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Lexmark C500n 5023-110 Service Manual

1. 5 14 Service Manual 5023 110 6 Preventive maintenance There is no preventive maintenance for this printer Preventive maintenance 6 1 5023 110 6 2 Service Manual 5023 110 7 Parts catalog How to use this parts catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Parts catalog 7 1 Base printer Assembly 1 AA kv DA Oey 7 2 Service Manual 5023 110 Assembly 1 Base printer Index P N Units Description 1 1 40X3383 1 Cover cleaning roller 2 40X3382 1 Roller cleaning 3 40X3412 1 Transfer unit 4 40X3418 1 Transfer roller assembly 5 40X3425 1 Paper tray standard 6 40X0297 1 Power cord USA 6 40X1766 1 Power cord LV USA APG Bolivia Canada Columbia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Nicaragua Panama Peru Venezuela 6 40X0301 1 Power cord HV Argentina
2. 115 Volts 11A 230 Volts 6A Average current while printing 115 Volts 6 5A 230 Volts 3 0A Environment Environment Specifications Operating Air temperature product operating 10 to 32 5 C 50 to 90 5 F Air temperature product power off 5 to 35 C 41 to 95 F Air relative humidity 15 to 80 Altitude 0 2 500 m 0 8 200 ft Ship Storage Temperature printer and supplies 0 to 35 C 32 to 95 oF Relative humidity 10 to 90 RH Atmospheric pressure 613 to 1607 hPa 460 to 800 mm Hg Severe High 35 to 40 C 95 to 104 F Severe Low 10 to 0 14 to 32 F The period under severe shall not be deemed to be continuous but rather a total of such intermittent periods 48 hours at most for any one period 1 12 Service Manual 5023 110 Printer identification Top cover Operator assembly panel cover Rear cover assembly Paper Release stopper Release Front lever cover Right cover Front view Left cover AC input inlet Power switch Back view General information 1 13 5023 110 Printer theory of operation The following diagram shows the major parts of the printer and paper path Cleaning roller Fuser Paper exit Photodeveloper assembly OPC belt cartridge Toner cartridge K Y M C Rear cover assembly LJ Transfer belt Transfer unit Transfer roller EC Laser un
3. 7 7 Parts packet harness 7 17 Paris packet harness gt ose eS eS Sie as S ean 7 17 Field relocation kit 7 17 1 4 Service Manual
4. 7 9 Clutch paper feed 7 9 Clutch registration 7 9 Clutch transfer roller 7 9 Clutch cleaning roller 7 9 Gear assembly main drive 7 9 Waste toner feeder 7 9 Drive assembly developer 7 9 Assembly waste toner holder 7 9 Sensor toner receiver TTR This is a two piece sensor system Ordering of this part number includes both the right and left side 7 13 Sensor toner sender TPD This is a two piece sensor system Ordering of this part number includes both the right and left side 7 9 Laser unit assembly printhead 7 7 Right tray guide 7 7 Auger waste toner 7 15 Agitator waste toner 7 15 Board
5. 3 Before charging the OPC belt surface is CBV V The charger unit evenly charges the OPC belt surface to Vo V by generating a negative charge Cleaning CO Se Skare ee General information 1 23 5023 110 Exposing process In the exposing process the OPC belt surface is exposed to the laser light which forms an electrostatic latent image The luminous source of the laser is a semiconductor laser See Printer theory of operation on page 1 14 for optical unit location The laser light scans the OPC belt forming an electrostatic latent image 1 The OPC belt surface is charged to Vo V potential a The laser scans the OPC belt in a rectangular pattern during forward movement of the OPC belt b High speed switching of the laser matches the transmitted image data c The charge of the areas radiated by the laser light is discharged creating a VR V potential d An electrostatic latent image is formed invisible on the OPC belt OPC charging i a Charging Exposing 1 24 Service Manual 5023 110 Developing process In the developing process an electrostatic latent image attracts printer toner and becomes visible on the OPC belt There are four toner cartridges See Printer theory of operation on page 1 14 for toner cartridges location The toner cartridges are located in the printer from top to bottom in the order o
6. Maintenance page printout 1 Power the printer up Press the Go 4 2 button to take the printer offline The printer is offline when the LED is OFF 2 Press the Back 5 button to enter the Not Ready state 3 Press and hold the right navigation gt button for approximately three seconds Please wait appears until the maintenance page prints 3 2 Service Manual 5023 110 Saving NVRAM settings for hardware replacement Before replacing the RIP or engine controller board it is important to save the settings contained on each FRU Saving the engine controller board settings 1 Press and hold the right navigation gt button down Simultaneously press the Stop X button three times Press the Select v button You have entered the CE Mode and the default menu should be the Service Menu If not use the left and right navigation buttons to scroll through the menus until Service Menu appears Press the Select button Use left and right lt fe navigation buttons to scroll to the Maintenance submenu Press the Select V button Use left and right lt gt navigation buttons to scroll to the MCTL gt PRC selection Press the Select V button Press the Back button twice to exit CE mode Saving the system RIP board settings 1 Press and hold the right navigation gt button down Simultaneously press the Stop xX button three times Press the Select v button You have entered the CE Mode an
7. 2 30 Toner empty sensor receiver TTR service 2 31 Lower feed unit secondary paper assembly service 2 32 Tray empty service CHECK 22 iones seeeeecetees babes ka EA 2 33 Paper tray missing service checK 4 44 44 4444 2 34 Toner low empty service check 2 cece eee cece wesc ence 2 35 Waste toner bottle service 4 45444 2 35 Missing toner cartridge service Check 22 220 soe 2 36 Missing photodeveloper cartridge service check 2 37 Transfer roller missing service check 2 4 4 2 2 38 Gover open service Check suas eee ewe ieee ORES ee RR KR eee 2 39 OPC belt photodeveloper cartridge drive service 2 40 Missing fuser service cance uua cease eee eee eee eee ee 2 40 Paper size sensing service Check 2 ce ecccee 45 2 41 Printer no power service Check sceccceseeveren see vee eens 2 42 Toner feed service Check 22 cece cs laeua RR ranREE
8. IPS S ok 4 6 toller TRIDDVE uaa exea uad pne d gba dE ma gd med d we 4 7 5023 110 Fuser assembly removal 22 4 7 Veere toner bette PETN NE 4 8 5 52 552 4555 6 5 4 9 oecondary paper feed assembly removal EE E wee EE 4 10 COVEFIGCMOVAS i e53 3guc Re SHES SSS SES EPPERHRETAG RR e 43 ESE 4 11 Top Cover assembly FEITIDVAL IU SUR Ea KE Bx Em M 4 12 Front cover assembly removal 22342929 ad ERE A a ER tc GERI cess CREER IE 4 13 Fiol COVE RE Edd Na dub wage ie Gmetad uds 4 14 Hear cover assembly SOMOVA usa ics cuoco e e rwr Ea EGG Eau Sea e g Sag dedo 4 15 Len GOVSF EE auno oxE Re EESORORicRERD NR RR pt 4 16 Laser unit assembly printhead 4 16 See aes Sd d Ka 4 18 Right side removals 25a segue bau pawn deer gae PE one ee 4 19 Front door qytellock switch VIN DE uuu nodes rox eee sa Rm ay oae cua Ri eum 4 20 Waste toner bottle holder removal 2 22 6222 x rr reR I ibis sce wed cde re RR RC RR EE 4 20 Developer d
9. 1 3 vii 5023 110 viii Service Manual 5023 110 Laser notices The following laser notice labels may be affixed to this printer as shown Laser advisory label Laser notices iX 5023 110 Class 1 Laser statement label LEXMARK 5 A X Service Manual 5023 110 Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem B amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen Landern gilt der Drucker als Laserprodukt der Klasse 1 der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gemaB amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des D
10. 1 12 EATON A 1 12 STE HIDN 4 eed es wurde RES UNES Ee Od KEEN DNE RENE de ad iR 1 13 Printer thegry Of daperdliOll cess e ase ehidsesst esque 1 14 EA babel Pall ITI EE 1 15 Prifiler Systems assa suus Rente RIPE RACE RI EEG S 1 16 Basic Bunceibles OF DOIQEIBEINUNO cuoco od aures Qi S V eu DS edo eder 1 16 Mechanical and electrical rk hei ad fec bag ena duds 1 16 Eier COMPONENE asc ue KR appe d eR pte qax RENE xe 1 17 Basic process 4352299 ara keed e 1 18 Pri system EE EEE dde 1 19 Structure of OPC belt photo developer cartridge 1 20 Basic Suche pi The RETE PIS ede RE 1 21 Details ot the pim 1 23 Changin seede eee 1 23 EXPOSING DIOCBSS uade c aa uio eds dessa degen SO Garde RN a 1 24 Dovo MO ibo aed PERF QE qe d eR Ee qu TED 1 25 First tansfer fun DOGOS seat eh eias Sa od ae paca aan d ind 1 26 Belt discharge Orage lamp aue is es s decr dE Qe Ex eda 1 27
11. ee eens 1 1 ME ge eee Je 1 1 Tools TSQUIFER TOl SerViGO a eme 1 1 Pela NOM Sq dura i EE 1 2 Pee FETE Coed OS eG Bea PRG 1 3 eee RE EN DRE ES es 1 4 MGSO b EE 1 4 aS Med dd 1 4 Technical specilicadoflg Ie aa 1 4 Fh ysipalspeciicatons aud Welgl dus 1 4 Cleatances Case eed 1 5 Packaging and shipping GINCNSIONS us 1 5 Print speed and 5222344 428 2 REG ca anii ra secu ease d 1 5 EDM eL TE ET T UT 1 5 Duy oVCle EROR ERES Gre IREGU AS ERE GER AEG dq edu 1 6 suse SE A EET 1 6 Paper and media specilicallolS 3 2339 x 39er yu re upra c da 1 6 TUTO EE E ee ee ee ee TE TTT 1 8 Outputcapacity by Media arid SOURCE nirp pr RE S SORGE Shrew Rad wae 1 8 22 sidus s m e quad dudes e 1 8 OTS CU LITE 1 10 Power and dertil sped ass dade x eer erd
12. Tray empty service check 5023 110 Step 1 Questions actions Remove paper tray from printer Press bottom of spring platform latches located in rear corners of paper tray This releases spring platform of paper tray Ensure tray is raising paper after insertion Is tray working properly Yes Go to step 2 No Replace paper tray Ensure paper empty sensor flag swings with ease and is not broken or damaged Is flag working properly Go to step 3 Replace paper guide C assembly See Paper guide C assembly removal on page 4 31 Turn printer off and remove engine controller board board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN9 Go to step 4 Properly connect cable Reconnect operator panel Turn printer on Touch negative lead of voltmeter to metal frame to obtain ground Touch positive lead to engine controller board pin 12 to ensure 5 VDC is being supplied to paper empty sensor Is 5 VDC present Go to step 5 Go to step 8 Insert empty paper tray into printer Check voltage level on MCN9 pin 14 Is 5 VDC present Go to step 6 Go to step 7 Remove paper tray fill with paper and reinsert Check voltage level MCN9 pin 14 Is 0 VDC present Replace engine controller board See Engine controller board remov
13. 6 40X1767 1 Power cord HV Brazil 6 40X0273 1 Power cord HV Chile 6 40X0286 1 Power cord HV UK Ireland 6 40X0278 1 Power cord HV Austria Belgium Euro English Finland France Germany Greece Netherlands Norway Poland Portugal Russia Slovakia Czech Hungary Spain Sweden Turkey 6 40X0275 1 Power cord HV Israel 6 40X0274 1 Power cord HV Switzerland French Switzerland German Switzerland Italian 6 40X0276 1 Power cord HV South Africa 6 40X0287 1 Power cord HV Italy 6 40X0279 1 Power cord HV Denmark Parts catalog 7 3 5023 110 Assembly 2 Covers 7 4 Service Manual 5023 110 Assembly 2 Covers Index P N Units Description 2 1 40X3384 1 Cover assembly top 2 40X3428 1 Assembly paper exit contains fuser exit sensor and flag 3 1 Packet parts P N 40X3420 4 40X3430 1 Assembly registration 5 40X3417 1 Rear cover assembly 6 40X3385 1 Cover right 7 40X3388 1 Cover front 8 40X3387 1 Cover inner front 9 40X3386 1 Cover left 10 40X3424 1 Operator panel 11 40X3423 1 Cover operator panel Parts catalog 7 5 5023 110 Assembly 3 Front ser N Gam k 0 NN 7 6 Service Manual Assembly 3 Front 5023 110 Index P N Units Description 3 1 40X3441 Cover laser unit assembly lens 2 40X3400 Laser unit assembly printhead 3 40X3431 Left tray guide assembly with cable includes paper size sensor and
