5060-XXX
Step
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
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
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
5060-XXX
Step
Yes
Properly align the ITU Light Shield Go to step 3
No
Go to step 2
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?
Step
Yes
Replace the ITU Light Shield Properly align ITU Light Shield
No
Go to step 2
Go to step 3
5060-XXX
Step
Yes
Replace the ITU Assembly on page 4-41 Go to step 5
No
Go to step 4
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?
5060-XXX
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
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?
5060-XXX
Yes
Go to step 2
No
Go to step 3
Go to step 3
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
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
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.
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
5060-XXX
Step
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
11
Step
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
5060-XXX
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
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
5060-XXX
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.
Step
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
5060-XXX
Step
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
Step
Yes
Go to step 5
No
Go to step 2
2 3
5060-XXX
Step
Yes
Replace the FRUs in the following order:
1. Paper Exit Sensor 2. Duplex System Board
No
Attach the cable correctly
Step
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
5060-XXX
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
Go to step 6
Go to step 7
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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
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
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Step
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
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Step
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
Check the Pick Motor cable to HCIT System Board cable connected to CN4 for correct installation. Is the cable connected 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
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Step
Yes
Go to step 10
No
Install the cable correctly
10
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
13
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?
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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
Step
Yes
Go to step 2
No
Connect the printer and options correctly
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Step
Yes
Go to step 3
No
Install the cable correctly
Go to step 6
Go to step 4
Go to step 5
Go to step 8
Go to step 9
9 10
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Yes
Go to step 2
No
Repair or replace the door assembly Go to step 3
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
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
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Step
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
Go to step 6
Yes
Go to step 2
No
Install the chad box correctly Replace the finisher system board
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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.
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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.
Color Trapping
Enter the Configuration Menu and select Color Trapping from the menu. The values are: =Off =1.5(2*)
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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
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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
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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.
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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.
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
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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.
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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.
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.
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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.
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.
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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.
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.
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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.
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.
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
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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.
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
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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.
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.
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
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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.
Source
Tray 1 Tray 2 Tray 3 Tray 4 Multi Purpose Feeder
L1
Yes Yes Yes Yes Yes
L2
Yes Yes Yes Yes No
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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.
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.
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
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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.
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:
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<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
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.
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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.
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.
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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...........
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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.
4. Select Finisher Tests from the menu. 5. Select Hole Punch Test.
Press Return after the test is complete to exit the test.
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.
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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
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.
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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.
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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.
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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.
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
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4. Repair Information
WARNING: Read the following before handling electronic parts.
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.
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.
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.
8. After you obtain correct front and rear printhead adjustments, tighten the left rear
printhead mounting screw.
Repair Information
4-3
5060-XXX
Reference number
002
Screw type
4-40 Machine
Location
Parallel Connector to Shield
Purpose
Attach
Qty
2
102
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
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
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
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
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
12 2 2 1
412
2.9x5.2mm Plastite
423
M3.5x9 Plastite
Mounting
484
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.
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.
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.
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.
5060-XXX
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).
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.
5060-XXX
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
1. Open the lower right door assembly. 2. Carefully flex the lower right door assembly to free the hinges from the mounting
posts.
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.
5060-XXX
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.
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.
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
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.
1. Remove the Front Cover Assembly on page 4-22. 2. Remove the Redrive Door on page 4-21. 3. Remove the redrive cap.
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.
5060-XXX
9. Remove the top cover mounting screws (A) from the front of the printer.
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.
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.
5060-XXX
4. Disconnect the operator panel cable from the operator panel and remove the
operator panel.
Repair Information
4-27
5060-XXX
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.
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.
5060-XXX
Repair Information
4-29
5060-XXX
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.
5060-XXX
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.
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
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).
5060-XXX
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.
1. Open the waste container door. 2. Flex the door and remove it from the hinges (A).
Repair Information
4-33
5060-XXX
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.
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
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.
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).
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.
5060-XXX
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
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.
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
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.
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.
5060-XXX
1. Remove the ITU Assembly on page 4-41. 2. Lift the transfer roll from the front bearing and remove the transfer roll.
1. 2. 3. 4.
Repair Information
4-43
5060-XXX
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.
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)
1 2 3 4
J4 VTB Fan
1 2 3 4
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7
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 +
1 2 3
1 2
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
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
1 2
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
1 2 3 4 5 6
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
1 2 3 4 5 6 7 8
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14
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
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 +
1 2 3 4 5 6 7 8 9 10
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 +
1 2 3 4 5 6 7 8 9 10
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
1 2 3 4 5 6 7 8 9 10 11
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
1 2 3 4 5 6 7 8 9 10 11
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
1 2 3 4 5 6 7 8 9 10
5-18
Service Manual
5060-XXX
Connector
Engine Board Cable
Connector Locations
5-19
5060-XXX
1 2 3 4 5 6 7 8 9 10
5-20
Service Manual
5060-XXX
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
1 2 3 4 5 6 7
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
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
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
1 2
1 2
1 2
1 2
CB Terminal
5-26
Service Manual
5060-XXX
Connector Locations
5-27
5060-XXX
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
1 2
5-28
Service Manual
5060-XXX
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
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
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
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
1 2 3 4 5 6 7 8
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
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
1 2
1 2 3 4 5
CN14 Power
1 2 3 4
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
1 20
Connector Locations
5-33
5060-XXX
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.
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:
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
5060-XXX
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
5060-XXX
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
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
5060-XXX
AsmIndex
Part Number
Units
Description
2.1-1 2 NS
12G6414 12G6545
1 4 1
Parts Catalog
7-7
5060-XXX
AsmIndex
Part Number
Units
Description
3-1 2 3
1 1 1
Vacuum Belt Transport Assembly Transfer Plate Assembly Second Transfer Roll
5060-XXX
Assembly 4: Printheads
AsmIndex
Part Number
Units
Description
4-1 2 3 4 NS NS
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
5060-XXX
5-1 2 3 4 5 6 7 8 9
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
5060-XXX
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
5060-XXX
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
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
5060-XXX
AsmIndex
Part Number
Units
Description
9-1 2 3 4 NS NS
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
1 1 1
1339520
1 1 1 1 1 1 2 2 3 4 5 6
1 1 1 1 1 1 1 1 8 2
12G6446 12G6543
1 1
Parts Catalog
7-23
5060-XXX
5060-XXX
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
5060-XXX
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
4 4 1 1 1 1 1 1
Parts Catalog
7-27
5060-XXX
AsmIndex
Part Number
Units
Description
11.3-1 2 3 4 5
1 12 1 1 14
Engine Board Shield Screw, PP 12G6531 Engine Board Ground Strap Screw, PP 12G6309
5060-XXX
AsmIndex
Part Number
Units
Description
11.4-1 2 3 4 5 6 NS
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
AsmIndex
Part Number
Units
Description
11.5-1 2 3 4 5 6 7 NS NS
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
5060-XXX
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
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
5060-XXX
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
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
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
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
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