Lexmark M5160 Manuals

Manuals and User Guides for Lexmark M5160. We have 1 Lexmark M5160 manual available for free PDF download: Service Manual

Lexmark M5160 Service Manual

Lexmark M5160 Service Manual (949 pages)

Brand: Lexmark | Category: Printer | Size: 68.64 MB

Table of Contents

Service Manual
1
Product Information

2
Edition Notice

2
- August
  2
- Table of Contents
  3
Notices and Safety Information

23
- Laser Notices
  23
- Safety Information
  26
Preface

31
- Service Manual Conventions
  31
- Change History
  31
General Information

41
Diagnostic Information

53
Service Menus

321
- Understanding the Printer Control Panel
  321
  - Using the Printer Control Panel
    321
  - Understanding the Colors of the Sleep Button and Indicator Lights
    322
- Updating the Printer Firmware
  322
- Menus List
  323
- Diagnostics Menu
  323
  - Entering the Diagnostics Menu
    323
  - Registration
    324
  - Print Tests
    324
    
    Print Quality Pages (Prt Quality
    325
  - Hardware Tests
    325
    
    Button Test
    325
    
    Panel Test
    325
    
    DRAM Test
    326
    
    Serial Wrap Test
    326
    
    USB HS Test Mode
    327
  - Duplex Tests
    327
    
    Quick Test
    327
    
    Sensor Test
    328
    
    Top Margin
    328
    
    Duplex Feed 1
    329
    
    Duplex Feed 2
    329
    
    Motor Test
    329
  - Input Tray Tests
    330
    
    Feed Tests
    330
    
    Sensor Tests
    330
  - Output bin Tests
    331
    
    Diverter Test
    331
    
    Feed Tests
    331
    
    Feed to All Bins
    331
    
    Sensor Test
    331
  - Finisher Tests
    332
    
    Feed Test
    332
    
    Hole Punch Test
    332
    
    Staple Test
    332
    
    Finisher Sensor Test
    333
  - Base Sensor Test
    333
  - Device Tests
    334
    
    Disk Test/Clean
    334
    
    Flash Test
    334
    
    Quick Disk Test
    334
  - Printer Setup
    335
    
    Defaults
    335
    
    Edge to Edge
    336
    
    Engine Setting [X]
    336
    
    Parallel Strobe Adjustment (Par 1 Strobe Adj)
    336
    
    Permanent Page Count (Perm
    336
    
    Printed Page Count
    336
    
    Processor ID
    336
  - Ep Setup
    337
    
    EP Defaults
    337
    
    Fuser Page Count
    337
    
    Fuser Temperature (Fuser Temp)
    337
    
    Warm up Time
    337
    
    Automatic Darkness Adjust (Auto Dark Adj)
    338
    
    Charge Roll
    338
    
    Gap Adjust
    338
    
    Print Contrast
    338
    
    Transfer
    338
  - Reports
    339
    
    Installed Licenses
    339
    
    Menu Settings Page
    339
  - Event Log
    339
    
    Display Log
    339
    
    Clear Log
    340
    
    Print Log
    340
  - Exit Diags
    340
- Configuration Menu
  340
  - Entering the Configuration Menu
    341
  - Roller Kit Counter Value
    342
  - Reset Roller Kit Counter
    342
  - Print Quality Pages
    342
  - Reports
    343
    
    Event Log
    343
    
    Menu Settings Page
    343
  - Size Sensing
    343
  - Panel Menus
    344
  - PPDS Emulation
    344
  - Download Emuls
    344
  - Safe Mode
    344
  - Factory Defaults
    345
  - Energy Conserve
    345
  - Paper Prompts
    345
  - Envelope Prompts
    346
  - Action for Prompts
    346
  - Jobs on Disk
    347
  - Disk Encryption
    347
  - Erase All Information on Disk
    347
  - Wipe All Settings
    348
  - Font Sharpening
    348
  - Require Standby
    348
  - A5 Loading
    348
  - UI Automation
    349
  - LES Applications
    349
  - Key Repeat Initial Delay
    349
  - Key Repeat Rate
    350
  - Wiper Message
    350
  - Clear Supply Usage History
    350
  - Clear Custom Status
    350
  - USB Speed
    350
  - Automatically Display Error Screens
    351
  - USB Pnp
    351
- Entering Invalid Engine Mode
  351
- Entering Recovery Mode
  352
- Accessing the Network SE Menu
  352
- Service Engineer Menu
  352
  - Accessing the Service Engineer (SE) Menu
    352
  - Service Engineer (SE) Menu
    352
Repair Information

