Lexmark C760 Service Manual
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Diagnostic information2-95 5060-4xx 956 service error Service < xxxx> System Board 990 service error This error indicates which option is causing the error. 5-Bin mailbox Step Action and questions Yes No 1 Remove all option boards from the system board. Turn on the printer. Does the error continue? Replace the system board. See “System board” on page 4-72 . Go to step 2 2Replace each option board one at a time, making sure the boards are properly seated. Turn the printer off and then on between each option board to view any error messages. Does the error reappear? Replace the failing option board. Problem fixed. Step Action and questions Yes No 1 Mechanical linkage/DC motor assembly - Check the DC motor cable connector to make sure it is installed at J4 on the control board. Is the cable connected correctly? Go to step 2 Reseat the cable and recheck for correct operation of the option 2Resistance 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? Go to step 3 Replace the mechanical linkage/DC motor assembly 3DC 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 shorted, damage may result to the control board. Replace the mechanical linkage/DC motor assembly Go to step 4 4Output expander control board check - Disconnect the motor cable J2 and check the voltages at J2 on the board. Warning : Be careful not to short to adjacent pins on the connector. The voltages measure: (Note : All voltages are approximate values.) 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 Are the voltages correct? Replace the control board Replace the mechanical linkage/DC motor assembly
2-96Service Manual 5060-4 xx 500-sheet drawer option For 990 Service Error - Tray x, x=Tray 2, 3, 4 or 5, this is the tray that has a problem or needs service. Note: Verify the autoconnect housing is correctly snapped into the printer and all options, and is plugged into the system board correctly. Output expander Step Action and questions Yes No 1 Make sure the autocompensator cable is correctly installed at the tray system board. Is the cable correctly installed? Go to step 2 Install the cable correctly 2Make sure the drive assembly cable is connected correctly to the tray system board. Is the cable correctly installed? Go to step 3 Install the cable correctly 3Check for worn or broken parts in the autocompensator and drive assemblies. Are any parts worn, broken, or damaged? Replace the assembly that has the defective partsReplace the FRUs in the following order: 1. Electronic/ size sensing assembly 2. Autocom- pensator assembly 3. Drive Assembly Step Actions and questions Yes No 1 Mechanical linkage/DC motor assembly - Make sure the DC motor cable connector is installed at J4 on the output expander control board. Is the cable connected correctly? Go to step 2 Reseat the cable and recheck for correct operation of the option 2Resistance 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? Go to step 3 Replace the mechanical linkage/DC motor assembly 3DC 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 shorted damage may result to the system board. Replace the mechanical linkage/DC motor assembly Go to step 4
Diagnostic information2-97 5060-4xx Finisher 4Output expander control board check - Disconnect the motor cable J4 and check the voltages at J4 on the board. Warning : Be careful not to short to adjacent pins on the connector. The voltages measure approximately: 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? Replace the output expander control board Replace the mechanical linkage/DC motor assembly Step Actions and questions Yes No 1 Make sure the top options cable is correctly plugged into the system board. Is the cable correctly installed? Go to step 2 Install correctly 2Make sure the finisher cable is correctly installed on top of the printer. Is the cable correctly installed?Go to step 3 Install correctly 3Make sure the finisher cable is correcting install on the finisher system board. Is the cable correctly installed?Go to step 4 Install correctly 4When 990 error is installed, press and hold Return and Select to view the sub error code. Scroll down with Menu to see the additional display lines and view the value at the indicated position (EQC and DB1) and match the information to the table below. Does the information on the table help find the problem? Repair the finisher as indicated in the table. Contact your next level of support. EQC DB1 Explanation 45 05 Jogger motor homing timeout error. Obstruction in Jogger, motor or sensor failure. 4C 0C Offset motor timeout error. No clearance around output bin, motor or sensor failure. 50 10 Stapler unit is removed. Cable harness to stapler damaged or disconnected. Step Actions and questions Yes No Finisher (Bin 1) - No other output options 26 9D 81 EQC DB1 DB2 DB3 DB4 DB5 DB6 DB7
2-98Service Manual 5060-4 xx 5-bin mailbox option service check Note: Before proceeding with this service check make sure the option(s) are installed correctly before attempting to service the unit. Make sure the machine is configured correctly. The majority of the mechanical components can be observed during operation by removing the left and right side covers. Step Symptoms Yes No 1 Problems with excessive static electricity buildup. Go to “Problems with excessive static electricity buildup.” on page 2-129 Go to step 2 2The printer does not recognize one or more output options as installed. Go to “The printer does not recognize one or more output options as installed.” on page 2-99 Go to step 3 3271 Paper Jam - Check Bin 1 message Go to “271 Paper Jam - check bin 1” on page 2-80 Go to step 4 4 274 Paper Jam - Check Bin 4 displays. Go to “Ready bin x full message - may be able to clear message and will feed paper into bin selected.” on page 2-100 Go to step 5 5Ready Bin x Full message - May be able to clear message and will feed paper into Bin selected. Go to “Ready bin x full message - may be able to clear message and will feed paper into bin selected.” on page 2-100 Go to step 6 6Bin x Full - No message that bin x is full Go to “Bin x full - no message that bin x is full message” on page 2-100 Go to step 7 7Ready - Bin x Full displays and paper feeds into Bin xGo to “Ready - bin x full displays and paper feeds into bin x” on page 2-101 Go to step 8 8Paper does not feed into the bin selected. - 271 Paper Jam - Check Bin 1 displays. Go to “Paper does not feed into the bin selected. 271 Paper Jam - check bin 1 message” on page 2-101 Go to step 9
