Lexmark C792e 5062-210 - Sensor (D1, D2, and Fuser Bubble) Removal

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4-132 Service Manual

5062

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 Information13
- Laser Notice13
- Safety Information19
Preface22
- Navigation Buttons22
- Conventions23
General Information25
- Models25
- Maintenance Approach25
- Printer Configurations26
- Options and Features27
- Printer Specifications28
- Tools Required for Service36
- Acronyms37
Diagnostic Information39
- Troubleshooting Map39
  - Error Code Divisions40
  - Power-On Self Test (POST) Sequence40
- Paper Jams40
- Print Quality59
User Messages79
- User Prompts79
- User Attendance Messages (0-99)81
Service Errors88
- Printer Hardware Errors (100-199)88
- Firmware And/Or System Electronics (900-999)90
Symptoms94
- Symptom Table-Base Printer94
- Symptom Table-500-Sheet Tray Input Option94
- Symptom Table-2000-Sheet High Capacity Feeder Input Option94
Service Checks95
- 110.XX-Printhead Error Service Check95
- 120.XX-Motor (Fuser) Error Service Check96
- 121.XX-Fuser Error Service Check98
- 125.XX/145.XX-ITU Error Service Check100
- 126.XX-LVPS Error Service Check101
- 133.XX-Cartridge Sensor Error Service Check102
- 141.XX-Black Cartridge Motor Error Service Check104
- 142.XX-Cyan Cartridge Motor Error Service Check105
- 143.XX-Magenta Cartridge Motor Error Service Check107
- 144.XX-Yellow Cartridge Motor Error Service Check108
- 146.XX-Autocomp (Tray 1) Motor Error Service Check110
- 147.XX-Staging Motor Error Service Check111
- 149.XX-Paper Path Redrive Motor Error Service Check112
- 150.XX-Duplex Motor Error Service Check112
- 151.XX-ITU Motor Error Service Check114
- 171.XX-Main Fan Error Service Check115
- 172.XX-LVPS Fan Error Service Check115
- 173.XX-Blower Fan Error Service Check116
- 200.02-Paper Jam Error Service Check117
- 200.03, 200.08-Paper Jam Error Service Check118
- 200.05, 200.07-Paper Jam Error Service Check119
- 200.32-Paper Jam Error Service Check120
- 200.33, 200.38-Paper Jam Error Service Check122
- 200.35, 200.37-Paper Jam Error Service Check123
- 200.42-Paper Jam Error Service Check125
- 200.43, 200.48-Paper Jam Error Service Check126
- 200.45, 200.47-Paper Jam Error Service Check127
- Paper Jam Error Service Check128
- 202.32-Paper Jam Error Service Check130
- 241.02-Paper Jam Error Service Check131
  - Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check132
  - Option) Service Check134
  - Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check136
  - 250.21, 250.22-MPF Motor Error Service Check138
  - 900.XX-Software Error Service Check140
  - 938.16-MPF Paper out Sensor Error Service Check141
  - 938.18-Waste Toner Sensor Error Service Check142
  - 938.19-Waste Toner Full Sensor Error Service Check143
  - 938.27, 938.29, 938.30-Weather Station Error Service Check144
  - 938.28-Remote Weather Station Error Service Check145
  - 950.00-950.29-EPROM Mismatch Failure146
  - 956.XX-System Board Failure Service Check147
  - 990.01-POST Error (2000-Sheet Input Option) Service Check147
  - 990.05-POST Error (550-Sheet Input Option) Service Check149
  - Bubble Sensor Service Check150
  - D1 and D2 Sensor Service Check152
  - Dead Printer Service Check155
  - Double Feed (550-Sheet/2000-Sheet Input Option) Service Check156
  - Input Option Not Detected (550-Sheet/2000-Sheet Input Option) Service Check158
  - Input, S1, Narrow Media, and Near Narrow Media Sensor Service Check159
  - Jam Clearance Cover Open (550-Sheet/2000-Sheet Input Option) Service Check161
  - Media Size Error (550-Sheet/2000-Sheet Input Option) Service Check163
