Lexmark X792 7562-4xx - 2000-Sheet High-Capacity Feeder Option System Card

Lexmark X792 7562-4xx

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5-18 Service Manual

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2000-sheet high-capacity feeder option system card

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Table of Contents

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

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