Lexmark X792 7562-4xx

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4-364 Service Manual

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Installation note: Rollers (B) are different from rollers (C). Make sure that the color of the roller you will reinstall

matches the color of the roller you have removed.

Main Page

Default Chapter3
- Table of Contents3
Notices and Safety Information17
- Laser Notice17
- Safety Information23
  - Next26
Preface26
- Navigation Buttons26
  - Go Back26
- Change History27
- Conventions28
General Information29
- Models29
- Maintenance Approach29
- Printer Configurations30
- Options and Features31
- Printer Specifications31
- Tools Required for Service39
- Acronyms40
Diagnostic Information41
- Troubleshooting Map41
  - Error Code Divisions42
  - Power-On Self Test (POST) Sequence42
- Paper Jams43
- Output Option Paper Jams63
- Print Quality72
ADF & Scanner Print Quality93
- Image Quality Symptoms93
- Dark Image Quality (Using ADF or Scanner)93
- Vertical Lines (Process Direction Using the ADF)94
- Spots (Using Flatbed Scanner)94
- Skew (Using ADF)96
- Media Damage (Using ADF)97
User Messages98
- User Prompts98
- User Attendance Messages (0-99)100
Service Errors107
- Printer Hardware Errors (100-199)107
- ADF and Flatbed Scanner Errors (800-899)109
- Firmware And/Or System Electronics (900-999))110
Symptoms114
- Symptom Table-Base Printer114
- Symptom Table-500-Sheet Tray Input Option114
- Symptom Table-2000-Sheet High Capacity Feeder Input Option114
Service Checks115
- XX-Printhead Error Service Check115
- XX-Motor (Fuser) Error Service Check117
- XX-Fuser Error Service Check118
- XX, 145.XX-ITU Error Service Check121
- XX-LVPS Error Service Check122
- XX-Cartridge Sensor Error Service Check123
- XX-Black Cartridge Motor Error Service Check128
- XX-Cyan Cartridge Motor Error Service Check129
- XX-Magenta Cartridge Motor Error Service Check131
- XX-Yellow Cartridge Motor Error Service Check132
- XX-Autocomp (Tray 1) Motor Error Service Check134
- XX-Staging Motor Error Service Check135
- XX-Paper Path Redrive Motor Error Service Check136
- XX-Duplex Motor Error Service Check136
- XX-ITU Motor Error Service Check138
- XX-Main Fan Error Service Check139
- XX-LVPS Fan Error Service Check139
- XX-Blower Fan Error Service Check140
- Paper Jam Error Service Check141
- 200.08-Paper Jam Error Service Check142
- 200.07-Paper Jam Error Service Check143
- Paper Jam Error Service Check144
- 200.38-Paper Jam Error Service Check146
- 200.37-Paper Jam Error Service Check147
- Paper Jam Error Service Check148
- 200.48-Paper Jam Error Service Check150
- Go Back150
- 200.47-Paper Jam Error Service Check151
- Paper Jam Error Service Check152
- Paper Jam Error Service Check154
- Paper Jam Error Service Check155
- Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check156
- Option) Service Check157
- Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check159
- 250.22-MPF Motor Error Service Check161
- Media Missing Jam Service Check164
- Sensor (ADF Sheet Through) Late Jam Service Check165
- Sensor (ADF Sheet Through) Static Jam Service Check165
- Sensor (1St Scan) Static Jam Service Check167
- Sensor (ADF 1St Scan) Late Jam Service Check168
- Sensor (2Nd Scan) Lingering Jam Service Check169
- Sensor (2Nd Scan) Static Jam Service Check170
- Sensor (ADF Media Exit) Late Jam Service Check171
