Lexmark C782 Service Manual - Page 468

I-16

Service Manual

5061

40X2099

Locating pin, options rear left

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2100

Locating pin, options front right

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2101

Feed unit special sensors cable

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2102

Feed unit sensors cable

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2103

Paper size sensors cable

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2104

Elevator motor cable

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2105

Elevator motor assembly

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2106

Options autoconnect cable assembly

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2107

Magnetic latch

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2108

Sensor, photo interrupter

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2109

Options cable mounting plate

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2110

Flag, paper size R

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2111

Flag, paper size F

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2112

Flag, paper size C

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2113

Spring, paper size flag

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2114

Paper tray arms

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2115

Paper tray guide

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2116

Feed unit, complete assembly

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2117

Special optical sensors

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2118

Bushing

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2119

Feed roller

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2120

Feed cam

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2121

Feed unit spring

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2122

E-clips, parts packet

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2123

060 bushing

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2124

Front feed unit spring

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2125

Rear feed unit spring

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2126

Plastic 5W clip

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2127

Level sensor flag

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2128

Near empty sensor flag

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2129

Extension spring

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2130

Tray present lever

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2131

Separation/torque roller

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2132

Cable clamp

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2133

Emitter timing wheel

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2134

Elevator lift belt

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2135

Elevator lift gear

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2136

Elevator lift

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2137

Paper size sensor box assembly

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2138

Feed cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2139

Ring 7, elevator lift gear/elevator lift

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-59

40X2140

Stabilizer kit with mounting screws

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2141

Front cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2142

Cover, main CA

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2143

Right side cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2144

Left side cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2145

Rear cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2146

Upper left side jam cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-61

40X2150

Complete option

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2152

Front assembly cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2153

Stapler access cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2154

Top assembly cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2155

Jam access door

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2156

Front door latch

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2157

Access door rear latch

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-47

,

7-62

40X2159

Redrive cap cover

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-62

40X2610

Hard Disk, 40GB with/adapter (formatted)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-71

