Lexmark X792 - 5-Bin Mailbox Backup Roll Plate Assembly Removal

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4-312 Service Manual

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5-bin mailbox backup roll plate assembly removal

See “5-bin mailbox assembly (interior)” on page 7-49 for the part number.

1. Remove the mailbox from the printer.

2. Remove the mailbox rear cover. See “5-bin mailbox rear cover removal” on page 4-327.

3. Open the left access door, and press in to release the support pins from each side of the door.

4. Flex the sides to remove the roller frame.

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
- Data Security Notice39
- Tools Required for Service39
- Acronyms40
Diagnostic Information41
- Troubleshooting Map41
- Paper Jams44
- Output Option Paper Jams64
- Print Quality73
ADF & Scanner Print Quality94
- Image Quality Symptoms94
- Dark Image Quality (Using ADF or Scanner)94
- Vertical Lines (Process Direction Using the ADF)95
- Spots (Using Flatbed Scanner)95
- Skew (Using ADF)97
- Media Damage (Using ADF)98
User Messages99
- User Prompts99
- User Attendance Messages (0-99)101
Service Errors108
- Printer Hardware Errors (100-199)108
- ADF and Flatbed Scanner Errors (800-899)110
- Firmware And/Or System Electronics (900-999))111
Symptoms115
- Symptom Table-Base Printer115
- Symptom Table-500-Sheet Tray Input Option115
- Symptom Table-2000-Sheet High Capacity Feeder Input Option115
Service Checks116
- XX-Printhead Error Service Check116
- XX-Motor (Fuser) Error Service Check118
- XX-Fuser Error Service Check119
- XX, 145.XX-ITU Error Service Check122
- XX-LVPS Error Service Check123
- XX-Cartridge Sensor Error Service Check124
- XX-Black Cartridge Motor Error Service Check129
- XX-Cyan Cartridge Motor Error Service Check130
- XX-Magenta Cartridge Motor Error Service Check132
- XX-Yellow Cartridge Motor Error Service Check133
- XX-Autocomp (Tray 1) Motor Error Service Check135
- XX-Staging Motor Error Service Check136
- XX-Duplex Motor Error Service Check137
- XX-Paper Path Redrive Motor Error Service Check137
- XX-ITU Motor Error Service Check139
- XX-LVPS Fan Error Service Check140
  - Next140
- XX-Main Fan Error Service Check140
- XX-Blower Fan Error Service Check141
- Paper Jam Error Service Check142
- 200.08-Paper Jam Error Service Check143
- Go Back143
- 200.07-Paper Jam Error Service Check144
- Paper Jam Error Service Check145
- 200.38-Paper Jam Error Service Check147
- 200.37-Paper Jam Error Service Check148
- Paper Jam Error Service Check149
- 200.48-Paper Jam Error Service Check151
- 200.47-Paper Jam Error Service Check152
- Paper Jam Error Service Check153
- Paper Jam Error Service Check155
- Paper Jam Error Service Check156
- Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check157
- Option) Service Check158
- Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check160
- 250.22-MPF Motor Error Service Check162
- Media Missing Jam Service Check165
- Sensor (ADF Sheet Through) Late Jam Service Check166
- Sensor (ADF Sheet Through) Static Jam Service Check166
- Sensor (1St Scan) Static Jam Service Check168
- Sensor (ADF 1St Scan) Late Jam Service Check169
- Sensor (2Nd Scan) Lingering Jam Service Check170
- Sensor (2Nd Scan) Static Jam Service Check171
- Sensor (ADF Media Exit) Late Jam Service Check172
- 285.03, 285.07-Sensor (ADF Media Exit) Static Jam Service Check173
- Sensor (ADF Media Exit) Late Jam Service Check174
- ADF Top Door Open Jam Service Check175
- XX-HTU Input Sensor Error Service Check176
- XX-HTU Output Sensor Error Service Check177
- XX-HTU Second Sensor Error Service Check178
- XX-5-Bin Mailbox Input Sensor Error Service Check180
- XX-5-Bin Mailbox Pass Thru Sensor Error Service Check182
- Finisher/Stacker Main Motor Error Service Check184
- XX-Finisher/Stacker Sensor (Pass Thru) Error Service Check185
- 456.08-Finisher Stapler Home Sensor Error Service Check186