14. difference between VR V and DBV V A visible image is the result The negatively charged toner on the OPC belt is moved to the transfer belt because the potential GND of the transfer belt is greater than VR V of the OPC belt The OPC belt is discharged by the erase lamp radiating on the OPC belt Latent image vo _VO_ VO vo VO TEST VO VO PRINT JNO VO vo vo L diod K YMC Charging Developing 2 lamp 9 Transfer belt ov OPC belt surface qo VO 4 M toner Charge brush Developer mr Discharge roller y o charging system CHV Dev CBV BRV DBV 1 22 Service Manual 5023 110 Details of the print system Charging process In the charging process the OPC belt is evenly charged by the charger See Printer theory of operation on page 1 14 for charger unit location The charger unit consists of a charging brush and a discharge roller 1 The charge brush charges the OPC belt surface to Vo V potential The charge on the surface of the OPC belt is then smoothed to an even Vo V by the discharge roller 2 The charger unit controls the grid to a constant voltage of ZD V for even charging OPC Belt Brush Charge roller OPC charging system CHV DCV
15. 1 Transfer belt cleaning roller removal 1 Remove cleaning roller cover See Cleaning roller cover removal on page 4 5 2 Lift and remove transfer belt cleaning roller Repair information 4 5 5023 110 Transfer belt unit removal 1 Open rear cover assembly 2 Rotate two captive screws A counterclockwise until loose Warning Take great care when removing the transfer belt unit to prevent scratching the transfer belt Do not touch or hit the belt during removal 3 Pull transfer belt unit toward rear of printer lift and remove 4 6 Service Manual 5023 110 Transfer roller removal 1 Open rear cover assembly 2 Rotate transfer roller to release lift and remove Fuser assembly removal 1 Push rear cover assembly latch and lower rear cover assembly 2 Turn two green fuser release levers A Repair information 4 7 5023 110 3 Lift fuser straight up and away from printer Waste toner bottle removal 1 Open front cover 2 Remove waste toner bottle Warning Ensure that waste toner bottle is secured and not allowed to tip over during repair process Failure to adhere to this warning may result in toner spillage 4 8 Service Manual 5023 110 Photodeveloper cartridge removal Warning Follow precautionary procedures see Photodeveloper cartridge on page 4 3 when removing photodeveloper cartridge 1 Open top cover assembly 2 Depress release levers A 3 Lift and
16. 5 3091 sydo1 2WLVdO IWd 9v1vao Ivd SV1VGO Ivd vV1VOO Ivd V1VOO Ivd eV1VGO lvd IV1VGO Ivd Ov vGO Ivd 91 NOWd ANDS vnsd anos ON ensd 8 S AS N3S8d ZNOW YYANVSLO ANDd d NONV3LO OL NON S AS N MOHINOL uid ZNOW pieog 1ej ojjuoo d Nad 5 S AS QN9S OWA LOA AZOA S AS QN9S Nad 10sues z Rue LLd 40sues 91 S AS pL 6NOW Cu Josues Aysuep 1euo 21771 JOSUSS 1eJsueJ gev NAT 98 5718 LINOOT UL AS 2 NOT sev Nad peeujuud K quiesse jose GL Ave QL Avc QL Avet GL Avet GL Ave N NOAH8 QL Avet N dAOG N NOAH8 N dAOG N NOWMd N WMdAu8 N NOWMd N INMdAH8 HH3AH8 N AMdASO uudAdua NOHAHL N WNMdAg8O N WMd OW N WMdAHL NOHAHL N WMd OW N INMdAH L N WMd Ax N WMd FAHL N WMdA824 FAHL N INMdA824d anda at QN9d utd iz
17. N ld QN9d 5 8 auos 91 LNOW 5 29A INOI ON3INW N A3HWIA lt r NIVOIWIN NDS ON jun JEded 9 9 9 VZLNO ZWA 44 WOO v GL Ave v v Jedojenag et e az1no 2 gt WOO at Ave aud 1 911 0 a 9 VZLNOLWG WOO V GL Ape 7 v b YLLNO ING lt azLNO LAG 2 A WOOD 9 AL APZ eT L aL100 uid 92 aNd SNOW Jojow twa Wiring diagram 3 of 4 p1eog MSGLNOHS amp 1 7 SSUYINMS M20MAJU MSadoL MSG uvad gt d NadOGdOL anos ON d N3doduvau 1 YNON MHO NO dN3ILNS ZHL 9 NONA Ave INOS HO NO N9d vet Avet N ONASOV vot FONASOV 1 d ddOov I Sd 1 4409Y N NOH ON NOH NOS ON ASO GAbe HJO QAvc N 0dAS 0 HYL S 211531 HLSSL 201531 01631 uid 81 urs NOAT QL Avc QrAvet ANDd QL Avc GL AbZ ANDd
18. NOAH NDXHONODAH SdAH uidiz Nog A ddns samod 5 10 Service Manual 5023 110 Sk eseJ3 i JOSUBS 4 au en 2 1edoje eq L Lo a N NOT3 NIN3SLWO n SA SI gt N NOSS1L ONOS F gt 41019911 NOGSILA Fhe gt J9PIou anos ON ones a n 5311 N T1NSSL 110391 JOUO ONDS NOLfTIOMd dHAl 911 edd b Avet Lg em MHOSITL N NOT1038 gt 1edeg Nowe Ba ene d E E4OL APZ 9 d utd ZL SNOW y n JejsueJ Y 4apuas Josues Jeuo Y Y ole Al EN alen o w 1591 N NO 1084 JQL Ave oz PNON 19419991 Josues Jeuo Y 48 04 2 vy 1984 Y L AS N MHO NOHT S AS 1520 dad L1S0Sd 1Sd z1Sd 18 ON N NOTIONd 4 Ave 138 NOST utd 71 NON v 13 10 2 5 11 Locations and connectors lt N AGHNN N NOWIA Josuas JESN4 ue 195 4 OWN QLAve aNos JOJOW ulen lt lt 3
19. Netherlands Norway Poland Portugal Russia Slovakia Czech Hungary Spain Sweden Turkey 7 3 Power cord HV Denmark 7 3 Power cord HV UK Ireland 7 3 Power cord HV Italy 7 3 Power cord USA 7 3 Power cord HV Argentina 7 3 Power cord LV USA APG Bolivia Canada Columbia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Nicaragua Panama Peru Venezuela 7 3 Power cord HV Brazil 7 3 Roller cleaning 7 3 Cover cleaning roller 7 3 Cover assembly top 7 5 Cover right 7 5 Cover left 7 5 Cover inner front 5 24 45 sce ee ee ee 7 5 Cover 7 5 Motor assembly main
20. QL Avc ANDd aN9d DLON GNOS LOW ANDS LON L AS LOW L AS DLON GNOS LOW aN9S LON L AS OLON HAS DLON GNOS FLOWN L AS aN9S LOW ANDS PLOW L AS z A ANDS CAEEF GNOSd z A ANDS CAG Et GNOSd INO z A amp GNDS CAG Et GNOSd LNO 2 AS 2 AS aN5S LNO 2 AS 2 AS LNO 2 AS 2 AS 5023 110 Saa uid oe LNOV us Ajddns Jemod uid og NOOd Wiring diagram 4 of 4 pueog 49 041U09 5 12 Service Manual 5023 110 RIP board Engine controller board MCN9 8 MCN7 MCN6 Locations and connectors 5 13 5023 110 Low voltage power supply LVPS board
21. See Top cover assembly removal on page 4 12 2 Remove screw A from power supply fan 3 Disconnect cables from interlock switches and remove power supply fan 4 44 Service Manual 5023 110 5 Locations and connectors Printer Top cover Operator assembly panel cover Rear cover assembly Paper Release stopper Nan Release Front lever cover Right cover Paper tray Front view Left cover AC input inlet Power switch Back view Locations and connectors 5 1 5023 110 Part name Description Paper stopper Stopper for exited papers Operator panel cover Displays status of printer operation Top cover assembly Upper enclosure and also the paper exit tray Rear cover assembly Printer rear enclosure that opens allowing clearing of internal paper jams or maintenance work Release lever rear cover assembly Releases rear cover assembly Release lever top cover assembly Releases the opening portion of the top cover assembly Opening the top cover assembly allows access to the photodeveloper unit Right cover Covers the right side of the printer where the motors and drives are located Front cover Printer front enclosure that opens allowing toner cartridge or waste toner bottle replacement Paper tray Standard paper tray that holds printer paper Left cover Covers the left side of the printer where a majority of the electronic
22. if defective See Waste toner auger removal on page 4 43 Waste toner is not properly collected by waste toner feeder Check to ensure that waste toner feeder is not compacted If so replace waste toner feeder See Waste toner feeder removal on page 4 26 Check for waste toner in printer If found clean and vacuum printer 2 Transfer unit cleaning roller Cleaning roller is faulty Remove transfer belt unit see Transfer belt unit removal on page 4 6 Replace cleaning roller See Transfer belt cleaning roller removal on page 4 5 Prior to installation of new cleaning roller thoroughly clean cleaning roller installation area Check for waste toner in printer If found clean and vacuum printer 3 Toner cartridge Replace faulty toner cartridge 2 58 Service Manual Vertical line service check A vertical line appears in printed image 5023 110 Problem area Action 1 Photodeveloper cartridge OPC belt and transfer belt Foreign particles dust and so on adhere to parts located around photodeveloper cartridge and transfer belt unit which consequently contact toner image on transfer belt unit Remove and clean photodeveloper cartridge transfer belt unit and adjacent areas 2 Transfer unit cleaning roller and waste toner auger Cleaning roller and waste toner auger area are dirty Remove cleaning roller and clean waste toner auger and area around Reinstall
23. outlet During inspection Avoid checking any IC directly with a multimeter use connectors on the board Never create a closed circuit across IC pins with a metal tool e Ifitis necessary to touch the ICs and other electrical components on the board be sure to ground your body 4 2 Service Manual 5023 110 Photodeveloper cartridge The following precautions must be observed when handling the photodeveloper cartridge or commonly called OPC optical photo conductor The photodeveloper cartridge is a supply item you will have to remove during some of the repair procedures During transportation storage Use the specified carton whenever moving or storing the photodeveloper cartridge Handling The OPC belt in the photodeveloper cartridge exhibits the greatest light fatigue after being exposed to strong light over an extended period of time Never expose it to direct sunlight Cover the photodeveloper cartridge when you remove it from the printer Use care not to contaminate the surface of the OPC belt with oil base solvent fingerprints and other foreign matter Do not scratch the surface of the OPC belt Parts not to be touched Any part where the mounting screws are used to meet a machine alignment set at the factory must not be removed disassembled or adjusted For example the paper pickup roll mounting bracket or internal parts not provided as replacement parts Printer removal procedures Precautions to
24. solved otherwise go to Step 6 6 If waste toner bottle is removed reinsert it Replace developer drive Go to step 7 Ensure rear cover assembly is shut assembly if error EO or E1 Override top and front cover interlock See Developer drive switches For location see Interlock assembly removal on switch locations on page 5 6 Reconnect page 4 21 Go to step 9 operator panel Turn printer on Allow printer to run until error posts Disconnect If the error is a DO or D1 connector from each developer motor and error go to step 7 check for the following on each disconnected cable connector Pin 2 to ground 24VDC Pin 5 to ground 24VDC Are voltages present 7 Remove engine controller board board Go to step 8 Replace cable Retest shield See Engine controller board printer If error clears removal on page 4 34 for steps to remove problem solved otherwise engine controller board shield Disconnect go to step 8 MCN5 from engine controller board Check for continuity and shorted pins on cable that connects MCNS to developer motors Is cable okay 8 Disconnect cable from engine controller Replace engine controller Replace cable that board POCN Check the following on board See Engine connects ACN1 on LVPS to disconnected cable connector controller board removal POCN on engine controller on page 4 34 Go step 9 board Remove RIP board Pin 21 to pin 22 24VDC cage to gain access to Pin 13 to pin 14 5VDC cable See System b
