Lexmark C760 Service Manual

							
Diagnostic information2-75
  5060-4xx
HCIT
Use the  “HCIT standalone test mode” on page 3-36  inside the HCIT to help isolate paper jams. Run the 
Standalone Feeding Operation Test to observe paper feeding from the tray and through the feed assembly. Use 
the  “HCIT system board LED error code table” on page 2-121  to further isolate paper jam or sensor 
problems.
Before proceeding with this service check, make sure the HCIT is installed correctly.
9Check the autocompensator cable for correct 
installation to Tray  x system board.
Is the cable connected correctly? Replace the 
option or replace 
the following 
parts in the order 
until the error is 
cleared:
 “Autocom-
pensator 
pick assem-
bly” on 
page 4-20
Tray  x system 
board. Install the cable 
correctly
Step Action and questions Yes No 1 Check for pieces of paper or other obstructions in the 
feed assembly.
Are any pieces of paper or obstructions in the feed 
assembly? Remove any 
paper or 
obstructions
Go to step 2
2Make sure the media loaded in the paper tray meets 
printer supplies specifications and the media is loaded 
correctly. Make sure the side and back restraints are 
located and seated properly.
Does the media meet specifications? Go to step 3 Inform the 
customer that 
media in the 
paper tray does 
not meet 
specifications
3Use the Standalone Feeding Operation Test to observe 
paper feeding from the tray.
Does the paper feed from the paper tray? Go to step 14 Go to step 4
4Using 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?Go to step 5 Go to step 6
5Does the pick motor, the lower motor in the feed unit 
assembly, turn?
Go to step 8 Go to step 7
6Check the registration motor cable to HCIT system 
board cable connected to CN3 for correct installation.
Is the cable connected correctly?Replace the 
following FRUs in 
the order shown:
1. HCIT system  board
2. Feed unit  assembly Install the cable 
correctly
Step Action and questions Yes No 
						

							
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7Check the pick motor cable to HCIT system board 
cable connected to CN4 for correct installation.
Is the cable connected correctly?Replace the 
following FRUs in 
the order shown:
1. HCIT system  board
2. Feed unit  assembly Install the cable 
correctly
8Use the 
“HCIT system board LED error code table” 
on page 2-121 .
Does the LED flash 7 times? Go to step 9 Go to step 11
9Make sure the registration home sensor cable is 
installed correctly to the sensor and to CN6 on the 
system board.
Is the cable connected correctly?Go to step 10 Install the cable 
correctly
10Is the registration home sensor operating correctly? Replace the  following FRUs in 
the order shown:
1. HCIT system  board
2. Feed unit  assembly Replace the 
following FRUs in 
the order shown:
1. Registration  sensor
2. HCIT system  board
11Use the  “HCIT system board LED error code table” 
on page 2-121 .
Does the LED flash 8 times? Go to step 12 Go to step 14
12Make sure the pick home sensor cable is installed 
correctly to the sensor and to CN6 on the system 
board.
Is the cable connected correctly?Go to step 13 Install the cable 
correctly
13Is the registration home sensor operating correctly? Replace the  following FRUs in 
the order shown:
1. HCIT system  board
2. Feed unit  assembly Replace the 
following FRUs in 
the order shown:
1. Registration  Sensor
2. HCIT system  board
14Use the Standalone Feeding Operation Test to 
determine where the paper jams. Use the  “HCIT 
system board LED error code table” on page 2-121  
to help isolate problems in the feed unit assembly.
Are you able to determine where the failure is 
occurring? Repair or replace 
parts as 
necessary
Replace the feed 
unit assembly
Step Action and questions Yes No 
						