355
- Removal Precautions
  355
- Adjustments
  374
  - Media Aligner Roller Adjustment
    376
  - Polygon Printhead Mechanical Registration Adjustment
    377
- Removal Procedures
  380
- Front Side Removals
  380
  - Duplex Exit Diverter Removal
    381
  - Front Door Removal
    383
  - Inner Guide Deflector Removal
    384
  - Laser Printhead Removal
    386
  - Left Inner Cover Removal
    390
  - Media Aligner Roller Removal
    392
  - Media Turn Guide Removal
    394
  - Media Vertical Guide Removal
    395
  - MPF Feeder Lift Plate Removal
    397
  - MPF Pick Roller Removal
    400
  - MPF Solenoid Removal
    402
  - MPF Tray Removal
    404
  - Right Inner Cover Removal
    406
  - Sensor (Input) Removal
    407
  - Sensor (Toner Density) Removal
    408
  - Transfer Roller Left Arm with Cable Removal
    410
  - Transfer Roller Right Arm Removal
    411
  - Transfer Roller Removal
    414
  - 4.3-Inch Tilting Display Removal
    417
  - 7-Inch Tilting Display Removal
    419
  - Control Panel Removal (2.4-Inch Screen)
    422
  - Control Panel Removal (4.3-Inch Screen, 7-Inch Screen)
    428
  - Control Panel Board (2.4-Inch Tilting Display) Removal
    434
  - Control Panel Board (4.3-Inch Tilting Display) Removal
    437
  - Control Panel Board (7-Inch Tilting Display) Removal (Ms812De)
    440
  - Control Panel Front Cover Removal
    443
  - Control Panel Latch Removal
    445
  - Control Panel Left Bezel Removal
    446
  - Left Control Panel Hinge Removal
    447
  - Right Control Panel Hinge Removal
    450
- Rear Side Removals
  453
  - Rear Lower Cover Removal
    454
  - Rear Door Removal
    456
  - Duplex Motor Removal
    457
  - Fuser Removal
    459
  - Rear Door Removal
    459
  - Fuser Access Door Removal
    461
  - Rear Door Removal
    461
  - Left Frame Pivot Removal
    462
  - Output bin Sensor Cover Removal
    463
  - Right Frame Pivot Removal
    464
  - Rear Door Removal
    464
  - Sensor (Rear Door Interlock) Removal
    465
- Top Side Removals
  465
  - Top Cover Removal
    466
  - Sensor (Standard bin Full) Removal
    466
  - Standard bin Cover Removal
    467
  - Upper Redrive Motor Removal
    469
  - Upper Redrive Removal
    471
- Bottom Side Removals
  472
  - Duplex Removal
    473
  - Duplex Front Flap Removal
    475
  - Duplex Rear Flap Removal
    476
  - Left Frame Extension Removal
    477
  - Media Tray Removal
    479
  - Media Size Actuator Removal
    480
  - Pick Roller Assembly Removal
    482
  - Right Frame Extension
    483
  - Sensor (Duplex Path) Removal
    484
  - Sensor (Tray 1 Media Out) Removal
    485
  - Separator Roller Assembly Removal
    487
- Left Side Removals
  488
  - Separator Roller Assembly Left Side Removals
    488
  - Left Cover Removal
    489
  - Controller Board Removal
    492
  - Left Cover Removal
    492
  - Controller Board Access Cover Removal
    493
  - Controller Board Access Shield Removal
    494
  - Fuser Drive Motor Removal
    494
    