25. 4 24 Go to step 4 4 Does noise go away Problem solved Go to step 5 5 Is cable properly connected to main motor Go to step 6 Properly connect cable Retest printer If error clears problem solved otherwise go to step 6 6 If waste toner bottle is removed reinsert it Replace main motor See Go to step 7 Ensure rear cover assembly cover is shut Main motor assembly Override top and front cover interlock removal on page 4 24 switches For location see Interlock Go to step 9 switch locations on page 5 6 Reconnect operator panel Turn printer on Allow printer to run until error posts Disconnect connector from main motor and check the following on disconnected cable connector Pin 4 to pin 5 24VDC Pin 6 to pin 5 24VDC Pin 10 to pin 5 5VDC Are voltages present 7 Remove engine controller board board Go to step 8 Replace cable Retest shield See Engine controller board printer If error clears removal on page 4 34 for steps to remove problem solved otherwise engine controller board shield Disconnect go to step 8 MCN5 from engine controller board Check for continuity and shorted pins on cable that connects MCN5 to main motor Is cable okay 2 18 Service Manual 5023 110 Step 8 Questions actions Disconnect cable from engine controller board POCN Check the following on disconnected cable connector Pin 21 to pin 22 24VDC Pin 13 to pin 14 5VDC Are voltages present
26. Bell cleahiliqg DIODBSS ue daas REG e p dees Sa cem eid essp eds 1 27 or ine Transrer SSE aep nA qu Rugs SKARNES M aW RUN M ap GEER d 1 29 Second transfer paper 068 8 22245 225 cm eese aues eee Mie E M RES RR 1 29 Dell Cleaning BIOEOSS Lisenser Ge eden 1 30 Details or the Optical SySIBITI 2 243322542 22 45453554454 PIS aad eas 1 31 Details of the paper transportation SVSIBITI essem 1 32 ss oux em Rie ERU es arog Rede Ru RR ER EGER E 1 33 FUSING esc Ads dd DU ME EM 1 34 5023 110 Control system structure 2 22 22a ehh eR RO badeand aka dad 1 35 Elecireal cyce ad UNCON s dua Saab i poses a EE cama ao Ke oa M QR Rp dd 1 35 Control ord MOCOS 2552 NER PEE 1 35 EH SeQuUchCe Chadian eee EE de bag E d dei a 1 36 L ser dive control ees MESES ME 1 37 Diagnostic LG 2 1 Olai lt 2 1 Service errOf COdGS 2 2 Parts replacement maintenance codes
27. CD B A C 6 Remove screw D and disconnect all connectors from LVPS 7 Remove three metal screws E and 3 plastic screws F that attach LVPS with cage remove LVPS with cage 4 38 Service Manual 5023 110 HVPS cage removal 1 Remove HVPS See High voltage power supply HVPS removal on page 4 37 2 Remove LVPS with cage See Low voltage power supply LVPS with cage removal on page 4 38 3 Remove three screws A remove HVPS cage Toner present sensor removal 1 Remove HVPS cage See HVPS cage removal on page 4 39 2 Remove two screws A remove toner present sensor Repair information 4 39 5023 110 Toner sensor receiver removal Note The toner sensor is comprised of two separate parts the sender and receiver The sender portion of the toner sensor is located on the right side of the printer See Toner sensor sender removal on page 4 22 for removal 1 Remove HVPS cage See HVPS cage removal on page 4 39 2 Remove 2 screws A remove toner sensor receiver 3 Disconnect toner sensor cable from connector B on toner sensor receiver Note Bottom screw is longer than top screw Left tray guide assembly removal 1 Remove marker sensor See Marker sensor assembly removal on page 4 42 2 Remove HVPS cage See HVPS cage removal on page 4 39 3 Reroute cable A to allow sufficient cable length for removing left tray guide as
28. Check cable continuity from MCN4 pins 1and 2 cable to connector that attaches to cleaning roller clutch Ensure that pins are not shorted Is cable okay board See Engine controller board removal on page 4 34 If problem persists replace faulty cleaning roller clutch See Cleaning roller clutch removal on page 4 23 persists replace faulty cleaning roller clutch See Cleaning roller clutch removal on page 4 23 2 22 Service Manual Paper feed clutch service check 5023 110 Engine controller board removal on page 4 34 for steps to remove engine controller board shield Disconnect cable from MCN4 on engine controller board Check cable continuity from MCN4 pins 9 and 10 cable to outer pins on connector that attaches to paper feed clutch Ensure that pins are not shorted Is cable okay Step Questions actions Yes No 1 Turn printer off and remove printer right Go to step 2 Properly connect cable If cover See Right cover removal on problem persists go to step page 4 14 Is cable properly connected to 2 paper feed clutch 2 Disconnect paper feed clutch from cable Go to step 3 Replace faulty paper feed Measure resistance between two outer pins clutch See Clutch on paper feed clutch Does resistance removal on page 4 25 measure between check these values 119 and 145 ohms 3 Remove engine controller board shield See Replace engine controller Replace ca
29. Clutch removal on page 4 25 Diagnostic information 2 23 5023 110 OPC belt marker sensor service check connects LVPS 1 to engine controller board POCN and check for continuity shorted pins or any other cable damage Is cable ok voltage power supply LVPS with cage removal on page 4 38 Step Questions actions Yes No 1 Remove photodeveloper cartridge and Go to step 2 Replace photodeveloper check for defects Does photodeveloper cartridge appear ok 2 Observe markers on side Are belt markers Clean marker area with Go to step 3 covered with foreign particles cotton cloth If problem persists go to step 3 3 Reinstall photodeveloper cartridge Turn Go to step 3 Properly connect cable If printer off and remove engine controller problem persists go to step board shield See Engine controller 4 board removal on page 4 34 for steps to remove engine controller board shield Is cables MCN7 properly connected to engine controller board 4 Ensure rear cover assembly and front cover Engine controller board is Go to step 5 assembly are closed Override top interlock providing 5 VDC to OPC switch and turn printer on Wait until printer Sensor Replace OPC displays error and remove MCN7 from marker sensor See engine controller board Check for 5 VDC Marker sensor assembly between MCN pin on engine controller On page FEE problem persists replace board
30. DHHS 21 CFR Subchapter I Xj 53 28 I 1 RIT i BY R TMH Hb X Wu SEGA ES IEC 825 1 HE H I BOL Bh IR VL TR ROG EE HE TIED OLA 27 Hb 3b HIE EREHE HANE 5 EG HBR WE 770 795 ZH BMI ENLAI VE fH HEIDE ERE BIETET AA EA KB fh PET A E ES SRL Korean laser notice 188 alo x ASSO CHE DHHS 21 CFR Subchapter 32 PAS Uee olz 215990 12 92 IEC 825 TAS Frye 184 olaxEesxoss HSL 158 40 ASSES HNS raeg 5 28 fado 770 795 L O E S 2 35h Class ill 3b 4o48 Lysol 27 HA HE FA ET 5 EE uA 4219 Class I 2 9 alo x Y 0 Ao Ach MSS AAS USC Laser notices XVii 5023 110 XViil Service Manual 5023 110 Safety information e safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger
31. Photodeveloper cartridge is a customer order supply 4 Transfer belt unit Transfer belt is off track Replace transfer belt unit See Transfer belt unit removal on page 4 6 Diagnostic information 2 49 5023 110 Insufficient fusing service check Printed image is partially missing Problem area Action 1 Fuser tension release lever Fuser tension release lever is open Check fuser and remove shipping pieces if still installed Close release lever 2 Driver media settings Driver media setting is wrong Ensure proper media setting is selected for specific media in use 3 Non recommended paper Non recommended paper is being used Replace paper with recommended 4 Fuser Replace failed fuser See Fuser assembly removal on page 4 7 Note The fuser is a customer order supply 2 50 Service Manual Insufficient gloss service check Gloss on paper is not sufficient 5023 110 Problem area Action 1 Driver media settings Driver media setting is wrong Ensure proper media setting is selected for specific media in use 2 Fuser Fuser roller is deteriorated Fuser temperature is not properly controlled Replace fuser See Fuser assembly removal on page 4 7 Note The fuser is a customer order supply Diagnostic information 2 51 5023 110 Jitter service check Uneven optical density appears periodically in horizontal d
32. Unit Sensor g Cleaning Roller Solenoid Transfer Clutch Toner Retract Solenoid Tray Empty Sensor Registration Sensor ESI Fuser Exit Sensor Output Tray Full Sensor Toner Present Sensor m PT N FUSER UNIT Thermistor TH HEATER E e PFUL 5023 110 Laser drive control circuit The laser drive control circuit LDC consists of a video signal input circuit laser drive circuit laser diode output sensing circuit and output control circuit See the illustration 1 When the video signal is received the laser drive control circuit switches the laser diode switch on and radiates according to the video signal 2 The radiated laser beam senses the photo detector PD The detected signal is returned to the output control circuit 3 The output control circuit controls the radiated output to a constant by comparing the laser output default with the feedback value transmitted from the output sensing circuit 4 The laser beam scanned by the scanner motor is sensed by the beam detector PD and then outputs the beam detecting timing BDT signal Engine board I Frequency control circuit m 3 F lens H Beam scanning control circuit Video signal General information 1 37 5023 110 1 38 Service Manual 5023 110 2 Diagnostic information Start CAUTION Remove power from the printer before you connect
33. Yes Replace engine controller board See Engine controller board removal on page 4 34 Go step 9 No Replace cable that connects ACN1 on LVPS to POCN on engine controller board Remove RIP board cage to gain access to cable See System board cage removal on page 4 36 Go to step 9 Reassemble and retest printer Does error clear Problem solved Contact next level of maintenance Diagnostic information 2 19 5023 110 Developer drive assembly service check Step Questions actions Yes No 1 Is the error a DO or D1 error Go to step 5 Go to step 2 if EO or E1 2 Are there any unusual noises heard around Replace toner cartridge Go to step 5 developer motor or developer drive customer ordered supply assembly before error posts Go to step 3 3 Does noise go away Problem solved Replace developer drive assembly See Developer drive assembly removal on page 4 21 Go to step 4 4 Does noise go away Problem solved Go to step 5 5 Turn printer off and remove right cover See Go to step 5 if EO or E1 Properly connect cable Right cover removal on page 4 14 Is error Retest printer If error cable properly connected to developer drive clears problem solved assembly motor If the error is DO replace the otherwise go to step 5 M and K toner cartridges Replace C anY cartridges if the error is a D1 error If the error clears problem