							
Diagnostic information2-77
  5060-4xx
Envelope feeder
Before proceeding with this service check, make sure the envelope option is installed correctly.
Step Action and questions Yes No 1 Make sure the envelopes installed in the tray meet 
specifications.
Some guidelines that can be used in selection of 
envelopes that will minimize the jam rate are:
 Flat envelopes that are not warped or twisted.
 Flexible envelopes that can conform to the paper  path.
 Smooth surface on the envelopes. Rough or ridged  surfaces may cause the envelopes to stick together 
in the tray.
 No cotton content, or as little as possible to meet  the user’s needs.
 If the envelopes have a pressure sensitive adhesive  flap, performance might be improved by reversing 
the orientation of the envelope in the tray and 
reversing the image in the drive or application.
Are any problems found with the envelopes? Inform the 
customer of the 
problems with the 
envelopes that do 
not meet 
specifications.
Go to step 2
2Make sure the envelopes are loaded correctly. Make 
sure the side and back restraints are located and 
seated properly.
Are the envelopes loaded correctly?
Go to step 3 Load the 
envelopes 
correctly.
3Observe if the envelopes feed from the tray.
Note: You can observe the autocompensator pick rolls 
and the envelopes through the tray access door.
Are the envelopes leaving the tray? Go to step 8 Go to step 4
4Check the pick rolls to verify both pick rolls are 
installed.
Are any of the pick rolls missing?
Go to step 5 Install a new pair 
of pick rolls. Both 
pick rolls should 
be installed at the 
same time. See 
“Pick rolls” on 
page 4-59
5Check to make sure the autocompensator pick rolls are 
correctly installed.
Are the autocompensator pick rolls correctly installed? Go to step 6 Install the pick 
rolls correctly. 
See “Pick rolls” 
on page 4-59 .
6Observe the pick rolls as they try to pick and feed 
envelopes from the tray.
Do the pick rolls turn? Go to step 7 Replace the 
envelope option.
7Check the autocompensator pick rolls for signs wear or 
contamination.
Are the pick rolls worn or contaminated? Replace the pick 
rolls. Both pick 
rolls should be 
replaced at the 
same time. See 
“Pick rolls” on 
page 4-59
.  Go to step 8
8If you continue to have problems, replace the complete 
envelope option. 
						

							
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250 Paper Jam
Unable to clear the message—Multipurpose feeder loaded
Note:  A 250 Paper Jam displays when using a multipurpose feeder. 
Step Action and questions Yes No 1 Make sure the media in the MPF meets specifications.
Does media meet specifications? Go to step 2 Inform user that 
the media in the 
MPF does not 
meet 
specifications.
2Does the media feed correctly from tray 1? Go to step 3 Go to “Tray 1 
service check” 
on page 2-142 .
3Is the Paper Type setting correct for media in the MPF? Go to step 4 Correct the Paper 
Type setting.
4Check the media is loaded properly. The side restraint 
should not be too tight. The leading edge of the media 
should be sitting on the friction buckler.
Is the media correctly loaded?Go to step 5 Properly load the 
media.
5Open the MPF to the horizontal position and check the 
paper path for obstructions. 
Is the paper path obstructed? Clear the 
obstruction.
Go to step 6
6Raise the pick tire off the media and test the MPF.
Does the pick tire turn? Go to step 8 Go to step 7
7Open the lower jam access door, move the MPF 
bracket assembly gear to the lowest position and test 
the MPF.
Does the MPF bracket assembly rise and engage the 
gear?Go to step 8 Replace the MPF 
bracket 
assembly. See 
“MPF bracket 
assembly” on 
page 7-19
8Does media jam on the friction buckler? Replace the 
“Friction 
buckler” on 
page 4-33. Call your next 
level of support. 
						

							
Diagnostic information2-79
  5060-4xx
Displayed with no media in MPF
A 250 Paper Jam indicates that the MPF tried to feed a sheet of media from the MPF tray. A 250 Paper Jam may 
occur when there is no paper in the MPF, MPF is selected as the paper source, or the MPF sensor is 
malfunctioning. If media is in the MPF it may feed normally with no 250 Paper Jam even though the sensor is 
malfunctioning.
Step Action and questions Yes No 1 Enter the Diagnostics Menu. Select  INPUT TRAY 
TESTS , Sensor Test , and MP Feeder . Manually 
actuate the MPF sensor by moving the paper flag in the 
MPF.
Does the test pass? Replace the MPF 
assembly.
Go to step 2
2Make sure that the MPF sensor cable from the system 
board is correctly installed at J21 on the system board.
Is the cable correctly installed? Go to step 3 Install the cable 
correctly
3Check the cable connection between the MPF sensor 
cable and the sensor. Check that the sensor is 
snapped into the bracket.
Is the connection good between the two cables? Go to step 4 Install the cable 
correctly
4Disconnect the sensor cable from J21 on the system 
board.
Measure the following voltages on J21, being careful 
not to short any adjacent pins in the connector. All 
voltages are approximate values.
Are the voltages correct? Go to step 5 Replace the 
“System board” 
on page 4-72
5Check continuity of the sensor cable that is between 
the system board and MPF assembly.
Is there continuity? Replace the 
sensor assembly
Replace the 
sensor cable 
assembly
Connector pin Voltage
J21-11 0 V dc
J21-12 +5 V dc
J21-13 +5 V dc
J21-14 +5 V dc 
						

