Lexmark C792 series - Tools Required for Service

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1-12 Service Manual

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Tools required for service

Flat-blade screwdriver

#1 Phillips screwdriver, magnetic

#2 Phillips screwdriver, magnetic

#2 Phillips screwdriver, magnetic short-blade

Needlenose pliers

Diagonal side cutters

Spring hook

Feeler gauges

Analog or digital multimeter

Parallel wrap plug 1319128

Twinax/serial debug cable 1381963

Coax/serial debug cable 1381964

Main Page

Default Chapter3
- Table of Contents3
Notices and Safety Information15
- Laser Notice15
- Safety Information21
  - Next24
Preface24
- Navigation Buttons24
  - Go Back24
- Change History25
- Conventions26
General Information27
- Models27
- Maintenance Approach27
- Printer Configurations28
- Options and Features29
- Printer Specifications30
- Tools Required for Service38
- Acronyms39
Diagnostic Information41
- Troubleshooting Map41
  - Error Code Divisions42
  - Power-On Self Test (POST) Sequence42
- Paper Jams43
- Output Option Paper Jams61
- Print Quality70
User Messages91
- User Prompts91
- User Attendance Messages (0-99)93
Service Errors100
- Printer Hardware Errors (100-199)100
- Firmware And/Or System Electronics (900-999)102
Symptoms106
- Symptom Table-Base Printer106
- Symptom Table-500-Sheet Tray Input Option106
- Symptom Table-2000-Sheet High Capacity Feeder Input Option106
Service Checks107
- XX-Printhead Error Service Check107
- XX-Motor (Fuser) Error Service Check108
- XX-Fuser Error Service Check110
- XX, 145.XX-ITU Error Service Check112
- XX-LVPS Error Service Check113
- XX-Cartridge Sensor Error Service Check114
- XX-Black Cartridge Motor Error Service Check120
- XX-Cyan Cartridge Motor Error Service Check121
- XX-Magenta Cartridge Motor Error Service Check123
- XX-Yellow Cartridge Motor Error Service Check124
- XX-Autocomp (Tray 1) Motor Error Service Check126
- XX-Staging Motor Error Service Check127
- XX-Paper Path Redrive Motor Error Service Check128
- XX-Duplex Motor Error Service Check129
- XX-ITU Motor Error Service Check130
- XX-Main Fan Error Service Check131
- XX-LVPS Fan Error Service Check132
- XX-Blower Fan Error Service Check133
- Paper Jam Error Service Check134
- 200.08-Paper Jam Error Service Check135
- 200.07-Paper Jam Error Service Check136
- Paper Jam Error Service Check138
- 200.38-Paper Jam Error Service Check139
- 200.37-Paper Jam Error Service Check141
- Paper Jam Error Service Check142
- 200.48-Paper Jam Error Service Check143
  - 200.47-Paper Jam Error Service Check144
  - Paper Jam Error Service Check147
  - 250.22-MPF Motor Error Service Check155
  - Go Back155
  - XX-HTU Input Sensor Error Service Check157
  - XX-HTU Output Sensor Error Service Check158
  - XX-HTU Second Sensor Error Service Check159
  - XX-5-Bin Mailbox Input Sensor Error Service Check161
  - XX-5-Bin Mailbox Pass Thru Sensor Error Service Check163
  - XX-Finisher/Stacker Sensor (Pass Thru) Error Service Check166
  - 456.08-Finisher Stapler Home Sensor Error Service Check167
  - X-Finisher Stapler Motor Error Service Check168
  - X-Finisher/Stacker Paddle Motor Error Service Check169
  - 461.08-Hole Punch Sensor Error Service Check170
  - 461.32-Hole Punch Motor Error Service Check171
  - System Software Error172
  - MPF Paper out Sensor Error Service Check175
  - Waste Toner Sensor Error Service Check176
  - Waste Toner Full Sensor Error Service Check177
  - 938.29, 938.30-Weather Station Error Service Check178
  - Remote Weather Station Error Service Check179
  - 950.29-EPROM Mismatch Failure180
  - Processor Fan Failure Service Check181
  - XX-POST Error Service Check182