  - Media Tray Missing (550-Sheet Input Option) Service Check164
  - Media Tray Missing (2000-Sheet Input Option) Service Check165
  - Networking Service Check167
  - Bin-Full Sensor Service Check169
  - Pick Arm Stuck down Service Check170
  - Redrive Bubble Sensor Service Check171
  - Skew (550-Sheet Input Option) Service Check172
  - Skew (2000-Sheet Input Option) Service Check173
  - Tray Empty (2000-Sheet Input Option) Service Check175
  - Tray Jam Indicator (550-Sheet/2000-Sheet Input Option) Service Check177
  - Tray Linking Service Check177
Diagnostic Aids179
- Understanding the Operator Panel and Menus179
- Accessing Service Menus184
- Diagnostics Menu185
Configuration Menu203
- Entering the Configuration Menu203
- Exiting the Configuration Menu204
- Black Only Mode204
- Theory of Operation208
  - Paper Path, Transport Components208
  - Print Engine Theory210
- Printhead Verification218
Repair Information221
- Handling ESD-Sensitive Parts221
- Removal Procedures221
  - Arrangement of Removals in this Chapter222
- Base Printer Cover Removals222
Base Printer Removals255
- ACM Bias Spring Removal255
- Bin-Full Flag Removal256
- Bin-Full Sensor Removal257
- Cartridge Blower Assembly Removal257
- Cartridge Contact Block Assembly Removal261
- Cartridge Memory Block Removal262
- Cartridge Metering Cable Removal265
- Cartridge Rail Removal267
- Datum Bell Crank Removal269
- Duplex Assembly Removal271
- EP Drive Assembly Removal274
- Exit Cooling Duct Removal276
- Front Access Door Beacon Removal277
- Fuser Assembly Removal278
- Fuser Drive Assembly Removal281
- Fuser System Card and LVPS Cable Removal283
- Fuser Thermistor Removal286
- High-Voltage Power Supply (HVPS) Board Removal287
- Host USB Cable Removal291
- Housing Interlock Assembly Removal291
- ITU Assembly Removal292
- ITU Autoconnect Removal294
- ITU Block Assembly Removal296
- Left Access Door Piston Removal298
- Logo Panel Removal301
- Low-Voltage Power Supply (LVPS) Removal302
- LVPS Exit Duct Removal305
- LVPS Fan Removal306
- Main Fan Removal308
- Media Tray Rail Removal309
- MPF Breakaway Assemblies Removal314
- MPF Paper Pick Assembly Removal (Including the MPF Ratchet Collar and MPF Drive Pulley)317
- MPF Pick Rolls and Special Wear Strip Removal320
- MPF Drive Assembly Removal322
- MPF Sensor Plate Assembly Removal324
- MPF Wear Strips Removal325
- Operator Panel (OP) Assembly Removal325
- OP Panel Button Removal328
- OP Panel Display Removal329
- OP Panel UICC Card Removal330
- Pad Removal332
  - Paper Auto-Size Sensor Removal333
  - Paper Path Redrive Assembly with Sensors Removal333
  - Paper Pick Mechanism Assembly Removal336
  - Pick Rolls Removal338
  - Printhead Removal, Installation, and Alignment339
    - Installing and Coarse Aligning the Printhead341
    - Aligning the Printhead344
    - Dual Diode Alignment344
    - Registration (Black)345
    - Color Alignment (Cyan, Yellow, and Magenta)346
  - Redrive Gears Removal349
  - Redrive Motor Removal350
  - Sensor (D1, D2, and Fuser Bubble) Removal352
  - Sensor (Input, S1, Narrow Media, Near Narrow Media) Removal353
  - Speaker Removal354
  - Staging Deflector Assembly Removal355
  - Staging Paper Path Reference Edge Assembly Removal356
    - Aligning the Staging Paper Path Reference Edge360
  - Standard Media Tray Removal362
  - System Board Removal362
  - System Board Cage with Board Removal365
  - Waste Toner Container Removal367
  - Waste Toner Gears Removal367
  - Waste Toner Sensor Removal368
  - Waste Toner Cable Removal369
  - Waste Toner Full Cable Removal370
  - Waste Toner Full Sensor Removal371
  - Waste Toner Tray Bracket Removal372