- 285.03, 285.07-Sensor (ADF Media Exit) Static Jam Service Check172
- Sensor (ADF Media Exit) Late Jam Service Check173
- ADF Top Door Open Jam Service Check174
- XX-HTU Input Sensor Error Service Check175
- XX-HTU Output Sensor Error Service Check176
- XX-HTU Second Sensor Error Service Check177
- XX-5-Bin Mailbox Input Sensor Error Service Check179
- XX-5-Bin Mailbox Pass Thru Sensor Error Service Check181
- Finisher/Stacker Main Motor Error Service Check183
- XX-Finisher/Stacker Sensor (Pass Thru) Error Service Check184
- 456.08-Finisher Stapler Home Sensor Error Service Check185
- X-Finisher Stapler Motor Error Service Check186
- X-Finisher/Stacker Paddle Motor Error Service Check187
- 461.08-Hole Punch Sensor Error Service Check188
- 461.32-Hole Punch Motor Error Service Check189
- Scanner Cable Service Check190
- XX-Scanner Carriage Home Position Detection Service Check191
- XX-Scanner Card Service Check193
- Scanner Flatbed Fan Service Check194
- System Software Error195
- MPF Paper out Sensor Error Service Check198
- Waste Toner Sensor Error Service Check199
- Waste Toner Full Sensor Error Service Check200
- 938.29, 938.30-Weather Station Error Service Check201
- Remote Weather Station Error Service Check202
- 950.29-EPROM Mismatch Failure203
- Processor Fan Failure Service Check204
- XX-POST Error Service Check205
- Bin-Full Sensor Service Check206
  - Bubble Sensor Service Check207
  - D1 and D2 Sensor Service Check210
  - Dead Printer Service Check212
  - Double Feed (550-Sheet/2000-Sheet Input Option) Service Check213
  - Input Option Not Detected (550-Sheet/2000-Sheet Input Option) Service Check215
  - Input, S1, Narrow Media, and Near Narrow Media Sensor Service Check216
  - Interlock Switch Error Service Check218
  - Jam Clearance Cover Open (550-Sheet/2000-Sheet Input Option) Service Check219
  - Media Size Error (550-Sheet/2000-Sheet Input Option) Service Check221
Diagnostic Aids239
- Understanding the Operator Panel and Menus239
- Accessing Service Menus245
- Diagnostics Mode246
Configuration Menu267
- Entering the Configuration Menu267
- Exiting the Configuration Menu268
- Reset Separator Roll and Pick Assembly Counter268
- USB Scan to Local268
- Black Only Mode268
- Print Quality Pages268
- Reports269
- Color Trapping269
- Tray Insert Msg269
- Size Sensing269
- Panel Menus269
- PPDS Emulation269
- Download Emuls269
- Factory Defaults269
- Energy Conserve270
- Fax Low Power Support270
- Min Copy Memory270
- Numpad Job Assist270
- Format Fax Storage270
- Fax Storage Location270
- Color Adjustment270
- Auto Align Adj271
- Color Alignment271
- Motor Calibration271
- ADF Edge Erase271
- FB Edge Erase271
- Scanner Manual Registration271
- Disable Scanner271
- Paper Prompts271
- Envelope Prompts272
- Action for Prompts272
- Jobs on Disk272
- Disk Encryption272
- Wipe Disk272
- Font Sharpening272
- Require Standby272
- UI Automation273
- Key Repeat Initial Delay273
- Key Repeat Rate273
- Clear Custom Status273
- USB Speed273
- Exit Config Menu273
Theory of Operation274
- Paper Path, Transport Components274
- Print Engine Theory276
- Scanner Theory284
  - Document Scanning at ADF286
  - Document Scanning at Platen286
- Names and Functions of Components287
  - Scanner Unit Assembly287
  - Adf288
- Printhead Verification290
- Adjustments292
Repair Information307
- Handling ESD-Sensitive Parts307
