Lexmark C792 series - Sensor (D1, D2, and Fuser Bubble) Removal

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Sensor (D1, D2, and fuser bubble) removal

1. Open the left access door.

2. Remove two screws (A) from the duplex unit, and remove the rail cover.

3. Pull out the sensor assembly, and rotate it up.

4. Slide out the sensor you are replacing: fuser bubble (A), D1 (B), D2 (C).

ABC

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 - Sensor (D1, D2, and Fuser Bubble) Removal

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