- Input Option Removals374
- 550-Sheet Tray374
  - 550-Sheet Drawer Assembly Removal375
  - 550-Sheet Media Tray Assembly Removal375
  - 550-Sheet Tray Controller Card Assembly Removal376
  - 550-Sheet Tray Deflector Removal378
  - 550-Sheet Tray Drive Assembly Removal379
  - 550-Sheet Tray Left Anti-Tip Latch Removal382
  - 550-Sheet Tray Pass Thru Sensor Removal384
  - 550-Sheet Tray Pick Assembly Removal385
  - 550-Sheet Tray Pick Roll Assembly Removal389
  - 550-Sheet Tray Right Anti-Tip Latch Assembly Removal391
  - 550-Sheet Tray Top Metal Cover Removal392
- 2000-Sheet High-Capacity Feeder393
  - 2000-Sheet High-Capacity Feeder Bellcrank Assembly Removal393
  - 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal394
  - 2000-Sheet High-Capacity Feeder Drive Assembly Removal395
  - 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal399
  - 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal403
  - 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal407
  - 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal408
  - 2000-Sheet High-Capacity Feeder LED Bracket Removal410
  - 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal411
  - 2000-Sheet High-Capacity Feeder Left Side Cover Removal413
  - 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal415
  - 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal421
  - 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal424
  - 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal425
  - Sheet High-Capacity Feeder Pick Assembly Removal427
  - 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal434
  - 2000-Sheet High-Capacity Feeder Rear Cover Removal438
  - 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal440
  - 2000-Sheet High-Capacity Feeder Right Side Cover Removal441
Output Option Removals444
5-Bin Mailbox444
- 5-Bin Mailbox Access Door Removal444
- 5-Bin Mailbox Assembly Media bin Full Actuator Removal445
- 5-Bin Mailbox Assembly Sensor (Pass Thru) Removal446
- 5-Bin Mailbox Assembly Spring Removal447
- 5-Bin Mailbox Backup Roll Plate Assembly Removal448
- 5-Bin Mailbox Bin-Full Beacon Card and Covers Removal449
- 5-Bin Mailbox Cave Beacon Removal449
- 5-Bin Mailbox Controller Card Removal450
- 5-Bin Mailbox Diverter Solenoid Removal451
- 5-Bin Mailbox Feed Motor with Plate Removal452
- 5-Bin Mailbox Front Cover Removal453
- 5-Bin Mailbox Option Cable Removal455
- 5-Bin Mailbox Output bin Deflector Removal456
- Bin Mailbox Output bin Paper Bail Removal457
- 5-Bin Mailbox Output bin Sensors Removal458
- 5-Bin Mailbox Rear Cover Removal458
- 5-Bin Mailbox Top Cover Removal460
- 5-Bin Mailbox Tray Extension Removal462
Staplesmart Finisher and High-Capacity Output Stacker463
- Finisher or Stacker Access Door Beacon LED and Beacon Housing Removal463
- Finisher or Stacker Bin-Full Spring Removal463
- Finisher or Stacker Bottom Cover Removal465
- Finisher or Stacker Controller Card Assembly Removal465
- Finisher or Stacker Feed Roller Removal467
- Finisher or Stacker Front Cover Removal468
- Finisher or Stacker LED Sensor Cover Removal469
- Finisher or Stacker Left Access Door Assembly Removal470
- Finisher or Stacker Media Stack Flap and Media Stack Flap Actuator Removal471
- Finisher or Stacker Option Cable Removal472
- Finisher or Stacker Output bin Extension Removal474
- Finisher or Stacker Output bin LED and LED Lens Removal474
- Finisher or Offset Stacker Paddle Drive Gear Removal475
- Finisher or Stacker Paddle Drive Motor Assembly Removal475
- Finisher or Stacker Rear Cover Removal477
- Finisher or Stacker Sensor (Bin-Full Receive) Removal478
- Finisher or Stacker Sensor (Bin-Full Send) Removal479