34. adhering to the OPC belt surface is mechanically removed by a blade edge General information 1 27 5023 110 The residual toner is collected in a waste toner container located by the waste toner feeder OPC belt OPC belt cleaning blade OPC belt discharging First transfer erase lamp 1 28 Service Manual 5023 110 Details of the transfer system Second transfer paper process In the second transfer process the toner image on the transfer belt is transferred to paper See Printer theory of operation on page 1 14 for second transfer roller location The transfer roller normally separated from the transfer belt is positively biased by the power supply THV The transfer roller contacts the transfer belt as paper passes between the transfer roller and the transfer belt The positive bias of the transfer roller causes the toner to release from the transfer belt and adhere to the paper Transfer belt Transfer roller THV Power supply for transfer roller bias General information 1 29 5023 110 Transfer belt cleaning process The residual toner on the surface of the transfer belt is removed after the paper transfer process See Printer theory of operation on page 1 14 for transfer belt cleaner unit location The belt cleaner brush is a semiconductor type fur brush The cleaning roller is charged by voltage FCBV The resistance of th
35. and ground you can touch negative engine controller board lead of voltmeter to metal frame to obtain See Engine controller ground Is voltage present and correct board removal on page 4 34 5 Reconnect MCN7 and disconnect cable LVPS is providing 5 VDC to Go to step 6 from POCN On disconnected cable check engine controller board for 5 VDC on cable pin corresponding to Replace engine controller POCN pin 13 You can touch negative lead board See Engine E of voltmeter to metal frame to obtain ground Controller board removal Is voltage present and correct an page Ves 6 Turn printer off Disconnect cable that Replace LVPS See Low Replace cable 2 24 Service Manual Erase lamp service check 5023 110 Step Questions actions Yes No 1 Turn printer off and remove toner cartridges Go to step 2 Properly connect erase and photodeveloper cartridge Check erase lamp Retest printer If error lamp cable for proper connection Is erase clears problem solved lamp cable properly connected otherwise go to step 2 2 Check erase lamp for any visible damage Is Replace erase lamp See Go to step 3 erase lamp damaged Erase lamp removal on page 4 18 Retest printer If error clears problem solved otherwise remove toner cartridges and photodeveloper cartridge and go to step 3 3 Set multimeter to check diodes Looking at Replace erase lamp See Go to step 4 erase lamp through front c
36. controller board settings 4 lt 444444444 442444 3 3 Saving the system RIP board settings 2 22 2 452 44 4 54 4 4 2 3 3 Pepai intOrmmalion 522222222223 ec RE RIP Ga c p RP GG 4 Pe 4 1 Hoinoval and TRE 4 1 Handling the printed circuit boards with up EE TE 4 2 During tiansportation stol dgBr tar va ao ed ec ed deque dE 4 2 DUNG RE ERI Qaeda peque BEER Ea RE 4 2 Durno Mope 552555 dE 4 2 LEG MENS CANNING EE Sw 4 3 During tranmsporiglon sIoldgB 252242 3 Sade es REG GG 4 3 150 PC EEUU 4 3 Pars Horto oe iiie ie pe Rx see pud Rubeus 4 3 Pinter remgyal procedues s pus xa ERR CR he RR Rc Rede NS 4 3 Precautions to take before maintenance work 4 3 CRU AL and supplies romov Tee 4 4 Cleaning toller eaverTelridVal 3 3322 m wu eg mr bea a 4 5 Transit belt cleaning Ioller teImpyal aso cequac decr 4 5 Transier Dell qm fermpyal idause occa e eere sh ous e oA
37. de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria Service Manual Informacio de Seguretat r9 5023 110 La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les q estions de seguretat si s utilitzen peces de recanvi no autoritzades La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients og E o Di ru gt a 2 pe rio ren 2 Oe ri a PIT 2 H nio nio 2 2 9 x ae 2 4 9 In ret T Hu pit o r UV 9 oo E gt E Fal VE U or 9 4 o of ct H gt rm 40 gt ot mH o fo oot r 4x 40 4 lo o 10 BS ae E V GE dm gt a RB ARE XE P i AO UA dx gU AN EE A XL HES WARS MN NEH HEART ELE ES H M
38. hh rh mh hh E RRE ERRARE EAR AR 2 6 Operator MESSAGES xsaszkaucsikassRkaG RRRRGRXRARSERARARERSEERRARERRSEERRRRERSERRRGAES 2 8 Paper jam Messages rs locuucautueuu Ru RERRRARPRRRRIRAARRRRRSRARASRRRSTERASRRRAE E 2 9 Accessing 2 10 JAM A tray rear tray 1 sss emu ru screenees este eete ee aotsa aces 2 11 JAM A tray rear tray 2 4 lt eee dees eee eee een 2 12 EGRE ERG e 2 13 JAM Gre t ieee dees ieee EER Te NE E RA 2 15 Symptom t ables 222 24 62 RR RRRRSBRRRSRERASRRRASERRRERERRAIRERERSEEGA SES 2 16 Printer symptom table 2 cues ue hue huh en 2 16 Print quality symptom table 222 222 CERES REA MEX 2 17 Printer service CHECKS s pg rua Rui RAW ERR EGRE RARE ERE 2 18 Main motor service CHECK issues eh akebakke eda ek eda kh 2 18 Developer drive assembly service Check 2 0220c0cen ee eheu ee wee eee e xx RR xx 2 20 Transfer belt unit service CheCK 22 2c0cccccce secs ee este estes cece ee eR RAS 2 21 Transfer rolle
39. on page 4 38 4 With paper tray removed take voltage Replace engine controller Go to step 5 readings between ground and engine board See Engine controller board MCN7 pins 4 6 8 and 10 controller board removal Do you read 0 VDC on all the pins on page 4 34 5 Check cable for continuity between engine Replace paper size sensor Replace cable by replacing board MCN7 and paper size sensor Also See Left tray guide the left tray guide assembly check for shorted pins Is cable okay assembly removal on See Left tray guide page 4 40 assembly removal on page 4 40 2 34 Service Manual Toner low empty service check 5023 110 Step 1 Questions actions Turn printer off and remove engine controller board board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN8 Yes Go to step 2 No Properly connect cable Reconnect operator panel Turn printer on Touch negative lead of voltmeter to metal frame to obtain ground Touch positive lead Replace engine controller board See Engine controller board removal Check cable for continuity between engine controller board connector MCN8 and to MCN8 pin 2 4 6 or 8 for specific color as on page 4 34 toner sensor system both dictated by list below sender and receiver Also MCN8 chec
40. overflowing service check on page 2 35 4 Check waste toner auger for damage Is Replace waste toner auger Go to step 5 waste toner auger damaged See Waste toner auger removal on page 4 43 5 Check waste toner agitator for damage Is Replace waste toner Go to step 6 waste toner agitator damaged agitator See Waste toner agitator removal on page 4 43 6 Inspect waste toner feeder and opening in Replace waste toner Problem solved bottom of printer Is waste toner feeder feeder See Waste toner damaged feeder removal on page 4 26 Diagnostic information 2 43 5023 110 Paper feed service checks Printer paper feed service check Problem area Action Check for recommended paper Ensure paper being used is recommended Ensure paper is stored in an area free from high humidity Note Disconnect secondary paper assembly if installed to help isolate a paper transport problem Paper tray Ensure paper tray is not damaged Check for paper caught behind tray in pickup transport roll Replace any damaged parts Paper feed roller Separator pad Check paper feed roller and separator pad for wear or damage Paper feed roller removal on page 4 32 Replace any damaged parts Registration roller Transfer roller Check registration roller for damage or binds and replace if necessary See Registration assembly removal on page 4 33 Check transfer roller for damage
41. page 4 24 Note If you are removing the main drive gear assembly to get to the waste toner feeder you do not have to remove the fuser transfer roller registration or paper feed clutch The clutches are removed at the first of this procedure because the main drive gear assembly FRU does not include the clutches 3 Remove transfer roller clutch See Clutch removal on page 4 25 4 Remove registration clutch See Clutch removal on page 4 25 5 Remove paper feed clutch See Clutch removal on page 4 25 Repair information 4 25 5023 110 6 Remove five screws A that secure main drive gear assembly to printer Note screw A B shown removed 7 Remove two screws B that secure lower right frame 8 Remove main drive gear assembly from printer Note When reinserting the main drive gear assembly ensure that the bottom right corner is installed before the lower right frame Waste toner feeder removal 1 Remove main drive gear assembly See Main drive gear assembly removal on page 4 25 2 Loosen two screws A of sensor base to allow free movement of waste toner feeder 4 26 Service Manual 5023 110 3 Remove screw B from waste toner feeder pipe 4 Remove waste toner feeder pipe from waste toner bottle holder 5 Pull and remove waste toner feeder from printer Repair information 4 27 5023 110 Rear removals Paper guide Toner density Paper feed assembly sensor roll
42. page 4 32 Replace the tray 1 separator pad 40X3415 102 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the tray 2 paperfeed roller 40X3414 See Paper feed roller removal on page 4 32 Replace the tray 2 separator pad 40X3415 2 6 Service Manual 5023 110 Operator panel code Recommended actions 104 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the paperfeed roller 40X3414 in both trays See Paper feed roller removal on page 4 32 Replace the separator pad 40X3415 in both trays 110 Replace the transfer roller 40X3418 See Transfer roller removal page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 111 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 Replace the tray 1 paperfeed roller 40X3414 See Paper feed roller removal on
43. parts packet If actuators are not damaged and door will still not latch replace rear cover assembly See Rear cover assembly removal on page 4 15 2 Transfer roller Transfer roller is not properly installed Remove transfer roller and reinstall See Transfer roller removal on page 4 7 Ensure transfer roller bias pole is touching spring contact on left side as viewed from front of printer of roller 3 Laser unit assembly printhead Dust proof glass of laser unit is smeared with toner or foreign particles Clean glass Remove toner cartridges and photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Open glass cover Clean glass There are foreign particles adhering to laser beam opening of printhead Clean laser beam opening 4 Toner cartridge Toner cartridge has insufficient amount of toner Replace toner cartridge 5 Photodeveloper cartridge Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 6 Transfer belt unit Replace faulty transfer belt unit See Transfer belt unit removal on page 4 6 Diagnostic information 2 67 5023 110 Spacing table Roller specifications Diameter Number of rotation Repeating defect on assembly Name of roller rint mm rpm em Registration assembly rubber roller 14 283 43 Registration assembly steel r
44. por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe 1116 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano radia o laser superior um nivel de Classe I durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laser notices Xiii 5023 110 Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal g
