Lexmark C792e 5062-210 - Tools Required for Service

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1-12 Service Manual

5062

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 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 - Tools Required for Service

Table of Contents

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