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Lexmark
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C78x
Lexmark C78x User Manual
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3-46
Service Manual
5061
4.
Turn th
e
p
rinter of
f. Open the front
cover assembly.
5.
Remov
e
a
l
l
t
he pr
i
n
t
car
t
r
idges.
a.
Pull
up s
l
i
ghtly o
n the
cartridge
handhol
d.
b.
Pull
t
he cartridge st
r
ai
ght out, and use
t
he handle to lift
i
t
of
f the gui
des.
c.
Place
the car
t
r
i
d
ges on a clean, flat sur
face out
of direct li
ght.
227
229
Table of Contents
Default Chapter
3
Table of Contents
3
Notices and Safety Information
11
Laser Notice
11
Safety Information
17
Preface
20
Change History
20
Index
20
Conventions
21
General Information
23
Models
23
Tools Required for Service
23
Options and Features
24
Options for All Models
24
Options for C772 and C782 (310 and 410)
24
Toner Darkness
25
Printer Specifications
26
Power and Performance
29
Time to First Print
29
Memory Configuration
30
Media Specifications
31
Media Sizes
32
Media Guidelines
39
Paper
39
Paper Characteristics
40
Selecting Paper
41
Unacceptable Paper
41
Web Oiler Upgrade Kit and Replacements
42
Acronyms
43
Diagnostic Information
45
Start
45
POR (Power-On Reset) Sequence
46
Symptom Tables
47
Symptom Table-Base Printer
47
Symptom Table-500-Sheet Drawer Option
48
Symptom Table-HCIT 2000-Sheet Option
49
Symptom Table-Output Expander Option
49
Symptom Table-5-Bin Mailbox Option
49
Symptom Table-Staplesmart Finisher
50
Service Error Code and Paper Jam Message Table
51
1Xx Service Errors
51
2Xx Paper Jams
53
9Xx Service Errors
55
Service Checks
58
100.01 ITU Error Service Check
58
100.02 ITU Error Service Check
61
122.01 Error Code Service Check
62
122.03 Error Code Service Check
63
Error Code Service Check
64
122.05 and 122.06 Error Code Service Check
65
122.07, 122.14, and 122.15 Error Code Service Check
66
148.XX Error Code Service Check
69
XX Error Code Service Check
69
Error Code Service Check
70
XX Error Code Service Check
71
177.XX Error Code Service Check
72
200.03 Paper Jam Service Check
72
Paper Jam Service Check
73
200.05 Paper Jam Service Check
74
200.07 Paper Jam Service Check
75
200.21, 200.28, and 200.29 Paper Jam Service Check
76
200.93 Paper Jam Service Check
77
200.96 Paper Jam Service Check
79
201.XX and 202.XX Paper Jam Service Check
79
230.XX Paper Jam Service Check
81
241.XX Paper Jam Service Check
82
XX Paper Jam Service Check
83
243.XX Paper Jam Service Check
87
244.XX Paper Jam Service Check
92
XX Paper Jam Service Check
93
271.XX Paper Jam Service Check
95
272.XX Paper Jam Service Check
96
282.98 Paper Jam Service Check
97
940.XX Error Code Service Check
102
XX Error Code Service Check
104
XX Error Code Service Check
106
XX Error Code Service Check
108
956.XX Service Error Service Check
110
982.XX Error Service Check
110
Error Service Check
111
5-Bin Mailbox Option Service Check
113
500-Sheet Drawer Option Service Check
117
AC and DC Power Service Check
120
Autocompensator Service Check
122
Black Only Retract (BOR) Service Check
124
Close Door/Hvps/Printhead Interlock Switch Service Check
125
Duplex Option Service Check
127
Envelope Feeder Option Service Check
129
HCIT 2000-Sheet Option Service Check
130
Fuser Drive Assembly Noise Check
133
Operator Panel Lcd/Status Led/Buttons Service Check
134
Output Expander Option Service Check
136
Print Quality Service Check
139
Blank Page (no Image)
139
Entire Page Is Mostly One Color-Full Bleed Planes in One Color
140
Missing Colors-Complete or Partially Missing Color Planes
141
Black and White Only-Cyan, Magenta, and Yellow Are Missing
142
Light Print over the Entire Page
142
Horizontal Lines or Streaks
144
Vertical Lines or Streaks
144
Low Image Density
145
Poor Color Alignment
145
Transparency Print Quality Is Poor
146
Negative Ghosting or Faded Image
147
Residual Image
147
Uneven Printing
147
Smudged or Distorted Images on Fused Page
148
Toner Smears or Rubs off the Page with no Error Code Displayed
148
Light Lines or Streaks Appear on the Page
149
Toner Is on the Back of the Printed Page
149
Paper Wrapped Around the Second Transfer Roll
150