45. sensor pin 1 pin 1 pin 3 pin 2 pin 5 pin 3 Also check for shorted pins Is cable okay Go to step 3 Replace cable Retest printer If error clears problem solved otherwise go to step 3 Replace toner empty sensor sender TPD See Toner sensor sender removal on page 4 22 for steps Retest printer Does error clear Problem solved Go to step 4 Replace engine controller board See Engine controller board removal on page 4 34 POR printer Does error clear Problem solved Contact higher level support 2 30 Service Manual 5023 110 Toner empty sensor receiver TTR service check Step Questions actions Yes No 1 Turn printer off and remove engine Go to step 2 Properly connect cable controller board board shield See Engine Retest printer If error controller board removal on page 4 34 clears problem solved for steps to remove engine controller board otherwise go to step 2 shield Is cable properly connected to engine controller board connector MCN8 2 Check the following for continuity between Go to step 3 Replace cable Retest engine controller board MCN8 cable and printer If error clears toner empty sensor receiver TTR cable problem solved otherwise See Toner sensor receiver removal go to step 3 on page 4 40 for steps to gain access to sensor cable MCN8 Toner empty sensor sender pin 2 pin 1 pin 4 pin 2 pin 6 3 pin 8 pin
46. symptom table on page 2 17 Photodeveloper cartridge does not rotate or makes noise See OPC belt photodeveloper cartridge drive service check on page 2 40 2 16 Service Manual Print quality symptom table 5023 110 Symptom Action Background See Background service check on page 2 45 Missing image at edge See Missing image at edge service check on page 2 53 Jitter See Jitter service check on page 2 52 Ribbing See Ribbing service check on page 2 57 Wrinkle and image migration See Wrinkle image migration service check on page 2 66 White line See White line Il service check on page 2 63 White line See White line Il service check on page 2 63 Vertical white band See Vertical white band service check on page 2 61 Black line See Black line service check on page 2 48 Vertical line See Vertical line service check on page 2 59 Vertical staggering image See Vertical staggering image service check on page 2 60 Banding See Banding service check on page 2 47 White band See White band service check on page 2 62 Toner drop See Toner drop service check on page 2 58 White spots and black spots See White spot black spot service check on page 2 64 Mixed color image See Mixed color image service check on p
47. take before maintenance work Do not implement any operation removal or modification and so on which are not presented in this manual 1 Turn the printer power off and unplug the power cable from the outlet prior to starting removals or checks 2 Prior to starting any repairs read and understand the warnings in this manual High temperature High voltage Laser radiation 3 Collect and properly dispose of the waste toner or toner cartridge 4 Remove the ground wire when removing or replacing the low voltage power supply After installation is complete confirm the ground wire is reconnected to the earth mark D 5 Confirm the direction of all parts and screw length during removal replacement 6 Utilize the proper cleaning procedures solvents during maintenance 7 Confirm that all parts and covers are properly installed and assembled prior to starting the print test Repair information 4 3 5023 110 CRU FRU and supplies removals There are FRU CRUs and supply items that will need to be removed prior to some of the removal procedures The removal procedure will specify when the part must be removed Cleaning roller cover Cleaning roller Fuser Transfer belt unit N V QN x Q Nx 00 EN L 5 4 4 Service Manual 5023 110 Cleaning roller cover removal 1 Open top cover 2 Depress tabs and remove cleaning roller cover ww TV n
48. temperature thermistor 4 40X3401 Right tray guide 5 40X3416 Lamp erase Parts catalog 7 7 5023 110 Assembly 4 Right 7 8 Service Manual Assembly 4 Right 5023 110 Index P N Units Description 4 1 40X3395 1 Gear assembly main drive 2 40X3391 1 Clutch registration 3 40X3393 1 Clutch transfer roller 4 40X3394 1 Clutch cleaning roller 5 1 Packet parts P N 40X3420 6 40X3390 1 Clutch paper feed 7 40X3397 1 Drive assembly developer 8 40X3389 1 Motor assembly main 9 40X3398 1 Assembly waste toner holder 10 40X3396 1 Waste toner feeder 11 40X3399 1 Sensor toner sender TPD This is a two piece sensor system Ordering of this part number includes both the right and left side 12 40X3432 1 Assembly interlock switch Parts catalog 7 9 5023 110 Assembly 5 Rear 7 10 Service Manual Assembly 5 Rear 5023 110 Index P N Units Description 5 1 40X3429 Assembly bracket includes marker sensor transfer belt unit toner density sensor 2 40X3433 Paper guide assembly 3 40X3413 Paper guide C assembly with cable includes registration sensor tray empty sensor 4 40X3414 Roller paper feed 5 40X3415 Pad separator Parts catalog 7 11 5023 110 Left Assembly 6 7 12 Service Manual 5023 110 Assembly 6 Left Index P N Units Description 6 1 40X3436 1 Board Network RIP US 40X3440 1 Board Network RIP EC 2
49. tray 10 8 13 0 2 2 2 2 275 330 55 1 0 Legal tray 10 8 15 9 2 2 2 5 275 405 55 1 1 Comes with standard input tray and starter cartridges 2 Weight does not include packaging or pubs 1 4 Service Manual Operating clearances Printer sides C500n C500n with 530 sheet tray Left side 8 in 203 mm 8 in 203 mm Right side 20 in 508 mm 20 in 508 mm Front 28 in 711 mm 28 in 711 mm Rear 10 in 254 mm 10 in 254 mm Top 23 in 584 mm 29 in 736 mm Packaging and shipping dimensions Width Depth Height Weight Printers in in in Ib mm mm mm kg C500n 22 6 20 9 22 4 77 574 530 570 35 0 Options 530 Sheet drawer 21 7 22 2 10 4 18 8 550 564 265 8 5 Legal tray 13 2 19 0 5 7 5 5 335 483 144 2 5 Includes start up kit supplies Print speed and performance Pages minute Media size Standard tray Letter 31 8 A4 31 8 Legal 16 8 Transparencies 2 Thick card stock 2 Labels letter amp 3 A4 Medium thick card 4 3 stock letter amp A4 Envelopes 5 3 Time to first print 5023 110 Time from standby mode 13 seconds 19 seconds Time from power saver mode 45 seconds 45 seconds Note Time to first page TTFP is the time from the moment when the host sends the print signal until the moment the trailing edge of the first page leaves the exit feed rollers TTFP is m
50. 023 110 Left cover removal 1 Remove board See System board removal page 4 28 2 Remove top cover assembly See Top cover assembly removal on page 4 12 3 Remove two screws A from bottom of left cover 4 Remove left cover from printer Laser unit assembly printhead removal Open front cover Remove toner cartridges Remove photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Open top cover assembly Remove two screws A from laser unit assembly cover Photograph shows looking through opening in top cover assembly 4 16 Service Manual 5023 110 6 Unlatch and remove laser unit assembly cover 8 Remove laser unit assembly from printer 9 Disconnect connector from laser unit assembly Repair information 4 17 5023 110 Erase lamp removal Remove all toner cartridges Remove photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Remove transfer belt unit See Transfer belt unit removal on page 4 6 Remove two screws A meg Nos 5 Disconnect erase lamp cable B 6 Remove erase lamp 4 18 Service Manual 5023 110 Right side removals Front door interlock Cleaning Transfer roller switch roller clutch clutch Developer drive assembly Waste toner t holder 4 assembly Waste toner Main motor Paper Registra
51. 1 Tray empty sensor OP panel V2 Power supply fan VF controller Engine control board Erase lamp Paper size sensor OPC maker sensor Room temp sensor z Development motors BRV Cl High voltage power supply Cleaning roller solenoid clutch FBCL Transfer L1 roller clutch 5023 110 LV OCV Registration WTS LED DM1 rotation detection Waste toner sensor receiver Waste toner sensor sender Toner present sensor Rear cover assembly r L S Fuser exit sensor Exit fan 1 ACN2 Low voltage power suppy Front door Top door Rear door MCTL MCN3 MCTL MCN3 Fuser connection Fuser unit Locations and Scanner motor Laser assembly 5 9 connectors 5023 110 Wiring diagram 2 of 4 jaued Joyejedo jojsiuueu einjejeduie 10809 ezis Jedeg Josues HG OdO ue Kjddns Josues jueseud 1euo Soo 2 lt Er TE mm Or OF 6 6 lt 8 CZ D 9 G 7 a i ta QN9S
52. 1 23 developing process 1 25 exposing process 1 24 first transfer drum process 1 26 printer component systems 1 17 printer identification 1 13 printer removal procedures 4 3 printer systems description 1 16 R removals bracket assembly 4 29 cleaning roller clutch 4 23 cleaning roller cover 4 5 covers 4 11 developer drive assembly 4 21 engine controller board 4 34 erase lamp 4 18 front cover assembly 4 13 front door interlock switch with bracket 4 20 fuser assembly 4 7 high voltage power supply HVPS 4 37 HVPS cage 4 39 laser unit assembly printhead 4 16 left cover 4 16 left side 4 34 left tray guide assembly 4 40 low voltage power supply LVPS 4 38 main drive gear assembly 4 25 main motor assembly 4 24 paper exit assembly 4 32 paper exit unit 4 15 paper feed roller 4 32 paper guide C assembly 4 31 5023 110 paper guide assembly 4 30 photodeveloper cartridge 4 9 power supply fan 4 44 rear 4 28 registration assembly 4 33 right cover 4 14 right side 4 19 second paper feed assembly 4 10 sensor assembly 4 42 system board 4 28 system board cage 4 36 toner present sensor 4 39 toner sensor receiver 4 40 top 4 42 top cover assembly 4 12 transfer belt cleaning roller 4 5 transfer belt unit 4 6 transfer roller 4 7 waste toner agitator removal 4 43 waste toner auger 4 43 waste toner bottle 4 8 waste toner bottle holder 4 20 waste toner feeder 4 26 repair information 4 1 S safety informati
53. 4 pin 9 pin 5 pin 10 pin 6 Also check for shorted pins Is cable okay 3 Replace toner empty sensor receiver Problem solved Go to step 4 TTR See Toner sensor receiver removal on page 4 40 for steps Retest printer Does error clear 4 Replace engine controller board See Problem solved Contact higher level Engine controller board removal on support page 4 34 POR printer Does error clear Diagnostic information 2 31 5023 110 Lower feed unit secondary paper assembly service check Engine controller board removal on page 4 34 Does error clear Step Questions actions Yes No 1 Turn printer off and remove engine Go to step 2 Properly connect cable controller board shield See Engine Retest printer If error controller board removal on page 4 34 clears problem solved for steps to remove shield Is cable properly otherwise go to step 2 connected to engine controller board connector MCN6 2 Remove right cover See Right cover Go to step 3 Replace cable removal on page 4 14 Check cable that connects engine controller board connector to lower feed unit for continuity and pin shorts Is cable okay 3 Replace lower feed unit See Secondary Problem solved Go to step 4 paper feed assembly removal on page 4 10 Does error clear 4 Replace engine controller board See Problem solved Contact higher level support 2 32 Service Manual