- Removal Procedures307
  - Cable Ties307
  - Arrangement of Removals in this Chapter308
- Base Printer Cover Removals309
Base Printer Removals339
- ACM Bias Spring Removal339
- Bin-Full Flag Removal339
- Bin-Full Sensor Removal340
- Cartridge Blower Assembly Removal341
- Cartridge Contact Block Assembly Removal344
- Cartridge Memory Block Removal346
- Cartridge Metering Cable Removal348
- Cartridge Rail Removal350
- CPU Cooling Fan Removal352
- Datum Bell Crank Removal354
- Duplex Assembly Removal356
- ESD Bracket Removal358
- EP Drive Assembly Removal360
- Exit Cooling Duct Removal362
- Front Access Door Beacon Removal363
- Front USB Cable Removal365
- Fuser Assembly Removal366
- Fuser Drive Assembly Removal367
- Fuser System Card and LVPS Cable Removal369
- Fuser Thermistor Removal372
- High-Voltage Power Supply (HVPS) Board Removal373
- Housing Interlock Assembly Removal377
- ITU Assembly Removal378
- ITU Autoconnect Removal379
- ITU Block Assembly Removal381
- Left Access Door Piston Removal383
- Low-Voltage Power Supply (LVPS) Removal387
- LVPS Exit Duct Removal390
- LVPS Fan Removal391
- Main Fan Removal394
- Media Tray Rail Removal395
- MPF Breakaway Assemblies Removal401
- MPF Paper Pick Assembly Removal (Including the MPF Ratchet Collar and MPF Drive Pulley)404
- MPF Pick Rolls and Special Wear Strip Removal407
- MPF Drive Assembly Removal410
- MPF Sensor Plate Assembly Removal412
- MPF Wear Strips Removal413
- Operator (OP) Panel Assembly Removal413
- OP Panel Cables Removal416
- OP Panel Display Removal417
- OP Panel Housing Removal418
- OP Panel Speaker Removal419
- OP Panel UICC Card Removal419
- Pad Removal420
- Paper Auto-Size Sensor Removal421
- Paper Path Redrive Assembly with Sensors Removal422
- Paper Pick Mechanism Assembly Removal424
- Pick Rolls Removal426
- Printhead Removal, Installation, and Alignment427
  - Installing and Coarse Aligning the Printhead429
  - Aligning the Printhead433
  - Dual Diode Alignment433
  - Registration (Black)434
  - Color Alignment (Cyan, Yellow, and Magenta)435
- Redrive Gears Removal438
- Redrive Motor Removal439
- Sensor (D1, D2, and Fuser Bubble) Removal441
- Sensor (Input, S1, Narrow Media, Near Narrow Media) Removal443
- Staging Deflector Assembly Removal444
- Staging Paper Path Reference Edge Assembly Removal446
  - Staging Paper Path Reference Edge Adjustment451
  - Aligning the Staging Paper Path Reference Edge451
- Standard Media Tray Removal455
- System Board Removal456
- System Board Cage with Board Removal463
- Waste Toner Container Removal469
- Waste Toner Gears Removal469
- Waste Toner Sensor Removal470
- Waste Toner Cable Removal471
- Waste Toner Full Cable Removal473
- Waste Toner Full Sensor Removal474
- Waste Toner Tray Bracket Removal474
ADF Cover Removals476
- ADF Front Cover Removal476
- ADF Rear Cover Removal477
- ADF Top Door Assembly Removal477
ADF Removals479
- ADF Beacon Cable Removal479
- ADF Controller Card Removal480
- ADF Document Tray Assembly Removal480
- ADF Document Tray Extension Removal481
- ADF Duplex CCD Assembly Removal482
- ADF Duplex CCD Scan Glass Assembly Removal485
- ADF Feed 1-Way Bearing and Gears Removal486
- ADF Feed Drive Motor Assembly Removal486
- ADF Feed/Pick Roll Assembly Removal489
- ADF Left Hinge Removal490
- ADF Lower Door Assembly Removal491
- ADF Media Pinch Pad Assembly Removal492
- ADF Pick Pad Cover Assembly Removal494