- X-Finisher Stapler Motor Error Service Check187
- X-Finisher/Stacker Paddle Motor Error Service Check188
- 461.08-Hole Punch Sensor Error Service Check189
- 461.32-Hole Punch Motor Error Service Check190
- Scanner Cable Service Check191
- XX-Scanner Carriage Home Position Detection Service Check192
- XX-Scanner Card Service Check194
- Scanner Flatbed Fan Service Check195
- Steps before Starting the 9Yy Service Checks196
  - Collecting the History Information from the SE Menu196
  - Collecting the Firmware Logs (Fwdebug and Logs.tar.gz) from the SE Menu196
  - Collecting the Settings from the Menu Settings Page197
Diagnostic Aids241
- Understanding the Operator Panel and Menus241
- Accessing Service Menus247
- Diagnostics Mode248
Entering the Configuration Menu269
- Next269
- Exiting the Configuration Menu270
- Reset Separator Roll and Pick Assembly Counter270
- USB Scan to Local270
- Black Only Mode270
- Print Quality Pages270
- Reports271
- Color Trapping271
- Tray Insert Msg271
- Size Sensing271
- Panel Menus271
- PPDS Emulation271
- Download Emuls271
- Factory Defaults271
- Energy Conserve272
- Fax Low Power Support272
- Min Copy Memory272
- Numpad Job Assist272
- Format Fax Storage272
- Fax Storage Location272
- Color Adjustment272
- Auto Align Adj273
- Color Alignment273
- Motor Calibration273
- ADF Edge Erase273
- FB Edge Erase273
- Scanner Manual Registration273
- Disable Scanner273
- Paper Prompts273
- Envelope Prompts274
- Action for Prompts274
- Jobs on Disk274
- Disk Encryption274
- Wipe Disk274
- Font Sharpening274
- Require Standby274
- UI Automation275
- Key Repeat Initial Delay275
- Key Repeat Rate275
- Clear Custom Status275
- USB Speed275
- Exit Config Menu275
Theory of Operation276
- Paper Path, Transport Components276
- Print Engine Theory278
- Names and Functions of Components289
  - Scanner Unit Assembly289
  - Adf290
- Printhead Verification292
- Adjustments294
Repair Information311
- Handling ESD-Sensitive Parts311
- Data Security Notice311
- Removal Procedures312
  - Cable Ties312
  - Arrangement of Removals in this Chapter312
- Base Printer Cover Removals313
Base Printer Removals343
- ACM Bias Spring Removal343
- Bin-Full Flag Removal343
- Bin-Full Sensor Removal344
- Cartridge Blower Assembly Removal345
- Cartridge Contact Block Assembly Removal348
- Cartridge Memory Block Removal350
- Cartridge Metering Cable Removal352
- Cartridge Rail Removal354
- CPU Cooling Fan Removal356
- Datum Bell Crank Removal358
- Duplex Assembly Removal360
- ESD Bracket Removal362
- EP Drive Assembly Removal364
- Exit Cooling Duct Removal366
- Front Access Door Beacon Removal367
- Front USB Cable Removal369
- Fuser Assembly Removal370
- Fuser Drive Assembly Removal371
- Fuser System Card and LVPS Cable Removal373
- Fuser Thermistor Removal376
- High-Voltage Power Supply (HVPS) Board Removal377
- Housing Interlock Assembly Removal381
- ITU Assembly Removal382
- ITU Autoconnect Removal383
- ITU Block Assembly Removal385
- Left Access Door Piston Removal387
- Low-Voltage Power Supply (LVPS) Removal391
- LVPS Exit Duct Removal394
- LVPS Fan Removal395
- Main Fan Removal398
- Media Tray Rail Removal399
- MPF Breakaway Assemblies Removal405
- MPF Paper Pick Assembly Removal (Including the MPF Ratchet Collar and MPF Drive Pulley)408
- MPF Pick Rolls and Special Wear Strip Removal411
- MPF Drive Assembly Removal414
- MPF Sensor Plate Assembly Removal416
- MPF Wear Strips Removal417
- Operator (OP) Panel Assembly Removal417
- OP Panel Cables Removal420
- OP Panel Display Removal421
- OP Panel Housing Removal422
- OP Panel Speaker Removal423
- OP Panel UICC Card Removal423
- Pad Removal424
- Paper Auto-Size Sensor Removal425
- Paper Path Redrive Assembly with Sensors Removal426
- Paper Pick Mechanism Assembly Removal428
- Pick Rolls Removal430
- Printhead Removal, Installation, and Alignment431