54. 40X3405 1 Power supply high voltage 3 40X3399 1 Sensor toner receiver TTR This is a two piece sensor system Ordering of this part number includes both the right and left side 4 40X3410 1 Sensor toner present 5 40X3406 1 Power supply 110 V low voltage 6 40X3407 1 Power supply 220 V low voltage 7 40X3408 1 Bracket 110 V power supply 8 40X3411 1 Bracket 220 V power supply 9 40X3404 1 Board engine controller Parts catalog 7 13 5023 110 Assembly 7 Top NE AN FK LX SX SN NYE gt RES 7 14 Service Manual 5023 110 Assembly 7 Top Index P N Units Description 7 1 40X3402 1 Auger waste toner 2 40X3403 1 Agitator waste toner 3 40X3434 1 Assembly marker sensor OPC includes bracket 4 40X3409 1 Fan power supply includes top cover and rear cover assembly interlock switches Parts catalog 7 15 5023 110 Assembly 8 Miscellaneous Options 7 16 Service Manual Assembly 8 Miscellaneous Options 5023 110 Index P N Units Description 8 1 40X3421 1 Assembly secondary paper feed NS 40X3426 1 Paper tray legal NS 40X3419 1 Parts packet harness NS 40X3442 1 Cable 120V fuser NS 40X3443 1 Cable 240V fuser NS 40X3420 1 Parts packet screw NS 7372640 1 Field relocation kit NS 14D0403 1 Cable USB 2 meter Parts catalog 7 17 5023 110 7 18 Service Manual Index A acrony
55. 40X3441 40X3442 40X3443 7372640 Parts packet harness 7 17 Parts packet Screw 4 5 4 4 45 4 7 17 Assembly secondary paper feed 7 17 Cover operator panel 7 5 Operator panel s e ese ese He nise nere Serenade EE 7 5 Papertray standard ana set Soi E a i a aS eS eke ees dess 7 3 Papertray legal 5 c6 9 8 c0 REOR ee eet Ce Saa 7 17 Assembly paper exit contains fuser exit sensor and flag 7 5 Assembly bracket includes marker sensor transfer belt unit toner density sensor 7 11 Assembly registration 7 5 Left tray guide assembly includes paper size sensor and temperature thermistor 7 7 Assembly interlock switch 7 9 Paper guide assembly 7 11 Assembly marker sensor OPC includes bracket 7 15 Board Network RIP US 7 13 Board Network RIP EC 7 13 Cover laser unit assembly lens
56. 50 Total standard capacity 250 Optional input Optional legal tray capacity 250 Optional tray 1capacity 250 Optional tray 2 capacity 530 Output destinations Number of standard destinations 1 Output capacities Standard output bin capacity top Media up to 20 Ib paper 250 Optional input drawer is a 530 sheet capacity drawer Only one optional drawer may be installed at any time The printer supports top output face down as standard No additional output options are available Note All capacities are based on use of 20 Ib paper 1 6 Service Manual Media input types and weights 5023 110 Source Type Standard tray 530 Sheet tray Printer menu Item Legal tray Paper Paper type weight Paper Xerographic or bond 60 74 60 74 Plain paper Light grain long paper g m g m 16 19 Ib 16 19 Ib Xerographic or bond 75 120 75 120 Plain paper Normal paper g m 20 32 Ib g m 20 32 Ib 100 Cotton 75 120 75 120 Plain paper Heavy g m g m 24 32 Ib 24 32 Ib Card stock Index 163 g m N A Card stock Normal 90 Ib Index 164 210 g m N A Card stock Heavy 91 110 Ib Transparency PN 12A5940 N A Transparency PN 12A5941 Labels N A Label Envelopes 75 90 N A Envelope Normal g m 20 2410 1 Punched embossed water marked perforated punched inkjet paper plastic coated media should not be used Only occasional use of paper labels in an of
57. CM Drives laser beam scanning in optical unit Power supply fan PSFAN Exhausts heat from power supply unit and interface controller Exit fan EXFAN Exhausts heat from fusing unit Laser fan LDFAN Exhausts heat from laser assembly printhead Locations and connectors 5 5 5023 110 Interlock switch locations Rear cover assembly interlock switch Top cover interlock switch EM LA Name Code Function Front cover interlock DSWi switch Rear cover assembly DSW2 Safety interlock switches that break power when covers are opened interlock switch Top cover interlock DSW3 switch 5 6 Service Manual Clutch locations 5023 110 Cleaning roller clutch Registration clutch Paper feed clutch Name Code Function Paper feed clutch PCLU Feeds paper by coupling feed roller to the main gear unit at the time of a paper feed Registration clutch RECL Transports paper by coupling registration roller to main gear unit as synchronized with rotation of transfer belt Cleaning roller clutch Drives the transfer belt cleaner brush by coupling cleaning clutch FBCL to main gear unit at the time of transfer belt cleaning Transfer roller clutch Cam action clutch that rotates allowing transfer roller to press TRCL against the back of paper during second transfer The transfer roller touching the back of paper causes toner to rel
58. Detects toner density of images formed on the transfer belt surface Room temperature thermistor RTS Detects ambient room temperature sensor Transfer unit sensor TBS Detects irregular rotation of transfer belt Locations and connectors 5 3 5023 110 Printer circuit board locations HVPS LVPS Erase lamp Operator panel Engine controller board Name Function Engine controller board Controls the following printer processes Fuser temperature control Laser output control Operator panel indication Toner empty sensing control Error processing control Interface control Operator panel Displays the printer operation status and supports the manual input switch Erase lamp Discharges OPC belt located in the photodeveloper cartridge Low voltage power supply LVPS Provides power to control the printer High voltage power supply HVPS Provides power necessary for the printing process 5 4 Service Manual 5023 110 Fan motor locations Paper exit cover switch Main motor Exit fan Front cover Power supply switch fan Developer motor Top cover 24 Scanner Switch dM motor Q Name Code Function Main motor MM Drives OPC belt and paper transport system Developer motors DM Drives toner cartridge and developing system Scanner motor S
59. E MERE AE RIA RIX HS ES HA FF A d Ed RESI ERA R SEDI fs E PE Ss EE PRP FE 0 WEK TA m De 5 WEJ Wie SEAH 26 RAES om DUE TAS BRE B C d m ELV RHIZ ND MA rir ro lo ox 02 PRECAUCIO aquest simbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comengar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar Safety information Xxi 5023 110 Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment as well as general environmental and safety instructions are discussed 2 Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintena
60. IPER 2 56 Eee pgs diuum 2 57 Toner drop sBrvica CHECK 3 2 422 42 252272448251 hg eG PME RIS Gun RR 2 58 NS Eee EE 2 59 Vertical staggering image service check 2 60 Vertical white SEVIER CHECK tase 2 61 White bald Sente CHECK REGE SSG bE Ses eee 2 62 Winte line serios Seb s os esed Sed qd REN 2 63 White lia CHBOK 225 8 55 2 6 esos B 9eew RE x 2 63 White Spot black SBOLSBIVIDO CHECK 524255454545 ee e Es 2 64 White prim Servibe CHECK xau 3x43 G kb SR b Rr un uo oS Gen oe andes 2 65 Wrinkle image migration Service TEK BER CER 2 66 Uneven density Mo and left ae es cuite er setae eae x eds e MAUS uU E RR 2 67 PaO U a Ver E EET 2 68 Rolo spacifi alU Eco p Rb GU Pu due ages e eq 2 68 LET pe 1 CTETUR 3 1 Understanding the printer operator panel rh RR RESTE eek m 3 1 Maintenance page printout a 2s2 2cuueluuua inea cuu im mak beaded 3 2 Saving NVRAM settings for hardware replacement 3 3 Saving the engine
61. RRRRASRRRRRARSRARARZERRRAR AR APR 2 43 Waste toner feed Service 4 4 lt lt see eee we ewe deere se eee en 2 43 iV Service Manual 5023 110 Paper teed service CHECKS 22 22 22 2 4 6 2 44 Printer paper feed savito HEKK sees pREVESSSKERPEURREKEPEQEN ETE 2 44 Fin Quality SBrvibe CHECKS 222222242254545545 2 45 25 MESA E 2 45 Back Slam service CHECK ir mS NEIN E RS SS 2 46 Banda Sev ice CIBO EEE aquse ENG x NE Eq E 2 47 Black line Scions idee putem toes anew qq eI SR enke Ir eee ee caw M 2 48 Golormistegistidliom SBIVICO ChOCK videamur 2 49 INGUTIICIO NT heng Service CHECK iouis dre rio os ere isse 2 50 Meuncit Gloss Sel VICE Check 2 51 Jitter SorvicO DHBDK lise arsen 2 52 Missing mago Service Check ase rer eder qe E a ER 2 53 Mixed color image sees Merk usadas esae yu 83 des PE NE Rig esae d 2 54 Met SE ud et Er 2 55 Residual Mage 2 2 52 42 32 21 4 4056 5 wes mae PE
62. S Nes N Lexmark C500n Service Manual 5023110 Table of contents e Start diagnostics e Safety and notices Trademarks Index 5023 110 Edition June 14 2006 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to
63. VDC B5J 5 VDC 0 VDC 0 VDC 5 VDC B51 5 VDC 0 VDC 0 VDC 5 VDC 10 0 VDC 0 VDC 0 VDC 5 VDC DL 0 VDC 0 VDC 0 VDC 5 VDC Legal tray 0 VDC 0 VDC 5 VDC 5 VDC Diagnostic information 2 41 5023 110 Printer no power service check Note If secondary paper feed assembly or duplex unit is installed disconnect or remove before checking base printer operation Step Questions actions Yes No E mZ 06 gjerne more Ep egen 1 Reset printer and listen for any activation of Goto step 2 Go to step 3 motors and for power supply fan Look at operator panel to see if anything displays Do you hear sounds or does operator panel display anything 2 Disconnect and check continuity of power Go to step 3 Replace power cord cord Is power cord good 3 Ensure RIP board is properly installed Is Go to step 4 Install RIP board RIP board installed correctly 4 Replace RIP board See System board Replace engine controller Problem solved removal on page 4 28 Does problem board See Engine persist controller board removal on page 4 34 5 Turn printer off and check line voltage to Go to step 6 Inform customer ensure that it is present and correct Is voltage present and correct 6 Remove items see System board cage Go to step 7 Replace power supply removal on page 4 36 from left side of bracket See Low voltage printer to expose power supply bracket power supply LVPS with Using an
64. You may have to reach far under the printer to locate the jam as shown in the following illustration Pull the jam straight out 2 Insert the tray 3 If clearing paper doesn t resolve problem see Paper feed service checks on page 2 44 Diagnostic information 2 11 5023 110 JAM A tray rear tray 2 JAM A Tray Rear message indicates the media is jammed in either tray 1 or tray 2 The affected tray is indicated by the Tray x message To clear a jam from the optional 530 sheet tray Tray 2 1 Pull the tray out Remove the tray completely Foramisfeed of the media the single piece of media is laying on top of the stack Pull it straight out For media jammed behind the tray area locate the jam on the bottom surface of the support unit You may have to reach far under the printer to locate the jam Pull the jam straight out 2 Push the tray into the support unit 3 If clearing paper doesn t resolve problem replace secondary paper feed assembly See Secondary paper feed assembly removal on page 4 10 2 12 Service Manual 5023 110 JAM B rear JAM B Rear message indicates the media is jammed behind the rear door 1 Push the rear door release latch 2 Gently lower the rear door Diagnostic information 2 13 5023 110 3 Pull the fuser pressure release levers to release tension on the media 4 Grasp each side o