- Finisher or Stacker Sensor (Finisher bin Media Present) Removal480
- Finisher or Stacker Sensor (Paddle HP) Removal481
- Finisher Sensor (Stapler Access Door Interlock) Removal481
- Finisher Sensor (Stapler Pass Thru) Removal482
- Finisher or Stacker Sensor (Tamper HP Left and Right) Removal483
- Finisher or Stacker Standard Output bin LED and LED Lens Removal484
- Finisher or Stacker Tamper Drive Belt Removal485
- Finisher or Stacker Tamper Drive Motor Assembly Removal485
- Finisher or Stacker Tamper Recoil Spring Removal486
  - Finisher or Stacker Top Cover Removal487
  - Finisher Stapler Unit Assembly Removal488
- Horizontal Transport Unit (HTU)489
  - HTU Access Door Removal489
  - HTU Access Door Paper Jam Beacon (with Cover and Cable) Removal490
  - HTU Access Door Rollers Removal491
  - HTU bin Diverter Gate Spring Removal491
  - HTU bin Media Exit Spring Removal493
  - HTU Card (Bin-Full Receive Card and Lens) Removal493
  - HTU Card (Bin-Full Send Card and Lens) Removal495
  - HTU Controller Card Removal496
  - HTU Drive Belt Removal497
  - HTU Drive Gear Spring Removal497
  - HTU Engagement Roller Removal498
  - HTU Exit Roller Removal499
  - HTU Front Redrive Cover Removal499
  - HTU Front Standard bin Cover Removal500
  - HTU Locking Lever Removal501
  - HTU Locking Lever Card Removal502
  - HTU Lower Redrive Guide Removal503
  - HTU Option Hook Removal504
  - HTU Option Roller Removal507
  - HTU Output bin Removal509
  - HTU Output bin Extension Removal509
  - HTU Output bin Solenoid Removal510
  - HTU Output bin Wire Stop Removal511
  - HTU Output Option Guide Removal512
  - HTU Output Option Solenoid Removal512
  - HTU Output Sensor Removal513
  - HTU Outer Front Cover Removal (AIO Only)514
  - HTU Rear Redrive Cover Removal514
  - HTU Rear Standard bin Cover Removal516
  - HTU Right Bottom Cover Removal519
  - HTU Right Inner Cover Removal520
  - HTU Sensor (Access Door Interlock) Removal524
  - HTU Sensor (Empty Bin) Removal525
  - HTU Sensor (Input) Removal526
  - HTU Sensor (Output Option Position) Removal527
  - HTU Sensor (Second) Removal528
  - HTU Sensor Cable (Bin-Full Send and Receive) Removal528
  - HTU Stopper Diverter Removal529
  - HTU Timing Belts (Rear) Removal530
  - HTU to Printer Cable Removal530
  - HTU Top Redrive Cover Removal531
  - HTU Top Right Cover Removal532
  - HTU Transport Gear Removal533
  - HTU Transport Motor Removal534
  - HTU Upper Exit Shaft Removal534
  - HTU Upper Guide Removal535
Connector Locations539
- Locations539
  - System Board Cabling Reference539
- Connectors540
Preventive Maintenance557
- Safety Inspection Guide557
- Lubrication Specifications557
- Lubrication for Replacement Motors557
  - Redrive Parts Packet558
  - Fuser Drive Assembly559
Parts Catalog561
- How to Use this Parts Catalog561
- Assembly 1: Top, Right, and Front Covers562
- Assembly 2: Left and Rear Covers564
- Assembly 3: Front566
- Assembly 4: Left570
- Assembly 5: Rear574
- Assembly 6: Optional 550-Sheet Tray576
- Assembly 7: Optional 550-Sheet Drawer Assembly578
- Assembly 8: Optional 2000-Sheet High-Capacity Feeder580
- Assembly 9: Finisher Assembly582
- Assembly 10: Finisher Stapler Assembly586
- Assembly 11: High-Capacity Output Stacker588
- Assembly 12: Internal Options592
- Assembly 13: Miscellaneous593
- Cable and Thermistor Location Table594
- Screw and Retainer Identification Table598
Appendix A-Print Samples605
- Print Tests605
- Registration and Alignment610
Index615
Part Number Index627

Lexmark C792e 5062-210 - Sensor (D1, D2, and Fuser Bubble) Removal

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