    Left Cover Removal
    495
    
    Left Cover Removal
    496
  - Main Cooling Fan Removal
    496
  - Main Drive Motor Removal
    497
  - Media Feeder Removal
    498
  - Left Cover Removal
    499
  - PCBA Housing Removal
    500
  - Left Cover Removal
    501
  - Sensor (Control Panel Interlock) Removal
    501
  - Sensor (Pick Roller Position) Removal
    502
  - Toner Add Motor Removal
    503
- Right Side Removals
  504
  - Toner Add Motor Right Side Removals
    504
  - Right Cover Removal
    505
  - Cartridge Cooling Fan Removal
    507
  - Duplex Cooling Fan Removal
    508
  - Fuser Cooling Fan Removal
    509
  - HVPS Removal
    510
  - LVPS Removal
    511
- 250/550-Sheet Media Tray Option Removals
  514
  - 250/550-Sheet Media Tray and Drawer Assembly Removal
    514
  - Media Tray Separation Roller Removal
    514
  - Media Tray Assembly Removal
    515
  - Media Tray Front Cover Removal
    515
  - Drawer Pick Roller Removal
    516
  - Sensor (Pick Roll Position) Removal
    516
  - Drawer Assembly Rear Cover Removal
    517
  - Drawer Assembly Left Cover Removal
    518
  - Drawer Controller PCBA Removal
    519
  - Drawer Upper Interface Cable Removal
    520
  - Drawer Lower Interface Cable Removal
    521
  - Drawer Media Feeder Removal
    522
  - Drawer Transport Motor Removal
    524
  - Sensor (Pick) Removal
    525
  - Sensor (Drawer Pass Through) Removal
    527
- High Capacity Input Tray Option Removals
  530
  - High Capacity Input Tray Option Removal
    530
  - HCIT Removal
    531
  - HCIT Drawer Assembly Removal
    531
  - HCIT Separator Roller Assembly Removal
    532
  - HCIT Media Guide Removal
    532
  - HCIT Front Cover Removal
    533
  - HCIT Pick Roller Assembly Removal
    535
  - HCIT Rear Cover Removal
    536
  - HCIT Left Cover Removal
    537
  - HCIT Right Cover Removal
    539
  - HCIT Controller PCBA Removal
    541
  - HCIT Top Cover Assembly Removal
    542
  - HCIT Lift Drive Motor Removal
    544
  - HCIT Interface Cable Removal
    546
  - Sensor (HCIT Media Low) with Flag Removal
    547
  - Sensor (HCIT Pick Roller Position) Removal
    548
  - Sensor (HCIT Pick) Removal
    550
  - HCIT Media Feeder Removal
    551
- Output Expander Option Removals
  554
- High Capacity Output Expander Option Removals
  584
  - High Capacity Output Expander Option Removal
    584
  - HCOE Top Cover Removal
    584
  - HCOE Rear Door Removal
    585
  - HCOE Sensor Cover Removal
    586
  - HCOE bin Full Flag Removal
    587
  - Sensor (HCOE Media bin Full) with Flag Removal
    587
  - HCOE Sensor Cover Removal
    587
  - HCOE Right Cover Removal
    588
  - HCOE Left Cover Removal
    589
  - HCOE Controller PCBA Removal
    591
  - HCOE Lower Interface Cable Removal
    593
  - HCOE Upper Interface Cable Removal
    594
  - HCOE Option Latch Removal
    594
  - HCOE Diverter Motor Removal
    595
  - Sensor (HCOE Tray HP) Removal
    596
  - HCOE Tray Spring Removal
    597
  - HCOE Tray Pinion Removal
    598
  - Sensor (HCOE Rear Door Interlock) Removal
    599
  - HCOE Belt Tensioner Removal
    601
  - HCOE Tray Pinion Removal
    601
  - HCOE Drive Belt Removal
    602
  - HCOE Diverter Plunger Assembly Removal
    604
  - HCOE Main Drive Gear Assembly Removal
    605
  - HCOE Main Motor Removal
    607
  - Sensor (HCOE Diverter HP) Removal
    609
  - HCOE Top Diverter Spring Removal
    611
  - HCOE Top Diverter Removal