  - Installing and Coarse Aligning the Printhead433
  - Aligning the Printhead437
  - Dual Diode Alignment437
  - Registration (Black)438
  - Color Alignment (Cyan, Yellow, and Magenta)439
- Redrive Gears Removal442
- Redrive Motor Removal443
- Sensor (D1, D2, and Fuser Bubble) Removal445
- Sensor (Input, S1, Narrow Media, Near Narrow Media) Removal447
- Staging Deflector Assembly Removal448
- Staging Paper Path Reference Edge Assembly Removal450
  - Staging Paper Path Reference Edge Adjustment455
  - Aligning the Staging Paper Path Reference Edge455
- Standard Media Tray Removal458
- System Board Removal459
- System Board Cage with Board Removal467
- Waste Toner Container Removal473
- Waste Toner Gears Removal473
- Waste Toner Sensor Removal474
- Waste Toner Cable Removal475
- Waste Toner Full Cable Removal477
- Waste Toner Full Sensor Removal478
- Waste Toner Tray Bracket Removal478
ADF Cover Removals480
- ADF Front Cover Removal480
- ADF Rear Cover Removal481
- ADF Top Door Assembly Removal481
ADF Removals483
- ADF Beacon Cable Removal483
- ADF Controller Card Removal484
- ADF Document Tray Assembly Removal484
- ADF Document Tray Extension Removal485
- ADF Duplex CCD Assembly Removal486
- ADF Duplex CCD Scan Glass Assembly Removal489
- ADF Feed 1-Way Bearing and Gears Removal490
- ADF Feed Drive Motor Assembly Removal490
- ADF Feed/Pick Roll Assembly Removal493
- ADF Left Hinge Removal494
- ADF Lower Door Assembly Removal495
- ADF Media Pinch Pad Assembly Removal496
- ADF Pick Pad Cover Assembly Removal498
- ADF Pick Roll Position Cam Assembly Removal499
- ADF Pinch Roll Assembly Removal502
- ADF Platen Cushion Removal503
- ADF Right Hinge Removal504
- ADF Separator Roll Removal504
- ADF Separator Torque Limiter Assembly Removal505
- ADF Solenoid Assembly Removal506
- ADF Transport Drive Gears (Front) Removal507
- ADF Transport Drive Gears (Rear) and Pulley Removal509
- ADF Transport Drive Motor Bracket Assembly with Cable Removal510
- ADF Turn Guide Removal512
- ADF Unit Assembly Removal513
- Sensor (ADF 1St Scan) Removal515
- Sensor (ADF 2Nd Scan) Removal515
- Sensor (ADF Document Set) Removal516
- Sensor (ADF Lower Door Interlock) Removal517
- Sensor (ADF Media Exit) Fan Bracket Assembly Removal518
- Sensor (ADF Sheet Through) Removal519
- Sensor (ADF Top Door Interlock) Removal519
- Switch (ADF Closed Interlock) Removal520
Scanner Cover Removals521
- AIO Rear Scanner Cover Removal521
- AIO Lower Scanner Cover Removal522
- Scanner Front Cover Removal523
- Scanner Left Side Front Cover Removal524
- Scanner Left Side Rear Cover Removal524
- Scanner Rear Cover Removal525
- Scanner Right Side Cover Removal525
- Scanner Top Cover Removal526
Scanner Removals527
- Carriage Belt Tensioner Assembly Removal527
- Carriage Drive Motor Assembly Removal528
- Flatbed Scanner Cooling Fan Filter Removal530
- Flatbed Scanner Cooling Fan Removal530
- Flatbed Scanner CCD Assembly Removal531
- Scanner Exposure Lamp Removal532
- Scanner FB Length Sensor Cable Removal534
- Flatbed Scanner Assembly Removal536
- Scanner Interface Card Removal543
- Scanner Platen Glass Cover Removal544
- Scanner Reference LED Removal545
- Scanner Reference LED Sensor Cable Removal545
- Sensor (Platen Glass Length) Removal546
- Sensor Cable (Scanner HP) Removal547
- Sensor (Scanner HP) Removal548
Input Option Removals549
550-Sheet Tray549
- 550-Sheet Drawer Assembly Removal549
- 550-Sheet Media Tray Assembly Removal550
- 550-Sheet Tray Controller Card Assembly Removal551
- 550-Sheet Tray Deflector Removal553
- 550-Sheet Tray Drive Assembly Removal554
- 550-Sheet Tray Left Anti-Tip Latch Removal557
- 550-Sheet Tray Pass Thru Sensor Removal559
- 550-Sheet Tray Pick Assembly Removal560
- 550-Sheet Tray Pick Roll Assembly Removal564
- 550-Sheet Tray Right Anti-Tip Latch Assembly Removal566
- 550-Sheet Tray Top Metal Cover Removal567
2000-Sheet High-Capacity Feeder568