Diagnostic information2-99 5060-4xx 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 service check of the failing output option. 9990 Service Error Go to 950 Error Code service check.Call your next level support Step Action and questions Yes No 1 Options - 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 2 Check the autoconnect system in base printer 2Mechanical linkage (cables) - Check the 5-Bin Mailbox autoconnect cable and connector for any signs of damage, especially the connector pins. Are there any signs of damage to the cable, connector, or connector pins? Replace the autoconnect cable Go to step 3 3Mechanical linkage (electrical) - Make sure the autoconnect cables are connected correctly to the control board. Are the cables attached securely and correctly? Go to step 4 Reseat the cables 4Voltage check, base printer autoconnect connector - Turn the power off and remove the 5-Bin Mailbox option from the printer. Check the voltages on the base printer top autoconnect connector. See “Autoconnect—top” on page 5-18 . Are the voltages correct? Go to step 5 Check the autoconnects in the printer 5Voltage check, 5-Bin Mailbox system board - Reinstall the 5-Bin Mailbox option and check the voltages at J1A and J1B on the connector. Are the voltages correct? Replace the output expander option system board Replace the output expander option mechanical linkage assembly Step Symptoms Yes No
2-100Service Manual 5060-4 xx Ready bin x full message - may be able to clear message and will feed paper into bin selected. Note: This sensor is normally in a open position with the flag out of the sensor slot. Bin x full - no message that bin x is full message Step Action and questions Yes No 1 Bin x sensor (bin x=Sensor 1 through 5) - Make sure the sensor is seated correctly in the side of tray x. Is the sensor seated correctly? Go to step 2 Install the sensor correctly 2Bin x sensor cable - Make sure that bin x sensor cable is connected to the sensor and to the control board. Is the sensor cable connected correctly? Go to step 3 Install the sensor cable correctly 3Bin x sensor flag - Check the bin x sensor flag for binding and proper operation. Are there any problems with the sensor flag? Repair or replace the sensor flag Go to step 4 4Bin x sensor cable - Check the continuity of the sensor cable. Is there continuity? Replace the bin x sensor Replace the bin x Cable Step Action and questions Yes No 1 Bin x sensor (bin x=sensor 1 through 5) - Make sure the sensor is seated correctly in the side of tray x. Is the sensor seated correctly? Go to step 2 Install the sensor correctly 2Bin x sensor cable - Make sure that bin x sensor cable is connected to the sensor and to the control board. Is the sensor cable connected correctly? Go to step 3 Install the sensor cable correctly 3Bin x sensor flag - check the bin x sensor flag for binding and proper operation. Are there any problems with the sensor flag? Repair or replace the sensor flag Go to step 4 4Bin x sensor cable - Check the continuity of the sensor cable. Is there continuity? Replace the bin x sensor Replace the bin x cable
Diagnostic information2-101 5060-4xx Ready - bin x full displays and paper feeds into bin x Paper does not feed into the bin selected. 271 Paper Jam - check bin 1 message Step Action and questions Yes No 1 Bin x sensor flag - Make sure the bin x sensor flag is not in the up position and is operating correctly. Is the sensor flag operating correctly? Replace the bin x sensor. If this does not fix the problem replace the control board. Repair or replace as necessary Step Action and questions Yes No 1 Bin parts - Check all the bin parts, deflector, deflector spring, deflector cover, deflector cover spring, and shaft assemblies for signs of missing or loose springs. Check for binds in the deflector or deflector cover, broken or binding shaft assemblies, or broken gear teeth. Are parts broken, loose, binding, or missing? Replace parts or repairs necessary Go to step 2 2Bin x solenoid - Check the solenoid for any binds or sticking problems. Is the solenoid binding or sticking? Replace the solenoid assembly Go to step 3 3Bin x solenoid - Check the resistance of the solenoid. It measures between approximately 30 ohms and 50 ohms. Is the resistance correct? Replace the 5-Bin Mailbox control board assembly Replace Bin x solenoid assembly 4Mechanical linkage/motor assembly - Check the gears, clutch and other linkage parts for correct operation and any signs of wear, broken gear teeth or damaged parts. Are the mechanical linkage assembly mechanical parts broken, worn or damaged? Replace the mechanical linkage/DC motor assembly Replace the 5-Bin Mailbox control board assembly