- ADF Pick Roll Position Cam Assembly Removal495
- ADF Pinch Roll Assembly Removal498
- ADF Platen Cushion Removal499
- ADF Right Hinge Removal500
- ADF Separator Roll Removal500
- ADF Separator Torque Limiter Assembly Removal501
- ADF Solenoid Assembly Removal502
- ADF Transport Drive Gears (Front) Removal503
- ADF Transport Drive Gears (Rear) and Pulley Removal505
- ADF Transport Drive Motor Bracket Assembly with Cable Removal506
- ADF Turn Guide Removal508
- ADF Unit Assembly Removal509
- Sensor (ADF 1St Scan) Removal511
- Sensor (ADF 2Nd Scan) Removal511
- Sensor (ADF Document Set) Removal512
- Sensor (ADF Lower Door Interlock) Removal513
- Sensor (ADF Media Exit) Fan Bracket Assembly Removal514
- Sensor (ADF Sheet Through) Removal515
- Sensor (ADF Top Door Interlock) Removal515
- Switch (ADF Closed Interlock) Removal516
Scanner Cover Removals517
- AIO Rear Scanner Cover Removal517
- AIO Lower Scanner Cover Removal518
- Scanner Front Cover Removal519
- Scanner Left Side Front Cover Removal520
- Scanner Left Side Rear Cover Removal520
- Scanner Rear Cover Removal521
- Scanner Right Side Cover Removal521
- Scanner Top Cover Removal522
Scanner Removals523
- Carriage Belt Tensioner Assembly Removal523
- Carriage Drive Motor Assembly Removal524
- Flatbed Scanner Cooling Fan Filter Removal526
- Flatbed Scanner Cooling Fan Removal526
- Flatbed Scanner CCD Assembly Removal527
- Scanner Exposure Lamp Removal528
- Scanner FB Length Sensor Cable Removal530
- Flatbed Scanner Assembly Removal532
- Scanner Interface Card Removal539
- Scanner Platen Glass Cover Removal540
- Scanner Reference LED Removal541
- Scanner Reference LED Sensor Cable Removal541
- Sensor (Platen Glass Length) Removal542
- Sensor Cable (Scanner HP) Removal543
- Sensor (Scanner HP) Removal544
Input Option Removals545
550-Sheet Tray545
- 550-Sheet Drawer Assembly Removal545
- 550-Sheet Media Tray Assembly Removal546
- 550-Sheet Tray Controller Card Assembly Removal547
- 550-Sheet Tray Deflector Removal549
- 550-Sheet Tray Drive Assembly Removal550
- 550-Sheet Tray Left Anti-Tip Latch Removal553
- 550-Sheet Tray Pass Thru Sensor Removal555
- 550-Sheet Tray Pick Assembly Removal556
- 550-Sheet Tray Pick Roll Assembly Removal560
- 550-Sheet Tray Right Anti-Tip Latch Assembly Removal562
- 550-Sheet Tray Top Metal Cover Removal563
2000-Sheet High-Capacity Feeder564
- 2000-Sheet High-Capacity Feeder Bellcrank Assembly Removal565
- 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal566
- 2000-Sheet High-Capacity Feeder Drive Assembly Removal567
- 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal570
- 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal574
- 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal579
- 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal580
- 2000-Sheet High-Capacity Feeder LED Bracket Removal583
- 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal584
- 2000-Sheet High-Capacity Feeder Left Side Cover Removal586
- 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal588
- 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal595
- 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal598
- 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal599
- 2000-Sheet High-Capacity Feeder Pick Assembly Removal601
- 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal607
- 2000-Sheet High-Capacity Feeder Rear Cover Removal610