White Streak in Color Plane
150
User Troubleshooting for Quality
151
Second Transfer Roll Service Check
155
Staplesmart Finisher Service Check
157
Tray 1 Service Check
161
Tray 1 Media Size Sensing Service Check
162
User Operator Panel, Menus, and Messages
163
Operator Panel Buttons
163
Understanding the Printer Operator Panel
163
Menu Map
165
Quality Menu
166
Selected Menus
166
Utilities Menu
168
User Attendance Messages
170
Diagnostic Aids
183
Diagnostic Procedures
183
Printhead Diagnostics
183
Print Quality Defect Locator Chart
185
Partial Print Test
186
HCIT Standalone Test Mode
187
Accessing Service Menus
188
Diagnostics Mode
189
Entering Diagnostics Mode
189
Diagnostic Mode Menus
189
Exiting the Diagnostics Mode
191
Registration
192
Alignment Menu
193
Setting Alignment for Color
193
Drift Sensors
194
Misc Tests
195
Belt Tracking (ITU 4Th Point Adjustment)
195
Toggle ITU
195
Printhead Inst
196
Print Tests
196
Print Tests (Input Sources)
196
Print Quality Pgs
197
Hardware Tests
197
Button Test
197
LCD Test
197
CACHE Test
198
DRAM Test
198
Parallel Wrap Test
199
Serial Wrap Test
200
Duplex Tests
201
Duplex Quick Test
201
Duplex Top Margin Offset
201
Duplex Sensor Test
201
Input Tray Tests
202
Feed Test
202
Sensor Test
202
Output bin Tests
203
Feed Test
203
Feed to All Bins
203
Diverter Test
204
Sensor Test
204
Finisher Tests
205
Finisher Feed Test
205
Finisher Sensor Test
205
Staple Test
205
Base Sensor Test
206
Device Tests
207
Disk Test/Clean
207
Flash Test
207
Quick Disk Test
207
Printer Setup
208
Defaults
208
Page Counts
208
Configuration ID
209
Engine Setting X
209
Model Name
209
Serial Number
209
Cal Ref Adj
210
Edge to Edge
210
Reset Color Calibration
210
Ep Setup
210
DC Charge Adjustment
210
Dev Bias Adj
210
EP Defaults
210
Fuser Temp
210
Transfer Adjust
210
Error Log
211
Display Log
211
Print Log
211
Clear Log
212
Exit Diagnostics
212
Configuration Menu
213
Entering Config Menu
213
Exiting the Config Menu
213
Reset Fuser Cnt
214
Black Only Mode
214
Prt Quality Pgs
214
Color Trapping
214
Tray Insert Msg
214
Size Sensing
214
Panel Menus
215
PPDS Emulation
215
Demo Mode
215
Factory Defaults
215
Energy Conserve
215
Event Log
215
Auto Color Adjust
216
Paper Prompts
216
Env Prompts
216
Font Sharpening
216
Jobs on Disk
217
Disk Encryption
217
Exit Config Menu
217
Paper Jams
218
Identifying Jams
218
Access Doors and Trays
218
Understanding Jam Messages
219
Paper Jam Messages
219
Clearing the Entire Paper Path
220
Area a
220
Area B
221
Area C
221
Area D
222
Area T1
222
Area E
223
Area T<X
223
Area J
224
Area K
224
Area L
225
Clearing Mailbox, Finisher, or Output Expander Jams (Area M)
225
Clearing Fuser Jams
226
Clearing Image Transfer Unit Jams
227
If You Still Need Help
232
Repair Information
233
Handling ESD-Sensitive Parts
233
Screw Identification Table
234
Removal Procedures
238
Operator Panel Bezel Removal
239
Lens Removal
241
Front Cover Rear Pivot Cover Removal
242
Front Cover or Front Cover Backplate Assembly Removal
243
Redrive Cap Removal
244
Top Cover Assembly Removal
245
Front Lower Left Cover Removal
249
Paper Path Access Door Removal
250
Front Left Handle Cover Assembly Removal
251
Front Lower Right Cover Removal
251
Front Right Handle Cover Assembly Removal
253
Rear Cover Removal
254
Lower Right Door Assembly Removal
256
Left Lower Cover Removal
256
Lower Jam Access Door Assembly Removal
257
Redrive Door Removal
258
Autocompensator Pick Assembly Removal
259
BOR Drive Assembly Removal
266
Cartridge Contact Assembly Removal
267
Cartridge Drive Assembly Removal
270
Developer HVPS Board Removal
271
Friction Buckler and Buckler Housing Removal
272
Front Right Light Shield Removal
274
Fuser Assembly Removal
276
Fuser Bottom Duct Removal
278
Fuser Drive Assembly Removal
278
Fuser Fan Removal
279
Fuser Top Duct Removal
279
Inner System Board Shield Removal
280
ITU Assembly Removal
281
ITU Drive Assembly Removal
284
LVPS Assembly Removal
285
Media Size Sensing Assembly Removal
287
Media Size Sensing Board Removal
290
Multipurpose Feeder (MPF) Removal
291
Multipurpose Feeder (MPF) Autocompensator or Side Restraints Removal
294
Multipurpose Feeder (MPF) Motor Removal
296