2-102Service Manual 5060-4 xx 500-sheet drawer option service check If the paper does not feed from the 500-sheet option, see “Autocompensator service check” on page 2-107. Whenever the 500-Sheet Tray is removed, use care as the autocompensator may be in its down position which could result in damage to the autocompensator assembly. The tray empty sensor, paper low sensor, and pass thru sensor for any installed tray x ( x=2 through 4) can be checked using the “Sensor Test” on page 3-25 . The base printer does not recognize that tray x is installed. Step Action and questions Yes No 1 Is tray x the only paper input option that is not recognized? Go to step 5 Go to step 2 2Make sure the printer and any option above tray x is installed correctly. Is the printer and any options installed correctly? Go to step 3 Install the option correctly and recheck 3Verify correct installation of the lower options autoconnect cable to system board connector J37. Is the cable to J37 installed correctly? Go to step 4 Install the cable correctly and recheck 4Autoconnect cables - check the autoconnect from the printer or option above tray x. Check for cuts, pinched wiring, or damage to the contacts in the connector. Are there any problems with the autoconnect cables? Repair or replace as necessary Go to step 5 5Tr a y x autoconnect cable - check the tray x autoconnect cable(s) for correct installation at the tray x system board. Are the tray x autoconnect cable(s) connected correctly? Go to step 6 Install the cables correctly and recheck 6Tr a y x autoconnect cable continuity - Check the continuity of the Tray x Autoconnect cable(s). Is there continuity? Go to step 7 Replace electronic size sensing assembly (includes the system board) 7Disconnect J37 from the system board and check the voltages on connector J37 on the system board. Note: All voltages are approximate values: Are the voltages correct? Replace electronic size sensing assembly (includes the tray system board) Replace the “System board” on page 4-72 Connector pins Voltage J37-1 +5 V dc J37-2 Ground J37-3 Ground J37-4 +5 V dc J37-5 +24 V dc J37-7 +5 V dc J37-8 +5 V dc
Diagnostic information2-103 5060-4xx Tr a y x autocompensator fails to retract, stays in down position. The printer detects paper low in tray x when adequate paper is installed in the tray. Step Action and questions Yes No 1 Use care when removing a tray assembly when the autocompensator is in its down position. Remove the tray and manually reset the autocompensator to its uppermost position by actuating the pick arm lift bellcrank. Does the autocompensator assembly stay in the up position? Go to step 2 Go to step 3 2Carefully replace the tray and recheck to see if the autocompensator operates correctly. Does the autocompensator assembly operate correctly? Problem solved Go to step 3 3Make sure the autocompensator pick arm lift bellcrank is installed correctly. Is the pick arm lift bellcrank installed correctly? Go to step 4 Install the bellcrank correctly 4Check the following for loose, broken, or missing parts: Boss on the side of the arm Bellcrank lift spring Tray interlock bellcrank Are any of these parts loose, broken, or missing? Repair or replace as necessary Call your next level of support. Step Action and questions Yes No 1 Run Tray x sensor test from the Diagnostics Menu. Does the test pass for sensor L2? Go to step 3 Go to step 2 2Check the cable connection for the paper low/out sensor to tray x system board. Is the cable correctly installed? Go to step 3 Install the cable correctly 3Check the paper level sensing assembly for correct installation. Check the following for damaged or broken par ts: Check the paper level sensing flag bellcrank. Check the paper level sensor is seated correctly. Check the paper level sensing flag. Check the paper level sensing flag spring. Is the paper level sensing assembly installed correctly? Go to step 4 Install the paper level sensing assembly correctly 4Is the paper level sensing assembly damaged or broken? Replace the paper level sensing assembly
2-104Service Manual 5060-4 xx The printer detects paper out in tray x when adequate paper is installed in the tray. Tr a y x does not detect size media installed Step Action and questions Yes No 1 Run Tray x Sensor Test from the Diagnostics Menu. Does the test pass for Sensor L1? Go to step 5 Go to step 2 2Check the cable connection for the paper level sensing assembly to tray x system board. Is the cable correctly installed? Go to step 3 Install the cable correctly 3Check the paper level sensing assembly for correct installation. Is the paper level sensing assembly installed correctly? Go to step 4 Reinstall the assembly if not installed correctly 4Check continuity of the paper level sensing assembly cable. Do you measure continuity? Go to step 5 Replace the cable 5Check the paper level sensing assembly for correct installation. Check the following for damaged or broken par ts: Paper level sensing flag bellcrank Paper level sensing flag Paper level sensing flag spring Is the paper level sensing assembly installed correctly? Replace the paper level sensing assembly Go to step 6 6Make sure the paper level sensing assembly arm goes all the way through the bottom of tray x. Does the arm extend all the way down through the bottom of the tray? Recheck the arm. If the problem continues, replace the paper leveling sensing assembly. If the problem persists, replace the tray x system board. See why the arm is not extending all the way to the bottom of the tray. Repair as necessary. Step Action and questions Yes No 1 Is the tray set for the size paper loaded in the tray and are the restraints in the correct location? Go to step 2 Set the correct size 2Are there damaged or broken size sensing gears or size sensing barrel cam in the tray assembly? Repair or replace defective partsGo to step 3 3Check the paper size sensing assembly for any signs of damaged, binding, or broken parts. Are there broken or damaged parts? Replace the paper size sensing assemblyReplace the electronics/size sensing assembly