    612
  - HCOE Tray Shaft Removal
    614
  - HCOE bin Removal
    615
  - Sensor (HCOE Pass Through) Removal
    618
- Staple Finisher Option Removals
  621
  - Staple Finisher Option Removal
    621
  - Stapler Rear Door Removal
    622
  - Stapler Right Cover Removal
    624
  - Stapler Door Close Limit Switch Removal
    626
  - Sensor (Cartridge Door Interlock) Removal
    627
  - Stapler Carriage Assembly Removal
    628
  - Stapler Left Cover Removal
    630
  - Stapler Cartridge Access Door Removal
    632
  - Sensor (Throat Media Present) Removal
    632
  - Stapler Top Cover Removal
    635
  - Stapler Spring with String Removal
    637
  - Stapler Option Latch Removal
    638
  - Stapler Tray Spring Removal
    639
  - Stapler Tray Link Assembly Removal
    640
  - Sensor (Stapler Rear Door Interlock) Removal
    642
  - Sensor (Paddle Motor HP) Removal
    643
  - Media Stack Flap (Right) Removal
    643
  - Media Stack Flap (Left) Removal
    645
  - Sensor (Right Tamper Motor HP) Removal
    647
  - Sensor (Left Tamper Motor HP) Removal
    649
  - Standard Output bin LED Removal
    652
  - Sensor (Finisher bin Media Present) Removal
    653
  - Tamper Assembly Removal
    654
  - Tamper Motor (Right) Removal
    656
  - Tamper Motor (Left) Removal
    656
  - Tamper Drive Belt Removal
    657
  - Stapler Output bin LED Removal
    658
  - Paddle Drive Motor Removal
    660
  - Stapler Lower Interface Cable Removal
    661
  - Stapler Controller PCBA Removal
    663
  - Stapler Main Motor Removal
    664
  - Stapler Diverter Motor Removal
    666
  - Stapler Diverter Plunger Assembly Removal
    667
  - Stapler Drive Gear Assembly Removal
    668
  - Sensor (bin Full Send) Removal
    669
  - Sensor (bin Full Receive) Removal
    670
  - Media Pusher Assembly Removal
    672
  - Stapler Feed Roll Removal
    672
  - Stapler Chute Assembly Removal
    674
  - Sensor (Stapler Pass Through) Removal
    677
  - Stapler Ejector Motor Assembly Removal
    678
  - Sensor (Stapler Ejector HP) Removal
    681
  - Sensor (Media Pusher HP) Removal
    684
  - Sensor (Stapler Diverter Plunger HP) Removal
    686
- Mailbox Option Removals
  688
  - Mailbox Option Removal
    688
  - Mailbox Top Cover Removal
    688
  - Mailbox Rear Door Removal
    689
  - Mailbox Right Cover Removal
    691
  - Mailbox Top bin Cover with Bail Removal
    692
  - Mailbox Spring with String Removal
    693
  - Mailbox Solenoid Removal
    694
  - Mailbox Left Cover Removal
    696
  - Mailbox Option Latch Removal
    697
  - Sensor (Mailbox Rear Door Interlock) Removal
    697
  - Mailbox Diverter Plunger Assembly Removal
    698
  - Mailbox Main Drive Gear Removal
    703
  - Mailbox Main Motor Removal
    706
  - Mailbox Controller PCBA Removal
    707
  - Sensor (Mailbox Diverter Plunger HP) Removal
    708
  - Mailbox Lower Interface Cable Removal
    710
  - Mailbox Upper Interface Cable Removal
    712
  - Mailbox Diverter Motor Removal
    712
  - Mailbox Media bin Full Flag Removal
    714
  - Sensor (Mailbox bin Full Receive) Removal
    715
  - Mailbox Belt Removal
    718
  - Mailbox Output bin LED Assembly Removal
    720
  - Mailbox Top Diverter Removal
    723
  - Mailbox Middle Diverter Removal
    728
  - Mailbox Top Diverter Spring Removal
    729
  - Sensor (Mailbox Pass Through) Removal
    733
- Staple, Hole Punch Finisher Option Removals
  738
Component Locations