40X3240

Dual bin level sensor

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-47

40X3242

5-bin mailbox pass thru sensor

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

7-47

Lexmark C782 Service Manual - Page 468

Cover, main CA, Plastic 5W clip

Page 468 highlights

Section	Page
Table of contents	3
Notices and safety information	11
Laser notice	11
Preface	20
1. General information	21
Models	21
Tools required for service	21
Options and features	22
Printer specifications	24
Power and performance	27
Media specifications	29
Media input and output capacities	29
Media sizes	30
Media guidelines	37
Web oiler upgrade kit and replacements	40
Upgrade kit	40
Acronyms	41
2. Diagnostic information	43
Start	43
POR (Power-On Reset) sequence	44
Symptom tables	45
Symptom table—base printer	45
Symptom table—500-sheet drawer option	46
Symptom table—HCIT 2000-sheet option	46
Symptom table—output expander option	47
Symptom table—5-bin mailbox option	47
Symptom table—StapleSmart finisher	47
Service error code and paper jam message table	49
Service checks	56
100.01 ITU error service check	56
100.02 ITU error service check	59
122.01 error code service check	60
122.02 error code service check	61
122.03 error code service check	61
122.04 error code service check	62
122.05 and 122.06 error code service check	63
122.07, 122.14, and 122.15 error code service check	64
122.08 error code service check	65
122.10 error code service check	65
122.11 error code service check	66
122.12 error code service check	66
122.13 error code service check	66
148.xx error code service check	67
150.xx error code service check	68
151.xx error code service check	68
152.xx error code service check	69
153.xx error code service check	69
177.xx error code service check	70
200.03 paper jam service check	70
200.04 paper jam service check	71
200.05 paper jam service check	71
200.06 paper jam service check	72
200.07 paper jam service check	72
200.16 paper jam service check	72
200.21, 200.28, and 200.29 paper jam service check	73
200.93 paper jam service check	73
200.96 paper jam service check	75
201.xx and 202.xx paper jam service check	75
230.xx paper jam service check	77
241.xx paper jam service check	78
242.xx paper jam service check	79
243.xx paper jam service check	83
244.xx paper jam service check	88
250.xx paper jam service check	89
271.xx paper jam service check	91
272.xx paper jam service check	92
282.98 paper jam service check	93
900.xx RIP Software Error service check	93
925.02 error code service check	96
926.01 error code service check	96
927.03 error code service check	97
930.09 error code service check	97
940.xx error code service check	98
941.xx error code service check	100
942.xx error code service check	102
943.xx error code service check	104
956.xx service error service check	106
982.xx error service check	106
990.01 error service check	107
5-bin mailbox option service check	109
500-sheet drawer option service check	113
AC and DC power service check	116
Autocompensator service check	118
Black only retract (BOR) service check	120
Close door/HVPS/printhead interlock switch service check	121
Duplex option service check	123
Envelope feeder option service check	125
HCIT 2000-sheet option service check	126
Fuser drive assembly noise check	129
Operator panel LCD/status LED/buttons service check	130
Output expander option service check	132
Print quality service check	135
Second transfer roll service check	151
StapleSmart finisher service check	153
Tray 1 service check	157
Tray 1 media size sensing service check	158
User operator panel, menus, and messages	159
Understanding the printer operator panel	159
Operator panel buttons	159
Menu map	161
User attendance messages	166
3. Diagnostic aids	179
Diagnostic procedures	179
Printhead diagnostics	179
Print quality defect locator chart	181
Partial Print Test	182
HCIT standalone test mode	183
Accessing service menus	184
Diagnostics mode	185
Entering Diagnostics mode	185
Diagnostic mode menus	185
Exiting the Diagnostics mode	187
REGISTRATION	188
ALIGNMENT MENU	189
MISC TESTS	191
PRINT TESTS	192
HARDWARE TESTS	193
DUPLEX TESTS	197
INPUT TRAY TESTS	198
OUTPUT BIN TESTS	199
FINISHER TESTS	201
BASE SENSOR TEST	202
DEVICE TESTS	203
PRINTER SETUP	204
EP SETUP	206
ERROR LOG	207
EXIT DIAGNOSTICS	208
Configuration Menu	209
Entering Config Menu	209
Exiting the Config Menu	209
Reset Fuser Cnt	210
Black Only Mode	210
Prt Quality Pgs	210
Color Trapping	210
Tray Insert Msg	210
SIZE SENSING	210
Panel Menus	211
PPDS Emulation	211
Demo Mode	211
Factory Defaults	211
Energy Conserve	211
EVENT LOG	211
Auto Color Adjust	212
Paper Prompts	212
Env Prompts	212
Font Sharpening	212
Jobs On Disk	213
Disk Encryption	213
Exit Config Menu	213
Paper jams	214
Identifying jams	214
Access doors and trays	214
Understanding jam messages	215
Clearing the entire paper path	216
4. Repair information	229
Handling ESD-sensitive parts	229
Screw identification table	230
Removal procedures	234
Operator panel bezel removal	235
Lens removal	237
Front cover rear pivot cover removal	238
Front cover or front cover backplate assembly removal	239
Redrive cap removal	240
Top cover assembly removal	241
Front lower left cover removal	245
Paper path access door removal	246
Front left handle cover assembly removal	247
Front lower right cover removal	247