							
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271 Paper Jam - check bin 1
Output bin
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 par t of sensor assembly)
F Full (Lower part of sensor assembly)
P Pass Thru Sensor
Step Actions and questions Yes No
1 DC motor cable connection - Make sure the DC motor 
connector is correctly installed at J4 on the output 
expander option board.
Is the cable installed correctly? Go to step 2 Install the cable 
correctly
2DC motor mechanical linkage assembly - Check the 
resistance of the motor on the cable connector. Check 
the resistance between J4-1 and J4-2. The resistance 
measures between 115 ohms and 135 ohms.
Is the resistance correct? Go to step 3 Replace the DC 
motor 
mechanical 
linkage assembly
3DC motor mechanical linkage assembly - Check for 
continuity between J4-1 and J4-2 and the case of the 
motor. It measures infinity.
Is there continuity between J4-1 or J4-2 and the case 
of the motor?
Note: If the motor is shorted from either J4-1 or J4-2 
and the case of the motor, it may be necessary to 
replace the output expander control board. Replace the DC 
motor 
mechanical 
linkage assembly
Go to step 4
4Output expander board - Disconnect the motor cable 
from J4 and check the voltages at J4 on the board.
Note
: All voltages are approximate values:
J4-1 (motor idle) +24 V dc
J4-2 (motor idle) +24 V dc
J4-5 (motor idle) +5 V dc
J4-6 (motor idle) +5 V dc
Warning:  Be careful not to short to adjacent pins on 
the connector.
Are the voltages correct? Replace the DC 
motor 
mechanical 
linkage assembly
Replace the 
output expander 
control board 
						

							
Diagnostic information2-81
  5060-4xx
272 Paper Jam - check bin x
5-bin mailbox
5-bin mailbox
POST incomplete
Step Action and questions Yes No
1 Bottom pass thru sensor flag - Make sure the flag is 
operating correctly and is not binding, broken, and 
there is no interference from the sensor cable.
Is there any problem found with the sensor flag? Fix or replace the 
flag
Go to step 2
2Bottom pass thru sensor - Make sure the sensor is 
correctly connected to J5 on the control board.
Is the sensor connected correctly? Go to step 3 Reseat the cable
3Bottom pass thru sensor voltage check 1 - Disconnect 
the pass thru sensor cable and check the voltage at 
J5-3 on the board. The voltage measures 
approximately +5 V dc.
Is the voltage correct?Go to step 4 Replace the 
control board
4Bottom pass thru sensor voltage check 2 - Check the 
voltage at J5-2 on the board, the voltage measures 
approximately 0 V dc.
Is the voltage correct? Replace the 
sensor assembly
Replace the 
control board
Step Actions and questions Yes No 1 Pass thru sensor flag - Check the sensor flag for 
correct operation.
Is the flag operating correctly? Go to step 2 Repair or replace 
as necessary
2Pass thru sensor cable - Make sure the pass thru 
sensor cable is correctly connected to J3 on the control 
board.
Is the cable connected correctly? Go to step 3 Reseat the cable
3Voltage check - Disconnect the pass thru sensor cable 
from the control board and check the voltage on J3-3. 
The voltage measures approximately +5 V dc.
Is the voltage correct?
Go to step 4 Replace the 
control board
4Voltage check - Measure the voltage at J3-2. The 
voltage measures approximately 0 V dc.
Is the voltage correct? Replace the 
control board
Replace the 
sensor assembly 
						

							
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280 Paper Jam
Use the table below to determine where to check for jams in the printer and to diagnose a 280 Paper Jam. Check 
the area indicated to find the jam and the problem. If this does not fix the problem, contact the next level ow 
support.
DB1 Explanation
01 Paper detected at inverter timing sensor too long. Paper jam in inverter, sensor failure.
02 Paper detected at inverter jam sensor too long. Paper jam in inverter, sensor failure.
03 Paper detected at drop timing sensor too long. Paper jam at accumulator entrance,  sensor failure.
04 Paper detected at exit timing sensor too long. Paper jam at exit, chad stuck in sensor,  sensor failure.
06 Punch motor homing timeout error. Backup chads jamming motor, motor or sensor  failure.
07 Stapler jam detected. Too many sheets or stiff paper in accumulator, motor or sensor  failure.
08 Belt motor homing timeout error. Paper jam in accumulator, motor or sensor failure.
09 Tray elevation motor timeout error. Stuck or failed paper level sensor, motor failure.
13 Paper not detected at inverter timing sensor within timeout. Jam near input, misdirected  sheet (diverter stuck or misaligned), sensor failure.
14 Paper not detected at inverter jam sensor within timeout. Paper jam in inverter, sensor  failure.
15 Paper not detected at drop timing sensor within timeout. Paper jam in inverter, sensor  failure.
16 Paper not detected at exit timing sensor within timeout. Jam in accumulator, belt motor  failure, sensor failure.
1B Paper detected at inverter timing sensor before punch timing sensor. Damaged sheet  (dogear), transparency sent to finisher, sensor failure.
Scroll down with  Menu to see the additional display lines and view the value at the indicated position (data bit 1 
- DB1) and match the information to the table below.
Finisher (Bin 1) - No other output options
2D 15
DB1 DB2 DB3
DB4 DB5 DB6 DB7
Finisher (Bin 2) - With output expander installed
2D 16
DB1 DB2 DB3
DB4 DB5 DB6 DB7
Finisher (Bin 6) - With 5-bin mailbox installed
2D 1A
DB1 DB2 DB3
DB4 DB5 DB6 DB7 
						