65. a bracket between MCN9 1 on engine controller assembly Seb e board and ground you can touch negative Soe pn page 4 29 If problem lead of voltmeter to metal frame to obtain persists replace engine ground Is voltage present and correct controller board See Engine controller board removal on page 4 34 5 On engine controller board reconnect LVPS is providing 5 VDC to Replace LVPS See Low and disconnect cable from POCN engine controller board voltage power supply On cable disconnected from POCN check Replace faulty engine LVPS with cage for 5 VDC from pin 13 to ground you can controller board See removal on page 4 38 touch negative lead of voltmeter to metal Engine controller board frame to obtain ground Is voltage present ENE MEN and correct Diagnostic information 2 21 5023 110 Transfer roller clutch service check Engine controller board removal on page 4 34 for steps to remove engine controller board shield Disconnect cable Step Questions actions Yes No Turn printer off and remove printer right Go to step 2 Properly connect cable If cover See Right cover removal on problem persists go to step page 4 14 Is cable properly connected to 2 transfer roller clutch 2 Disconnect transfer roller clutch from cable Go to step 3 Replace faulty transfer Measure resistance between two outer pins roller clutch See Clutch on transfer
66. a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark Lexmark with diamond design and MarkNet are trademarks of Lexmark International Inc registered in the United States and or other countries Optra Forms is a trademark of Lexmark International Inc PostScript is a registered trademark of Adobe Systems Incorporated PCL is a registered trademark of the Hewlett Packard Company All other trademarks are the property of their respective owners 2006 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G9663 5023 110 Table of contents LaSernoticeS iacu ho uncus uuRRRRRRRRRRARRRRARRERRAREERRARRRARRRRARRERRRRERRRIRER ix xxii General Informatil H 522 2 222 2 1 4 4 7224 4 4644
67. age 2 54 Color misregistration See Color misregistration service check on page 2 49 Mottle See Mottle service check on page 2 55 Residual image See Residual image service check on page 2 56 Insufficient gloss See Insufficient gloss service check on page 2 51 Back stain See Back stain service check on page 2 46 White print See White print service check on page 2 65 Insufficient fusing See Insufficient fusing service check on page 2 50 Diagnostic information 2 17 5023 110 Printer service checks Main motor service check Step Questions actions Yes No 1 Turn printer off and remove right cover See Replace photodeveloper Go to step 2 Right cover removal on page 4 14 cartridge Open top cover and override top cover interlock switch Restart printer and observe Note Photo developer main motor and photodeveloper cartridge cartridge is a customer OPC belt Does main motor attempt to turn ordered supply but OPC belt will not rotate 2 Observe main motor and fuser Does main Replace fuser assembly Go to step 3 motor attempt to turn but fuser will not See Fuser assembly removal on page 4 7 Note Fuser is a customer ordered supply 3 Are there any unusual noises around main Replace main motor See Go to step 5 motor before error posts Main motor assembly removal on page
68. al on page 4 34 Replace paper guide C assembly See Paper guide C assembly removal on page 4 31 Turn printer off Remove paper guide C assembly See Paper guide C assembly removal on page 4 31 Check cable for continuity that connects pins 12 13 and 14 to paper empty sensor Also check for shorted pins Is cable okay Replace paper guide C assembly See Paper guide C assembly removal on page 4 31 Replace cable Check cable continuity between LVPS 1 and engine controller board connector POCN Also check for shorted pins Is cable okay Replace LVPS See Low voltage power supply LVPS with cage removal on page 4 38 Replace cable Diagnostic information 2 33 5023 110 Paper tray missing service check Step Questions actions Yes No 1 Turn printer off and remove engine Go to step 2 Properly connect cable controller board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN7 2 Turn printer on and check for 5 VDC Go to step 4 Go to step 3 between MCN7 pin 2 and ground Is 5 VDC present 3 Check for cable continuity between LVPS Replace LVPS See Low Go to step 4 ACN1 and engine controller board POCN Is voltage power supply continuity present LVPS with cage removal
69. aluminum drum Transfer belt Aluminum drum tube Aluminum drum tube Film transfer belt 2 The OPC belt has been biased to CBV V potential The potential of the transfer belt and drum is nearly GND 3 Toner on the OPC belt is moved to the transfer belt This occurs because of the difference of potential between the OPC belt and the transfer belt Toner that has been developed in each color is moved from the OPC belt to the transfer belt and the two color toner image is overlapped on the transfer belt 1 26 Service Manual 5023 110 4 The toner image is then transferred to paper Residual charge OPC belt Residual toner OPC belt cleaning wee blade OPC belt discharging First transfer erase lamp Belt discharge erase lamp process Electrical belt cleaning is accomplished by an erase lamp radiating on the OPC belt Radiation discharges the residual charge VR V remaining on the belt after the first transfer process Electrical cleaning occurs after each toner color transfer The erase lamp is a luminous source consisting of 24 light emitting diodes After the electrical belt cleaning the OPC belt is cleaned with a mechanical blade OPC belt OOOO tt ROO OPC belt cleaning blade OPC belt discharging First transfer erase lamp Belt cleaning process In the belt cleaning process residual toner
70. and replace if necessary Transfer roller removal on page 4 7 Transfer belt unit Ensure transfer unit is not damaged and is free of foreign material Note Do not touch transfer belt with your hands Transfer belt unit cleaning roller Ensure no paper is jammed in cleaning roller Ensure cleaning roller is not damaged Replace cleaning roller if necessary Fuser assembly Ensure fuser assembly is not damaged or dirty Ensure fuser assembly guides and gears are not broken and are free of paper Note Fuser assembly is a customer ordered supply Paper exit assembly Gears Check rear cover assembly for damage Ensure paper exit roller located in paper exit assembly is not damaged Ensure paper exit gears and bearings are good Ensure paper guides are not bent or dirty Clean or replace parts if necessary 2 44 Service Manual 5023 110 Print quality service checks Background service check Background is smeared due to toner spread Problem area Action 1 Toner cartridge Too small charging amount in the development process 2 Check developer high voltage contact points Insufficient contact of developer roller s primary or secondary high voltage contact points Ensure primary and secondary contact points are free from contamination and toner debris Check toner cartridge developer roller bias pole If contaminated clean it If damaged or deformed re
71. ard shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN7 2 Turn printer on and check for 5 VDC Go to step 4 Go to step 3 between MCN7 pin 2 and ground Is 5 VDC present 3 Check for cable continuity between LVPS Replace LVPS See Low Go to step 4 ACN1 and engine controller board POCN Is voltage power supply continuity present LVPS with cage removal on page 4 38 4 If paper tray is removed set paper tray for Replace engine controller Go to step 5 desired paper size and insert paper tray into board See Engine printer Using table below check for proper controller board removal paper size sensor action by taking voltage on page 4 34 readings between ground and engine controller board MCN7 pins 4 6 8 and 10 Is paper size sensor working properly 5 Check cable for continuity between engine Replace paper size sensor Replace cable by replacing board MCN7 and paper size sensor Also See Left tray guide the left tray guide assembly check for shorted pins Is cable okay assembly removal on See Left tray guide page 4 40 assembly removal on page 4 40 Paper tray setting MCN7 all voltages measured from pin to ground Standard tray pin 4 pin 6 pin 8 pin 10 4 5 VDC 5 VDC 0 VDC 5 VDC Letter 5 VDC 0 VDC 5 VDC 5 VDC EXE 0 VDC 5 VDC 0 VDC 5
72. away from you check toner present sensor actuators located on left rear of toner cartridge Are actuators damaged 2 Insert toner cartridge and ensure toner Go to step 3 Replace toner present present sensor flag moves forward sensor See Toner Remove toner cartridge Toner present present sensor removal sensor flag should spring forward Does on page 4 39 toner present sensor flag operate correctly 3 Turn printer off and remove engine Go to step 4 Properly connect cable controller board board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN2 4 Reconnect operator panel Turn printer on Go to step 5 Go to step 8 Touch negative lead of voltmeter to metal frame to obtain ground Touch positive lead to engine controller board connector MCN2 pin 2 to ensure 5 VDC is being supplied to toner present sensor Is 5 VDC present 5 Check voltage level on MCN pin 1 Is 5 Go to step 6 Go to step 7 VDC present 6 Install toner cartridge Check voltage level Replace engine controller Replace toner present on MCN 1 Is 0 VDC present board See Engine sensor See Toner controller board removal present sensor removal on page 4 34 on page 4 39 7 Turn printer off Check cable for continuity Replace toner present Replace cable that connects MCN2 pins 1 2 and 3 to sensor See Toner toner presen
73. baciones del disefio original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de dafios personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes
74. ble If problem board See Engine controller board removal on page 4 34 If problem persists replace faulty paper feed clutch See Clutch removal on page 4 25 persists replace faulty paper feed clutch See Clutch removal on page 4 25 Registration clutch service check Engine controller board removal on page 4 34 for steps to remove engine controller board shield Disconnect cable from MCN4 on engine controller board Check cable continuity from MCNA pins 7 and 8 cable to outer pins on connector that attaches to registration clutch Ensure that pins are not shorted Is cable okay Step Questions actions Yes No 1 Turn printer off and remove printer right Go to step 2 Properly connect cable If cover See Right cover removal on problem persists go to step page 4 14 Is cable properly connected to 2 registration clutch 2 Disconnect registration clutch from cable Go to step 3 Replace registration clutch Measure resistance between two outer pins See Clutch removal on on paper feed clutch Does resistance page 4 25 measure between check these values 119 and 145 ohms 3 Remove engine controller board shield See Replace engine controller Replace cable If problem board See Engine controller board removal on page 4 34 If problem persists replace faulty registration clutch See Clutch removal on page 4 25 persists replace faulty registration clutch See
75. board See Engine controller board removal on page 4 34 Diagnostic information 2 15 5023 110 Symptom tables Printer symptom table Symptom Action Paper feed problems See Paper feed service checks on page 2 44 Close door displayed when all doors are closed See Operator messages on page 2 8 and follow the action suggested Paper jam messages do not reset after removing paper See Operator messages on page 2 8 and follow the action suggested Toner cartridge does not turn or does not put toner on the photodeveloper cartridge See Toner feed service check on page 2 43 Developer motor makes noise or continuously runs See Developer drive assembly service check on page 2 20 Main motor makes noise or continuously runs See Main motor service check on page 2 18 Transfer belt unit makes noise when rotated or does not rotate at all See Transfer belt unit service check on page 2 21 The transfer roll is not transferring images or does not turn See White band service check on page 2 62 No power See Printer no power service check on page 2 42 Waste toner feed problems See Waste toner feed service check on page 2 43 Fans not working or making noise See Service error codes on page 2 2 Find the failing fan and follow the action suggested Print image problems See Print quality