  - Bin-Full Sensor Service Check184
  - Bubble Sensor Service Check185
  - D1 and D2 Sensor Service Check187
  - Dead Printer Service Check189
  - Double Feed (550-Sheet/2000-Sheet Input Option) Service Check190
  - Input Option Not Detected (550-Sheet/2000-Sheet Input Option) Service Check192
  - Input, S1, Narrow Media, and Near Narrow Media Sensor Service Check193
  - Interlock Switch Error Service Check195
  - Jam Clearance Cover Open (550-Sheet/2000-Sheet Input Option) Service Check196
  - Media Size Error (550-Sheet/2000-Sheet Input Option) Service Check198
  - Media Tray Missing (550-Sheet Input Option) Service Check199
  - Media Tray Missing (2000-Sheet Input Option) Service Check200
  - Networking Service Check202
  - Pick Arm Stuck down Service Check204
  - Redrive Bubble Sensor Service Check205
  - Skew (550-Sheet Input Option) Service Check206
  - Skew (2000-Sheet Input Option) Service Check207
  - Tray Empty (2000-Sheet Input Option) Service Check209
  - Tray Jam Indicator (550-Sheet/2000-Sheet Input Option) Service Check211
  - Tray Linking Service Check211
Diagnostic Aids213
- Understanding the Operator Panel and Menus213
- Operator Panel213
- Understanding the Home Screen214
- Using the Touch-Screen Buttons215
- Other Touch-Screen Icons216
- Administrative Menus217
Accessing Service Menus218
Diagnostics Menu219
- Diagnostics Menus219
- Exiting the Diagnostics Mode221
- Dual Diode Adjust221
- Registration222
- Alignment Menu223
- Misc Tests225
- Print Tests225
  - Print Tests (Input Sources)225
  - Print Quality Pages226
- Hardware Tests226
- Duplex Tests228
  - Duplex Quick Test228
  - Duplex Top Margin Offset228
- Input Tray Tests229
  - Feed Test229
  - Sensor Test229
- Output bin Tests230
- Finisher Tests231
- Base Sensor Test233
- Device Tests233
- Printer Setup234
- Ep Setup236
- Event Log236
  - Print Log237
  - Clear Log237
- Exit Diags237
Configuration Menu238
- Entering the Configuration Menu238
- Exiting the Configuration Menu239
- Black Only Mode239
- Print Quality Pages239
- Reports239
- Color Trapping239
- Tray Insert Msg239
- Size Sensing240
- Panel Menus240
- PPDS Emulation240
- Download Emuls240
- Factory Defaults240
- Energy Conserve240
- Color Adjustment240
- Auto Align Adj241
- Color Alignment241
- Motor Calibration241
- Paper Prompts241
- Envelope Prompts241
- Action for Prompts241
- Jobs on Disk241
- Disk Encryption241
- Wipe Disk242
- Font Sharpening242
- Require Standby242
- UI Automation242
- Key Repeat Initial Delay242
- Key Repeat Rate242
- Clear Custom Status242
- USB Speed242
- Exit Config Menu242
Theory of Operation243
- Paper Path, Transport Components243
- Print Engine Theory245
- Printhead Verification253
Repair Information255
- Handling ESD-Sensitive Parts255
- Removal Procedures255
  - Arrangement of Removals in this Chapter256
- Base Printer Cover Removals257
- Base Printer Removals290
Input Option Removals419
550-Sheet Tray419
- 550-Sheet Drawer Assembly Removal420
- 550-Sheet Media Tray Assembly Removal420
- 550-Sheet Tray Controller Card Assembly Removal421
- 550-Sheet Tray Deflector Removal423
- 550-Sheet Tray Drive Assembly Removal424
- 550-Sheet Tray Left Anti-Tip Latch Removal427
- 550-Sheet Tray Pass Thru Sensor Removal429
- 550-Sheet Tray Pick Assembly Removal430
- 550-Sheet Tray Pick Roll Assembly Removal434
- 550-Sheet Tray Right Anti-Tip Latch Assembly Removal436
- 550-Sheet Tray Top Metal Cover Removal437
2000-Sheet High-Capacity Feeder438
- 2000-Sheet High-Capacity Feeder Bellcrank Assembly Removal438
- 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal439
- 2000-Sheet High-Capacity Feeder Drive Assembly Removal440
- 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal444