							
Diagnostic information2-83
  5060-4xx
900 RIP Software Error
The 900 error may indicate a communication problem (bad cable, network connection, and so on), software 
issue, or a hardware problem with the controller board/INA. The communication and software aspects should be 
checked first. Determine if the problem is constant or intermittent.
Constant 900 errors
1C Paper detected at punch timing sensor too long. Dirty or failed punch timing sensor.
1E Paper not detected at punch timing sensor within timeout. Jam near input, misdirected 
sheet (diverter stuck or misaligned), sensor failure.
1F Finisher internal software error. Intermittent sensor might cause this error.
20 Unexpected sheet detected at punch timing sensor. Stuck diverter (possibly due to  alignment), damaged sheet, dirty or failed sensor.
Step Action and questions Yes No 1 Reset the ITU electrical disconnect. Turn the printer off. 
Check the ITU Release Lever for correct operation. 
The ITU Release Lever is the black 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 oclock 
position. When unlocked it should be in a 3 oclock 
position. Undue pressure is not required to operate the 
lever
Turn the printer off, insert the ITU, move the lever to the 
6 oclock position, and turn the printer back on.
Does the 900 error display? Go to step 2 Problem resolved
2Disconnect the printer from any external connections. 
Turn the power off and remove any parallel, USB, or 
network connections. Turn the printer on.
Does the 900 error display?
Go to step 4 Go to step 3
3Run the internal test pages. Print one of the internal 
test pages from the Utilities Menu. If the printer works 
correctly while disconnected, have the user or their 
network administrator verify that there are no jobs in 
the queue which may be causing the error.
Does the error remain?Inform the user or 
network 
administrator of 
the issue.
Go to step 4
DB1 Explanation 
						

							
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Intermittent 900 Service RIP Error codes
It is important to determine under what circumstances the error occurs. Capturing the following information aids 
in categorizing the nature of the intermittent error.
1.Crash codes - With the 900 Service RIP Error displayed, press Select and Return  together. Record the 
complete secondary codes by scrolling with  Menu. The code may be a very long string of characters and 
numbers, but it is needed to analyze the problem.
2.Print history - Printed the printer history by entering Diagnostics Mode and selecting  Print History in the 
Development  menu.
3.Code level - Obtain the code level for the RIP, network, and engine. All of these can be found on  Print 
Menus  page from the  Utilities menu.
4.Type of connection being used to print - Record the type of connection. For example, direct USB or parallel, 
or network peer to peer, Ethernet, token ring, or so on.
5.Software application - Does one particular application or print job sent to the printer produce this error?
6.Driver - What driver or driver level. 
With this information in hand, contact you next level of support.
900 Error Code displayed when the machine is connected to a network while still in 
Setup Required Mode
4 Turn the printer off. Remove any options from the 
system board, such as additional memory, hard disk 
drives, or option cards. 
Does the 900 error persist when the printer is turned 
on? Go to step 5 Determine which 
option is causing 
the 900 error.
5Restore factory defaults from the Configuration Menu. 
Warning: When factory defaults or restored, all menu 
items are returned to the factory default values except:
 Display Language.
 All settings in the Parallel Menu, Serial Menu,  Network Menu, and USB Menu.
All downloaded resources (fonts, macros, and symbol 
sets) in printer memory (RAM) are deleted. (Resources 
residing in flash memory or on the hard disk are 
unaffected.) Record the 
secondary error 
codes. With the 
900 Service RIP 
Error displayed, 
press 
Select  and 
Return  together. 
Record the 
complete list by 
scrolling with 
Menu . The code 
may be a very 
long string of 
characters and 
numbers, but is 
needed for 
analysis.
Contact your next 
level of support. Problem solved.
Step Actions and questions Yes No 1 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.
 Is the same 900 Service Error displayed? Contact your next 
level support
Problem solved
Step Action and questions Yes No