779
- Exterior Locations
  779
  - Front View
    779
  - Configured Model
    780
  - Rear View
    781
- Connectors
  782
  - Controller Board
    782
Maintenance

791
- Inspection Guide
  791
- Scheduled Maintenance
  793
- Preventive Maintenance
  797
  - Device-Specific Preventive Maintenance
    797
- Lubrication Specification
  797
- Cleaning the Printer
  797
  - Emptying the Hole Punch Box
    798
Parts Catalog

800
- Legend
  801
- Assembly 1: Covers
  803
- Assembly 2: Paper Path
  807
- Fusers
  809
- Assembly 4: Electronics
  811
- Assembly 5: Drive Motors
  815
- Duplex
  817
- Assembly 7: Frame
  819
- Assembly 8: Control Panel
  821
- Assembly 9: Paper Tray
  825
- Assembly 10: Input Options
  827
- Assembly 11: 250-Sheet Tray Option
  829
- Assembly 12: 550-Sheet Tray Option
  831
- Assembly 13: High Capacity Input Tray Option 1
  833
- Assembly 14: High Capacity Input Tray Option 2
  835
- Assembly 15: Output Options
  837
- Assembly 16: Output Expander Option 1
  839
- Assembly 17: Output Expander Option 2
  841
- Assembly 18: Output Expander Option 3
  843
- Assembly 19: Output Expander Option 4
  845
- Assembly 20: High Capacity Output Expander Option 1
  847
- Assembly 21: High Capacity Output Expander Option 2
  849
- Assembly 22: High Capacity Output Expander Option 3
  851
- Assembly 23: High Capacity Output Expander Option 4
  853
- Assembly 24: Staple Finisher Option 1
  855
- Assembly 25: Staple Finisher Option 2
  857
- Assembly 26: Staple Finisher Option 3
  859
- Assembly 27: Staple Finisher Option 4
  861
- Assembly 28: Mailbox Option 1
  863
- Assembly 29: Mailbox Option 2
  865
- Assembly 30: Mailbox Option 3
  867
- Assembly 31: Staple, Hole Punch Finisher Option 1
  869
- Assembly 32: Staple, Hole Punch Finisher Option 2
  871
- Assembly 33: Staple, Hole Punch Finisher Option 3
  873
- Assembly 34: Staple, Hole Punch Finisher Option 4
  875
- Assembly 35: Power Cords
  877
- Assembly 36: Miscellaneous
  879
Appendix A: Printer Specifications

881
- Power Specifications
  881
- Operating Clearances
  882
- Acoustics
  882
- Environment
  882
- Processor
  883
- Security Reset Jumper
  883
Appendix B: Options and Features

885
- Available Internal Options
  885
- Input Options Supported
  885
- Output Options Supported
  885
- Physical Specifications (Options)
  886
- Options Configurations
  886
Appendix C: Theory of Operation

887
- Models Ms81X and Ms71X Paper Path Rollers and Sensors
  888
- Models Ms81X and Ms71X Sensors
  889
- Media Tray Assembly
  889
  - Media Tray
    889
  - Rear Media Guide
    889
  - Side Media Guide
    889
- Media Feeder Assembly
  890
  - Media Feeder
    890
  - Sensor (Media Size)
    890
  - Sensor (Pick Roller Position)
    890
- Multi-Purpose Feeder (MPF)
  890
  - MPF Pick Roller
    891
  - MPF Pick Solenoid
    891
- Registration
  891
  - Sensor (Input)
    892
- Duplex
  892
  - Sensor (Duplex Path)
    892
- Transfer
  892
  - Transfer Roller
    892
- Printhead
  893
- Fuser Components
  894
  - Heat Belt (Belt Fuser)
    895
  - Heat Belt (Hot Roll Fuser)
    895
  - Pressure Roll
    895
  - Heater Lamp (Hot Roll Fuser)
    895
  - Thermistor
    895
  - Sensor (Fuser Exit)
    896
  - Sensor (Narrow Media) (Hot Roll Fuser Only)
    896
- Exit
  896
  - Sensor (Standard bin Full)
    896
- Drive
  897
  - Main Drive Motor Assembly
    897
  - Fuser Drive Motor Assembly
    897
  - Toner Add Motor Assembly
    897
  - Redrive Motor Assembly
    897
- Sensors
  898
- Electrical Components and Controller
  898
  - Sensor (Control Panel Door Interlock)
    899
  - Sensor (Rear Door Interlock)
    899
  - Main Cooling Fan
    899
  - Cartridge Cooling Fan
    899
  - Duplex Cooling Fan
    899
  - Fuser Cooling Fan (Hot Roll Printer Only)
    899
  - LVPS Board Assembly
    900
  - HVPS Board Assembly
    900
  - Controller Board
    900
- Xerographic and Print Cartridge Components
  900
- Output Options Theory
  904
  - Output Expander Theory
    904
  - High Capacity Output Expander Theory
    905
  - Mailbox Theory
    906
  - Staple Finisher Theory
    907
Appendix D: Acronyms

909
- Acronyms
  909
Index

911
Part Number Index

923
Part Name Index

937

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