- 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal448
- 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal452
- 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal453
- 2000-Sheet High-Capacity Feeder LED Bracket Removal455
- 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal456
- 2000-Sheet High-Capacity Feeder Left Side Cover Removal458
- 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal460
- 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal466
- 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal469
- 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal471
- 2000-Sheet High-Capacity Feeder Pick Assembly Removal472
- 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal478
- 2000-Sheet High-Capacity Feeder Rear Cover Removal482
- 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal484
- 2000-Sheet High-Capacity Feeder Right Side Cover Removal485
Output Option Removals488
5-Bin Mailbox488
- 5-Bin Mailbox Access Door Removal488
- 5-Bin Mailbox Backup Roll Plate Assembly Removal489
- 5-Bin Mailbox Bin-Full Beacon Card and Light Pipe Removal491
- 5-Bin Mailbox Cave Beacon Removal491
- 5-Bin Mailbox Controller Card Removal492
- 5-Bin Mailbox Diverter Solenoid Removal493
- 5-Bin Mailbox Diverter Spring Removal494
- 5-Bin Mailbox Feed Motor with Plate Removal495
- 5-Bin Mailbox Front Cover Removal496
- 5-Bin Mailbox Media bin Full Actuator Removal498
- 5-Bin Mailbox Option Cable Removal499
- 5-Bin Mailbox Output bin Deflector Removal500
- 5-Bin Mailbox Output bin Paper Bail Removal501
- 5-Bin Mailbox Output bin Roller Removal502
- 5-Bin Mailbox Output bin Sensors Removal502
- 5-Bin Mailbox Paper Jam Beacon Removal503
- 5-Bin Mailbox Rear Cover Removal503
- 5-Bin Mailbox Roller Removal505
- 5-Bin Mailbox Sensor (Input) Assembly Removal506
- 5-Bin Mailbox Sensor (Pass Thru) Assembly Removal506
- 5-Bin Mailbox Top Cover Removal507
- 5-Bin Mailbox Tray Extension Removal508
Staplesmart Finisher and High-Capacity Output Stacker509
- Finisher or Stacker Access Door Beacon LED and Beacon Housing Removal509
- Finisher or Stacker Bin-Full Spring Removal510
- Finisher or Stacker Bottom Cover Removal511
- Finisher or Stacker Controller Card Assembly Removal512
- Finisher or Stacker Feed Roller Removal513
- Finisher or Stacker Front Cover Removal514
- Finisher or Stacker LED Sensor Cover Removal516
- Finisher or Stacker Left Access Door Assembly Removal516
- Finisher or Stacker Media Stack Flap and Media Stack Flap Actuator Removal518
- Finisher or Stacker Option Cable Removal519
- Finisher or Stacker Output bin Extension Removal520
- Finisher or Stacker Output bin LED and LED Lens Removal520
- Finisher or Stacker Paddle Drive Gear Removal521
- Finisher or Stacker Paddle Drive Motor Assembly Removal521
- Finisher or Stacker Rear Cover Removal523
- Finisher or Stacker Sensor (Bin-Full Receive) Removal525
- Finisher or Stacker Sensor (Bin-Full Send) Removal526
- Finisher or Stacker Sensor (Finisher bin Media Present) Removal527
- Finisher or Stacker Sensor (Paddle HP) Removal528
- Finisher Sensor (Stapler Access Door Interlock) Removal528
- Finisher or Stacker Sensor (Pass Thru) Removal529
- Finisher or Stacker Sensor (Tamper HP Left and Right) Removal530
- Finisher or Stacker Standard Output bin LED and LED Lens Removal531
- Finisher or Stacker Tamper Drive Belt Removal532
- Finisher or Stacker Tamper Drive Motor Assembly Removal532
- Finisher or Stacker Tamper Recoil Spring Removal533
- Finisher or Stacker Top Cover Removal534
- Finisher Stapler Unit Assembly Removal535
Horizontal Transport Unit (HTU) and Holepunch Unit536
- HTU Access Door Removal536