- 2000-Sheet High-Capacity Feeder Bellcrank Assembly Removal569
- 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal570
- 2000-Sheet High-Capacity Feeder Drive Assembly Removal571
- 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal574
- 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal578
- 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal583
- 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal584
- 2000-Sheet High-Capacity Feeder LED Bracket Removal587
- 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal588
- 2000-Sheet High-Capacity Feeder Left Side Cover Removal590
- 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal592
- 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal599
- 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal602
- 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal603
- 2000-Sheet High-Capacity Feeder Pick Assembly Removal605
- 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal611
- 2000-Sheet High-Capacity Feeder Rear Cover Removal614
- 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal616
- 2000-Sheet High-Capacity Feeder Right Side Cover Removal618
Output Option Removals620
5-Bin Mailbox620
- 5-Bin Mailbox Access Door Removal620
- 5-Bin Mailbox Backup Roll Plate Assembly Removal622
- 5-Bin Mailbox Bin-Full Beacon Card and Light Pipe Removal623
- 5-Bin Mailbox Cave Beacon Removal624
- 5-Bin Mailbox Controller Card Removal625
- 5-Bin Mailbox Diverter Solenoid Removal626
- 5-Bin Mailbox Diverter Spring Removal627
- 5-Bin Mailbox Feed Motor with Plate Removal628
- 5-Bin Mailbox Front Cover Removal629
- 5-Bin Mailbox Media bin Full Actuator Removal631
- 5-Bin Mailbox Option Cable Removal632
- 5-Bin Mailbox Output bin Deflector Removal633
- 5-Bin Mailbox Output bin Paper Bail Removal634
- 5-Bin Mailbox Output bin Roller Removal635
- 5-Bin Mailbox Output bin Sensors Removal635
- 5-Bin Mailbox Paper Jam Beacon Removal636
- 5-Bin Mailbox Rear Cover Removal637
- 5-Bin Mailbox Roller Removal638
- 5-Bin Mailbox Sensor (Input) Assembly Removal639
- 5-Bin Mailbox Sensor (Pass Thru) Assembly Removal639
- 5-Bin Mailbox Top Cover Removal640
- 5-Bin Mailbox Tray Extension Removal641
Staplesmart Finisher and High-Capacity Output Stacker642
- Finisher or Stacker Access Door Beacon LED and Beacon Housing Removal642
- Finisher or Stacker Bin-Full Spring Removal643
- Finisher or Stacker Bottom Cover Removal644
- Finisher or Stacker Controller Card Assembly Removal645
- Finisher or Stacker Feed Roller Removal646
- Finisher or Stacker Front Cover Removal647
- Finisher or Stacker LED Sensor Cover Removal648
- Finisher or Stacker Left Access Door Assembly Removal649
- Finisher or Stacker Media Stack Flap and Media Stack Flap Actuator Removal651
- Finisher or Stacker Option Cable Removal652
- Finisher or Stacker Output bin Extension Removal653
- Finisher or Stacker Output bin LED and LED Lens Removal653
- Finisher or Stacker Paddle Drive Gear Removal654
- Finisher or Stacker Paddle Drive Motor Assembly Removal655
- Finisher or Stacker Rear Cover Removal656
- Finisher or Stacker Sensor (Bin-Full Receive) Removal658
- Finisher or Stacker Sensor (Bin-Full Send) Removal659
- Finisher or Stacker Sensor (Finisher bin Media Present) Removal660
- Finisher or Stacker Sensor (Paddle HP) Removal661
- Finisher Sensor (Stapler Access Door Interlock) Removal662
- Finisher or Stacker Sensor (Pass Thru) Removal662
- Finisher or Stacker Sensor (Tamper HP Left and Right) Removal664
- Finisher or Stacker Standard Output bin LED and LED Lens Removal665
- Finisher or Stacker Tamper Drive Belt Removal666
- Finisher or Stacker Tamper Drive Motor Assembly Removal667
- Finisher or Stacker Tamper Recoil Spring Removal668
- Finisher or Stacker Top Cover Removal669
- Finisher Stapler Unit Assembly Removal670
Horizontal Transport Unit (HTU) and Hole Punch Unit671
- HTU Access Door Removal671