Nip Relief Handle Removal
297
Installation Notes
298
Operator Panel Assembly Removal
300
Outer System Board Shield Removal
301
Pick Rolls Removal
302
Printhead Removal and Adjustments
305
Mechanical Alignment
305
Black Printhead Electronic Alignment
310
Color Printhead Electronic Alignment
311
Rear Bellcrank Removal (Cyan, Magenta, Yellow)
312
Rear Bellcrank (Black) Removal
314
Redrive Assembly Removal
315
Registration Motor Removal
316
Rib Housing Removal
317
RIP Fan Removal
319
S2/Narrow Media/Transparency/Multipurpose Feeder Cable Removal
320
S2/Narrow Media/Transparency/Multipurpose Feeder Sensors Removal
321
Second Transfer Roll Removal
321
System Board Removal
322
Transfer HVPS Board Removal
324
Transfer Plate Assembly Removal
327
Vacuum Transport Belt (VTB) Removal
328
Vacuum Transport Belt (VTB) Fan Removal
330
Waste Container Door Removal
330
Waste Container Latch Removal
331
Web Oiler Fuser Assembly and Card Removal and Replacement
332
Connector Locations
339
Locations
339
Printer Boards
339
Printer Motors
340
Printer Sensors
341
Cartridge Contact Assembly Pin Locations (Cyan, Magenta and Yellow)
342
Cartridge Contact Assembly Pin Locations (Black)
343
System Board Cabling Reference
344
Connectors
345
System Board
345
System Board
346
Autoconnect-Top
356
Autoconnect-Bottom
357
Transfer High Voltage Power Supply (HVPS)
358
Developer High Voltage Power Supply (HVPS) Board
360
Low Voltage Power Supply (LVPS)
361
LVPS Cable Connectors to System Board
361
LVPS Fuser Connectors
362
Media Size Sensing Board
363
High-Capacity Input Tray (HCIT)
364
Staplesmart Finisher
366
Preventive Maintenance
369
Safety Inspection Guide
369
Scheduled Maintenance
369
Standard Fusers
369
ITU Maintenance Kits
369
Lubrication Specifications
370
Lubrication for Replacement Motors
370
Fuser Drive Assembly
370
Cartridge Drive Assembly
371
ITU Drive Assembly
371
Parts Catalog
373
How to Use this Parts Catalog
373
Assembly 1: Covers
374
Assembly 2: Cartridge Mounting
378
Assembly 3: Fuser Assembly
379
Assembly 4: Fuser Drive
382
Assembly 5: Vacuum Transport Belt (VTB) Assembly
383
Assembly 6: Transfer
384
Assembly 7: Printheads
385
Assembly 8: Paper Feed Output (Redrive)
386
Assembly 9: Paper Feed Input
387
Assembly 10: Media Size Sensing
388
Assembly 11: Paper Feed Transport
389
Assembly 12: Multipurpose Feeder (MPF)
390
Assembly 13: 500-Sheet Integrated Tray
392
Assembly 14: Autocompensator Assembly
393
Assembly 15: ITU Assembly
394
Assembly 16: ITU Drive Assembly
395
Assembly 17: ITU Loading
396
Assembly 18: Waste Toner
398
Assembly 19: BOR Drive Assembly
399
Assembly 20: Cartridge Contact Assembly
400
Assembly 21: Cartridge Drive Assembly
401
Assembly 22: Electronics
402
Assembly 23: Electronics-Cabling Interconnections 1
408
Assembly 24: Electronics-Cabling Interconnections 2
410
Assembly 25: Electronics-Cabling Interconnections 3
412
Assembly 26: Electronics-Cabling Interconnections 4
413
Assembly 27: Output Expander
414
Assembly 28: 5-Bin Mailbox
418
Assembly 29: 500-Sheet Drawer Option
422
Assembly 30: Duplex Option
426
Assembly 31: High-Capacity Input Tray (HCIT)
430
Assembly 32: Staplesmart Finishe
434
Assembly 33: Envelope Option
438
Assembly 34: Outdoor Media Tray Option
440
Assembly 35: Banner Option
441
Assembly 36: Options
442
Appendix A-Service Tips
445
Identifying the Printheads
445
Redrive Belt Routing
446
Duplex Option Deflector Button Replacement
447
Appendix B-Print Quality Samples
449
Print Tests
449
Print Quality Pages-Title Page (Total of Five
449
Print Quality Pages-Page 1 (Total of Five
450
Print Quality Pages-Page 2 (Total of Five
451
Print Quality Pages-Page 3 (Total of Five
452
Print Quality Pages-Page 4 (Total of Five
453
Registration and Alignment
454
Quick Test Page
454
Printhead Mechanical Alignment Test Page
455
Printhead Electronic Alignment Test Page-Magenta (One of Two
456
Printhead Electronic Alignment Test Page-Magenta (Two of Two
457
Index
459
Part Number Index
467
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Lexmark C78x Specifications
General
Brand
Lexmark
Model
C78x
Category
Printer
Language
English
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