- 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal612
- 2000-Sheet High-Capacity Feeder Right Side Cover Removal614
Output Option Removals616
5-Bin Mailbox616
- 5-Bin Mailbox Access Door Removal616
- 5-Bin Mailbox Backup Roll Plate Assembly Removal618
- 5-Bin Mailbox Bin-Full Beacon Card and Light Pipe Removal619
- 5-Bin Mailbox Cave Beacon Removal620
- 5-Bin Mailbox Controller Card Removal621
- 5-Bin Mailbox Diverter Solenoid Removal622
- 5-Bin Mailbox Diverter Spring Removal623
- 5-Bin Mailbox Feed Motor with Plate Removal624
- 5-Bin Mailbox Front Cover Removal625
- 5-Bin Mailbox Media bin Full Actuator Removal627
- 5-Bin Mailbox Option Cable Removal628
- 5-Bin Mailbox Output bin Deflector Removal629
- 5-Bin Mailbox Output bin Paper Bail Removal630
- 5-Bin Mailbox Output bin Roller Removal631
- 5-Bin Mailbox Output bin Sensors Removal631
- 5-Bin Mailbox Paper Jam Beacon Removal632
- 5-Bin Mailbox Rear Cover Removal633
- 5-Bin Mailbox Roller Removal634
- 5-Bin Mailbox Sensor (Input) Assembly Removal635
- 5-Bin Mailbox Sensor (Pass Thru) Assembly Removal635
- 5-Bin Mailbox Top Cover Removal636
- 5-Bin Mailbox Tray Extension Removal637
Staplesmart Finisher and High-Capacity Output Stacker638
- Finisher or Stacker Access Door Beacon LED and Beacon Housing Removal638
- Finisher or Stacker Bin-Full Spring Removal639
- Finisher or Stacker Bottom Cover Removal640
- Finisher or Stacker Controller Card Assembly Removal641
- Finisher or Stacker Feed Roller Removal642
- Finisher or Stacker Front Cover Removal643
- Finisher or Stacker LED Sensor Cover Removal644
- Finisher or Stacker Left Access Door Assembly Removal645
- Finisher or Stacker Media Stack Flap and Media Stack Flap Actuator Removal647
- Finisher or Stacker Option Cable Removal648
- Finisher or Stacker Output bin Extension Removal649
- Finisher or Stacker Output bin LED and LED Lens Removal649
- Finisher or Stacker Paddle Drive Gear Removal650
- Finisher or Stacker Paddle Drive Motor Assembly Removal651
- Finisher or Stacker Rear Cover Removal652
- Finisher or Stacker Sensor (Bin-Full Receive) Removal654
- Finisher or Stacker Sensor (Bin-Full Send) Removal655
- Finisher or Stacker Sensor (Finisher bin Media Present) Removal656
- Finisher or Stacker Sensor (Paddle HP) Removal657
- Finisher Sensor (Stapler Access Door Interlock) Removal658
- Finisher or Stacker Sensor (Pass Thru) Removal658
- Finisher or Stacker Sensor (Tamper HP Left and Right) Removal660
- Finisher or Stacker Standard Output bin LED and LED Lens Removal661
- Finisher or Stacker Tamper Drive Belt Removal662
- Finisher or Stacker Tamper Drive Motor Assembly Removal663
- Finisher or Stacker Tamper Recoil Spring Removal664
- Finisher or Stacker Top Cover Removal665
- Finisher Stapler Unit Assembly Removal666
Horizontal Transport Unit (HTU) and Hole Punch Unit667
- HTU Access Door Removal667
- HTU Access Door Paper Jam Beacon (with Cover and Cable) Removal668
- HTU Access Door Rollers Removal669
- HTU bin Diverter Gate Spring Removal671
- HTU bin Media Exit Spring Removal672
- HTU Card (Bin-Full Receive Card and Lens) Removal673
- HTU Card (Bin-Full Send Card and Lens) Removal674
- HTU Controller Card Removal675
- HTU Drive Belt Removal676
- HTU Drive Gear Spring Removal677
- HTU Engagement Roller Removal678
- HTU Exit Roller Removal679
- HTU Front Redrive Cover Removal679