- HTU Access Door Paper Jam Beacon (with Cover and Cable) Removal672
- HTU Access Door Rollers Removal673
- HTU bin Diverter Gate Spring Removal675
- HTU bin Media Exit Spring Removal676
- HTU Card (Bin-Full Receive Card and Lens) Removal677
- HTU Card (Bin-Full Send Card and Lens) Removal678
- HTU Controller Card Removal679
- HTU Drive Belt Removal680
- HTU Drive Gear Spring Removal681
- HTU Engagement Roller Removal682
- HTU Exit Roller Removal683
- HTU Front Redrive Cover Removal683
- HTU Front Standard bin Cover Removal684
- HTU Locking Lever Removal685
- HTU Locking Lever Card Removal687
- HTU Lower Redrive Guide Removal687
- HTU Option Hook Removal690
- HTU Option Roller Removal692
- HTU Output bin Removal693
- HTU Output bin Extension Removal694
- HTU Output bin Solenoid Removal695
- HTU Output bin Wire Stop Removal696
- HTU Output Option Removal697
- HTU Output Option Guide Removal699
- HTU Output Option Solenoid Removal700
- HTU Output Sensor Removal701
- HTU Outer Front Cover Removal (AIO Only)701
- HTU Rear Redrive Cover Removal702
- HTU Rear Standard bin Cover Removal704
- HTU Right Bottom Cover Removal707
- HTU Right Inner Cover Removal708
  - HTU Sensor (Access Door Interlock) Removal712
  - HTU Sensor (Empty Bin) Removal713
  - HTU Sensor (Input) Removal714
  - HTU Sensor (Output Option Position) Removal715
  - HTU Sensor (Second) Removal716
  - HTU Sensor Cable (Bin-Full Send and Receive) Removal717
  - HTU Stopper Diverter Removal717
  - HTU Timing Belts (Rear) Removal718
  - HTU to Printer Cable Removal719
  - HTU Top Redrive Cover Removal720
  - HTU Top Right Cover Removal721
  - HTU Transport Gear Removal722
  - HTU Transport Motor Removal723
  - HTU Upper Exit Shaft Removal724
  - HTU Upper Guide Removal725
  - HTU Punch Motor Removal726
  - HTU Punch Unit Removal728
  - HTU Punch Gear Removal729
Connector Locations731
- Locations731
  - System Board Cabling Reference731
- Connectors732
Preventive Maintenance755
- Safety Inspection Guide755
- Individual Maintenance Part Expected Life755
- Lubrication Specifications756
- Lubrication for Replacement Motors756
  - Redrive Parts Packet756
  - Fuser Drive Assembly757
Parts Catalog759
- How to Use this Parts Catalog759
- Assembly 1: Front, Right, and Top Covers760
- Assembly 2: Left and Rear Covers762
- Assembly 3: Front764
- Assembly 3.1: Front (Continued)766
- Assembly 4: Left768
- Assembly 4.1: Left (Continued)770
- Assembly 5: Rear772
- Assembly 6: Flatbed Scanner776
- Assembly 7: ADF Unit Assembly778
- Assembly 8: ADF Covers780
- Assembly 9: ADF Feed and Drive782
- Assembly 10: ADF Electronics784
- Assembly 11: Optional 550-Sheet Tray786
- Assembly 12: Optional 550-Sheet Drawer Assembly788
- Assembly 13: Optional 2000-Sheet High-Capacity Feeder (Complete)790
- Assembly 14: Optional 2000-Sheet High-Capacity Feeder792
- Assembly 15: Finisher/High-Capacity Ouput Stacker Assembly794
- Assembly 15.1: Finisher /High-Capacity Output Stacker Assembly (Continued)796
- Assembly 16: Finisher Stapler Assembly798
- Assembly 17: Finisher/Stacker Assembly (Complete)800
- Assembly 18: 5-Bin Mailbox Assembly (Complete)802
- Assembly 19: 5-Bin Mailbox Assembly (Covers)804
- Assembly 20: 5-Bin Mailbox Assembly (Interior)806
- Assembly 21: HTU (Complete)808
- Assembly 22: HTU (Covers)810
- Assembly 23: HTU (Left Interior)812
- Assembly 24: HTU (Right Interior)814
- Assembly 25: HTU with Hole Punch (Complete)816
- Assembly 26: HTU with Hole Punch (Covers)818
- Assembly 27: HTU with Hole Punch (Left Interior)820
- Assembly 28: Miscellaneous822
- Assembly 29: Internal Options824
- Cable and Thermistor Location Table825
- Screw and Retainer Identification Table829
Appendix A-Print Samples835
- Print Tests835
- Registration and Alignment840
Index845
Part Number Index853

Lexmark X792 - 5-Bin Mailbox Backup Roll Plate Assembly Removal

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