Front right handle cover assembly removal	249
Rear cover removal	250
Lower right door assembly removal	252
Left lower cover removal	252
Lower jam access door assembly removal	253
Redrive door removal	254
Autocompensator pick assembly removal	255
BOR drive assembly removal	262
Cartridge contact assembly removal	263
Cartridge drive assembly removal	266
Developer HVPS board removal	267
Friction buckler and buckler housing removal	268
Front right light shield removal	270
Fuser assembly removal	272
Fuser bottom duct removal	274
Fuser drive assembly removal	274
Fuser fan removal	275
Fuser top duct removal	275
Inner system board shield removal	276
ITU assembly removal	277
ITU drive assembly removal	280
LVPS assembly removal	281
Media size sensing assembly removal	283
Media size sensing board removal	286
Multipurpose feeder (MPF) removal	287
Multipurpose feeder (MPF) autocompensator or side restraints removal	290
Multipurpose feeder (MPF) motor removal	292
Nip relief handle removal	293
Operator panel assembly removal	296
Outer system board shield removal	297
Pick rolls removal	298
Printhead removal and adjustments	300
Rear bellcrank removal (cyan, magenta, yellow)	307
Rear bellcrank (black) removal	309
Redrive assembly removal	310
Registration motor removal	311
Rib housing removal	312
RIP fan removal	314
S2/narrow media/transparency/multipurpose feeder cable removal	315
S2/narrow media/transparency/multipurpose feeder sensors removal	316
Second transfer roll removal	316
System board removal	317
Transfer HVPS board removal	319
Transfer plate assembly removal	322
Vacuum transport belt (VTB) removal	323
Vacuum transport belt (VTB) fan removal	325
Waste container door removal	325
Waste container latch removal	326
Web oiler fuser assembly and card removal and replacement	327
5. Connector locations	333
Locations	333
Printer boards	333
Printer motors	334
Printer sensors	335
Cartridge contact assembly pin locations (cyan, magenta and yellow)	336
Cartridge contact assembly pin locations (black)	337
System board cabling reference	338
Connectors	339
System board	339
Autoconnect—top	350
Autoconnect—bottom	351
Transfer high voltage power supply (HVPS)	352
Developer high voltage power supply (HVPS) board	354
Low voltage power supply (LVPS)	355
Media size sensing board	357
High-capacity input tray (HCIT)	358
StapleSmart finisher	360
6. Preventive maintenance	363
Safety inspection guide	363
Scheduled maintenance	363
Standard fusers	363
ITU Maintenance kits	363
Lubrication specifications	364
Lubrication for replacement motors	364
Fuser drive assembly	364
Cartridge drive assembly	365
ITU drive assembly	365
7. Parts catalog	367
How to use this parts catalog	367
Assembly 1: Covers	368
Assembly 1.1: Covers	370
Assembly 2: Cartridge mounting	372
Assembly 3: Fuser assembly	373
Assembly 3.1: Fuser (web oiler)	374
Assembly 4: Fuser drive	376
Assembly 5: Vacuum transport belt (VTB) assembly	377
Assembly 6: Transfer	378
Assembly 7: Printheads	379
Assembly 8: Paper feed output (redrive)	380
Assembly 9: Paper feed input	381
Assembly 10: Media size sensing	382
Assembly 11: Paper feed transport	383
Assembly 12: Multipurpose feeder (MPF)	384
Assembly 13: 500-Sheet integrated tray	386
Assembly 14: Autocompensator assembly	387
Assembly 15: ITU assembly	388
Assembly 16: ITU drive assembly	389
Assembly 17: ITU loading	390
Assembly 18: Waste toner	392
Assembly 19: BOR drive assembly	393
Assembly 20: Cartridge contact assembly	394
Assembly 21: Cartridge drive assembly	395
Assembly 22: Electronics	396
Assembly 22.1: Electronics	398
Assembly 22.2: Electronics	400
Assembly 22.3: Electronics	401
Assembly 23: Electronics—cabling interconnections 1	402
Assembly 24: Electronics—cabling interconnections 2	404
Assembly 25: Electronics—cabling interconnections 3	406
Assembly 26: Electronics—cabling interconnections 4	407
Assembly 27: Output expander	408
Assembly 27.1: Output expander	410
Assembly 28: 5-Bin mailbox	412
Assembly 28.1: 5-Bin mailbox	414
Assembly 29: 500-Sheet drawer option	416
Assembly 29.1: 500-Sheet drawer option	418
Assembly 30: Duplex option	420
Assembly 30.1: Duplex option	422
Assembly 31: High-capacity input tray (HCIT)	424
Assembly 31.1: High-capacity input tray (HCIT)	426
Assembly 32: StapleSmart finishe	428
Assembly 32.1: StapleSmart finisher	429
Assembly 32.2: StapleSmart finisher	430
Assembly 32.3: StapleSmart finisher	431
Assembly 33: Envelope option	432
Assembly 34: Outdoor media tray option	434
Assembly 35: Banner option	435
Assembly 36: Options	436
Appendix A—Service tips	439
Identifying the printheads	439
Redrive belt routing	440
Duplex option deflector button replacement	441
Appendix B—Print quality samples	443
Print tests	443
Print Quality Pages—Title page (total of five)	443
Print Quality Pages—Page 1 (total of five)	444
Print Quality Pages—Page 2 (total of five)	445
Print Quality Pages—Page 3 (total of five)	446
Print Quality Pages—Page 4 (total of five)	447
Registration and alignment	448
Quick Test Page	448
Printhead mechanical alignment test page	449
Printhead electronic alignment test page—Magenta (one of two)	450
Printhead electronic alignment test page—Magenta (two of two)	451
Index	453
Part number index	461
Repeating defect locator	471
Wiring diagrams	472
System board—left side	472
System board—right side	473