- HTU Front Standard bin Cover Removal680
- HTU Locking Lever Removal681
- HTU Locking Lever Card Removal683
- HTU Lower Redrive Guide Removal683
- HTU Option Hook Removal686
- HTU Option Roller Removal688
- HTU Output bin Removal689
- HTU Output bin Extension Removal690
- HTU Output bin Solenoid Removal691
- HTU Output bin Wire Stop Removal692
- HTU Output Option Removal693
- HTU Output Option Guide Removal695
- HTU Output Option Solenoid Removal696
- HTU Output Sensor Removal697
- HTU Outer Front Cover Removal (AIO Only)697
- HTU Rear Redrive Cover Removal698
- HTU Rear Standard bin Cover Removal700
- HTU Right Bottom Cover Removal703
- HTU Right Inner Cover Removal704
- HTU Sensor (Access Door Interlock) Removal708
- HTU Sensor (Empty Bin) Removal709
- HTU Sensor (Input) Removal710
- HTU Sensor (Output Option Position) Removal711
- HTU Sensor (Second) Removal712
- HTU Sensor Cable (Bin-Full Send and Receive) Removal713
- HTU Stopper Diverter Removal713
- HTU Timing Belts (Rear) Removal714
- HTU to Printer Cable Removal715
- HTU Top Redrive Cover Removal716
- HTU Top Right Cover Removal717
- HTU Transport Gear Removal718
- HTU Transport Motor Removal719
- HTU Upper Exit Shaft Removal720
  - HTU Upper Guide Removal721
  - HTU Punch Motor Removal722
  - HTU Punch Unit Removal724
  - HTU Punch Gear Removal725
Connector Locations727
- Locations727
  - System Board Cabling Reference727
- Connectors728
Preventive Maintenance751
- Safety Inspection Guide751
- Individual Maintenance Part Expected Life751
- Lubrication Specifications751
- Lubrication for Replacement Motors751
  - Redrive Parts Packet752
  - Fuser Drive Assembly753
Parts Catalog755
- How to Use this Parts Catalog755
- Assembly 1: Front, Right, and Top Covers756
- Assembly 2: Left and Rear Covers758
- Assembly 3: Front760
- Assembly 3.1: Front (Continued)762
- Assembly 4: Left764
- Assembly 4.1: Left (Continued)766
  - Assembly 4.1: Left (Continued)767
- Assembly 5: Rear768
- Assembly 6: Flatbed Scanner772
- Assembly 7: ADF Unit Assembly774
- Assembly 8: ADF Covers776
- Assembly 9: ADF Feed and Drive778
- Assembly 10: ADF Electronics780
- Assembly 11: Optional 550-Sheet Tray782
- Assembly 12: Optional 550-Sheet Drawer Assembly784
- Assembly 13: Optional 2000-Sheet High-Capacity Feeder (Complete)786
- Assembly 14: Optional 2000-Sheet High-Capacity Feeder788
- Assembly 15: Finisher/High-Capacity Ouput Stacker Assembly790
- Assembly 15.1: Finisher /High-Capacity Output Stacker Assembly (Continued)792
- Assembly 16: Finisher Stapler Assembly794
- Assembly 17: Finisher/Stacker Assembly (Complete)796
- Assembly 18: 5-Bin Mailbox Assembly (Complete)798
- Assembly 19: 5-Bin Mailbox Assembly (Covers)800
- Assembly 20: 5-Bin Mailbox Assembly (Interior)802
- Assembly 21: HTU (Complete)804
- Assembly 22: HTU (Covers)806
- HTU (Left Interior)808
- Assembly 24: HTU (Right Interior)810
- Assembly 25: HTU with Hole Punch (Complete)812
- Assembly 26: HTU with Hole Punch (Covers)814
- Assembly 27: HTU with Hole Punch (Left Interior)816
- Assembly 28: Miscellaneous820
- Assembly 29: Internal Options820
- Cable and Thermistor Location Table821
- Screw and Retainer Identification Table825
Appendix A-Print Samples831
- Print Tests832
- Registration and Alignment836
Index841
Part Number Index849

Lexmark X792 7562-4xx - Page 670

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