- HTU Access Door Paper Jam Beacon (with Cover and Cable) Removal537
- HTU Access Door Rollers Removal538
- HTU bin Diverter Gate Spring Removal540
- HTU bin Media Exit Spring Removal540
- HTU Card (Bin-Full Receive Card and Lens) Removal541
- HTU Card (Bin-Full Send Card and Lens) Removal542
- HTU Controller Card Removal543
- HTU Drive Belt Removal544
- HTU Drive Gear Spring Removal545
- HTU Engagement Roller Removal546
- HTU Exit Roller Removal547
- HTU Front Redrive Cover Removal547
- HTU Front Standard bin Cover Removal548
- HTU Locking Lever Removal549
- HTU Locking Lever Card Removal551
- HTU Lower Redrive Guide Removal551
- HTU Option Hook Removal554
- HTU Option Roller Removal556
- HTU Output bin Removal557
- HTU Output bin Extension Removal557
- HTU Output bin Solenoid Removal558
- HTU Output bin Wire Stop Removal559
- HTU Output Option Removal560
- HTU Output Option Guide Removal562
- HTU Output Option Solenoid Removal562
- HTU Output Sensor Removal563
- HTU Outer Front Cover Removal (AIO Only)564
- HTU Rear Redrive Cover Removal564
- HTU Rear Standard bin Cover Removal566
  - HTU Right Bottom Cover Removal569
  - HTU Right Inner Cover Removal570
  - HTU Sensor (Access Door Interlock) Removal574
  - HTU Sensor (Empty Bin) Removal575
  - HTU Sensor (Input) Removal576
  - HTU Sensor (Output Option Position) Removal577
  - HTU Sensor (Second) Removal578
  - HTU Sensor Cable (Bin-Full Send and Receive) Removal578
  - HTU Stopper Diverter Removal579
  - HTU Timing Belts (Rear) Removal580
  - HTU to Printer Cable Removal581
  - HTU Top Redrive Cover Removal582
  - HTU Top Right Cover Removal583
  - HTU Transport Gear Removal584
  - HTU Transport Motor Removal585
  - HTU Upper Exit Shaft Removal585
  - HTU Upper Guide Removal586
  - HTU Punch Motor Removal588
  - HTU Punch Unit Removal590
  - HTU Punch Gear Removal591
Connector Locations593
- Locations593
  - System Board Cabling Reference593
- Connectors594
Preventive Maintenance613
- Safety Inspection Guide613
- Individual Maintenance Part Expected Life613
- Lubrication Specifications613
- Lubrication for Replacement Motors613
  - Redrive Parts Packet614
  - Fuser Drive Assembly615
Parts Catalog617
- How to Use this Parts Catalog617
- Assembly 1: Top, Right, and Front Covers618
- Assembly 2: Left and Rear Covers620
- Assembly 3: Front622
- Assembly 3.1: Front (Continued)624
- Assembly 4: Left626
- Assembly 4.1: Left (Continued)628
- Assembly 5: Rear630
- Assembly 6: Optional 550-Sheet Tray632
- Assembly 7: Optional 550-Sheet Drawer Assembly634
- Assembly 8: Optional 2000-Sheet High-Capacity Feeder (Complete)636
- Assembly 9: Optional 2000-Sheet High-Capacity Feeder638
- Assembly 10: Finisher/High-Capacity Ouput Stacker Assembly640
- Assembly 10.1: Finisher/High-Capacity Output Stacker Assembly (Continued)642
- Assembly 11: Finisher Stapler Assembly644
- Assembly 12: Finisher/Stacker Assembly (Complete)646
- Assembly 13: 5-Bin Mailbox Assembly (Complete)648
- Assembly 14: 5-Bin Mailbox Assembly (Covers)650
- Assembly 15: 5-Bin Mailbox Assembly (Interior)652
- Assembly 16: HTU (Complete)654
- Assembly 17: HTU (Covers)656
- HTU (Left Interior)658
- Assembly 19: HTU (Right Interior)660
- Assembly 20: HTU with Hole Punch (Complete)662
- Assembly 21: HTU with Hole Punch (Covers)664
- Assembly 22: HTU with Hole Punch (Left Interior)666
- Assembly 23: Miscellaneous668
- Assembly 24: Internal Options670
- Cable and Thermistor Location Table671
- Screw and Retainer Identification Table675
Appendix A-Print Samples681
- Print Tests681
- Registration and Alignment686
Index691
Part Number Index699

Lexmark C792 series - Tools Required for Service

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