76. boards are located Power switch Turns the printer on and off AC input inlet Connects the power cord that supplies AC power to the printer 5 2 Service Manual 5023 110 Electronic components Sensor locations photodeveloper marker sensor Tray empty sensor Registration sensor Transfer unit sensor Toner density sensor Paper size sensor Toner key sensor Fuser exit sensor Temperature sensor fuser Toner empty sensor sender TPD The other half of this sensor pair receiver TTR is attached to left side frame Waste toner sensor waste toner holder assembly Room temperature thermistor sensor Name Code Function Paper size sensor PSU Detects paper size Registration sensor PT1 Detects whether paper is fed from paper drawer Fuser exit sensor PT2 Detects when paper exits from rear cover assembly Tray empty sensor PEU Detects if paper is loaded in paper drawer OPC marker sensor PBS Detects connecting position of OPC belt Toner empty sensor TPD TTR Detects if any toner cartridge is empty Waste toner sensor WTS Detects when waste toner bottle is full LED TR pene sensor for fuser TH Thermistor that detects fuser temperature uni Output tray full sensor PFUL Detects when paper exit tray is full Toner key sensor TNK Detects presence of toner cartridge Toner density sensor TDS
77. certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Xii Service Manual 5023 110 Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos l ser de Clase I 1 establecidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses re ne todas las condiciones expuestas en la norma IEC 60825 1 para productos l ser de Clase 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n disefiados de forma que ninguna persona pueda verse afectada por ningun tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado
78. cleaning roller Diagnostic information 2 59 5023 110 Vertical staggering image service check Printed image staggers in vertical direction Problem area Action 1 Printer vibration Check for printer vibrations or shock to printer 2 Laser unit assembly printhead Optical unit failure caused by vibration from scanner motor rotation Replace laser unit assembly See Laser unit assembly printhead removal on page 4 16 2 60 Service Manual Vertical white band service check White band appears in vertical direction of printed image 5023 110 Problem area Action 1 Toner cartridge Replace faulty toner cartridge 2 Photodeveloper cartridge Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 3 Transfer belt unit Replace faulty transfer belt unit See Transfer belt unit removal on page 4 6 Diagnostic information 2 61 5023 110 White band service check Horizontal white banding creates missing portion of image Problem area Action 1 Transfer roller Transfer roller bias pole is not making proper contact with high voltage spring contact Remove and reinstall transfer roller Ensure spring contact on left side looking from front of printer is not damaged Replace faulty transfer roller See Transfer roller removal on page 4 7 2 Transfer roller clutch Rep
79. color combination 3 The toner image formed on the transfer belt is transferred to paper 4 The toner is fused to the paper by the thermal fuser unit During the fusing process the primary colors mix yielding the desired color OPC belt Toner cartridge Transfer belt YXYXY X GGG VDO Transfer belt First transfer 2 b Second transfer Red Cyan Green Fusing ag hd 7 77 Paper 1 18 Service Manual 5023 110 Print system and transfer system This illustration shows the basic structure of the print system having the OPC belt as a main function and the transfer system including the transfer belt A color print is accomplished by actuating each process in the print system and the transfer system 1 Charging Exposing 6 OPC belt cleaning Print system Developing Belt discharge OPC belt K 4 First transfer transfer belt Transfer belt Transfer system Second transfer paper 8 Transfer belt cleaning 9 Fusing Transport system General information 1 19 5023 110 Structure of OPC belt photo developer cartridge The OPC belt consists of a surface layer having an optical photoconductor OPC of organic material the inner layer consists of an insulator material PET and the aluminum deposit layer in between The OPC belt is a main part of the print system Ph
80. connector 2 Turn printer off and remove items to expose Replace HVPS See High Replace cable Retest HVPS See High voltage power supply HVPS removal on page 4 37 for steps Check for continuity and pin shorts of cable that connects engine controller board HVCN and HVPS BCN1 Is cable okay voltage power supply HVPS removal on page 4 37 Retest printer If error clears problem solved otherwise turn printer off and replace engine controller board See Engine controller board removal on page 4 34 printer If error clears problem solved otherwise turn printer off and replace engine controller board See Engine controller board removal on page 4 34 Diagnostic information 2 29 5023 110 Toner empty sensor sender TPD service check Step 1 Questions actions Turn printer off and remove engine controller board board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN8 Yes Go to step 2 No Properly connect cable Retest printer If error clears problem solved otherwise go to step 2 Check the following for continuity between engine controller board MCN8 cable and toner empty sensor sender TPD cable See Toner sensor sender removal on page 4 22 for steps to gain access to sensor cable MCN8 Toner empty
81. d the default menu should be the Service Menu If not use the left and right navigation buttons to scroll through the menus until Service Menu appears Press the Select button Use left and right b navigation buttons to scroll to the Maintenance submenu Press the Select V button Use left and right lt b navigation buttons to scroll to the PRC gt MCTL selection Press the Select v4 button Press the Back 5 button twice to exit CE mode Diagnostic aids 3 3 5023 110 3 4 Service Manual 5023 110 4 Repair information Removal and cleaning precautions Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of removal unless otherwise specified Do not operate the printer anytime during removals If it is absolutely necessary to run the printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage parts such as the high voltage power supply Remove the ground wire when removing or replacing the low voltage power supply After installation is complete confirm the ground wire is reconnected to the earth mark L i After part replacement ensure the wiring harness is not caught or damaged Do not attempt to cut or
82. e 5 LDC laser diode control circuit 6 BTD mirror beam timing detector mirror to guide the laser beam to PD 7 Scanner motor rotates the polygon mirror 8 F lens laser beam focus lens 9 Mirror laser beam path reflecting mirror General information 1 31 5023 110 Details of the paper transportation system In the paper transportation process paper is automatically fed by the pick up roller and transported to the registration roller The registration roller synchronizes with the transfer belt The registration roller transports the paper to the transfer roller During the transfer process the transfer roller forwards the paper to the fuser rollers During the fusing process the fuser rollers transport the fused paper to the exit roller and the exit roller pushes the final paper out of the rear cover assembly Transfer belt The paper transportation system consists of the following parts No Part Function 1 Paper tray Accommodates paper to be automatically fed through the printer 2 Pick up roller Feeds paper one by one preventing multi feed 3 Registration roller Transports and synchronizes paper with the transfer belt 4 Transfer roller Works in conjunction with the transfer belt to transfer the image to paper and to transport the paper to the fuser 5 Fuser unit Utilizes a heat roller to fuse the toner image to the paper 6 Paper exit roller Exits the fused
83. e check on page 2 23 SVC E8 ERROR Registration clutch error Improper registration clutch cable connection or a shorted or cut cable See Registration clutch service check on page 2 23 SVC E9 ERROR OPC marker sensor error Marker sensor is not properly detecting mark on OPC belt See OPC belt marker sensor service check on page 2 24 SVC EL ERROR Erase lamp error Improper erase lamp cable connection or a shorted or cut cable Erase lamp LED terminal may be cut See Erase lamp service check on page 2 25 SVC FO ERROR Power supply fan error Improper fan motor rotation improper fan motor cable connection or a shorted or cut cable See Power supply fan service check on page 2 26 SVC F4 ERROR Exit fan error Improper fan motor rotation improper fan motor cable connection or a shorted or cut cable See Fuser fan service check on page 2 26 SVC F5 ERROR HV power supply HVPS error Output BRV of HVPS is shorted and or HVPS cable connector is improperly connected See High voltage power supply HVPS service check on page 2 27 SVC F6 ERROR LV power supply LVPS error Data communication error between LVPS and the engine controller board See Low voltage power supply LVPS service check on page 2 27 SVC HO ERROR Fuser thermistor error Temperature signal from thermistor is not detected See Fuser thermistor service check on pa
84. e cleaning brush against the cleaning roller charges the brush The brush in turn contacts the surface of the rotating transfer belt The negatively charged toner adheres to the positively charged FCBV brush which cleans the transfer belt The cleaning brush does not contact the transfer belt during the imaging process Waste toner adhering to the surface of the cleaning roller is removed by the cleaning blade routed by the waste toner feeder to the waste toner container where it is deposited Cleaning brush Cleaning roller Residual toner FCBV Transfer belt Waste toner feeder Cleaning roller FCBV Power supply for cleaning roller bias 1 30 Service Manual 5023 110 Details of the optical system In the optical system process the printer utilizes a semiconductor laser diode as a light source This laser diode is controlled by fast switching which matches the transmitted image data video signal The generated laser light scans the OPC belt through a polygon mirror and lens The electrostatic latent images are formed on the OPC belt E Bo The Optical printhead unit consists of following parts No Description 1 PD photo detector 2 Polygon mirror hexahedral mirror that reflects the laser beam 3 Cylinder lens laser beam condenser 4 Laser unit laser diode light emitting sourc
85. e femowval 12225253 p p Seed gau hosed eae eed 4 36 High voltage power supply HVPS removal REF E EE DERES 4 37 Low voltage power supply LVPS with cage 4 38 VPS Cale oer es Dex E da 4 39 Tones Present sensor removal sau cedro eee RS RP y ree 4 39 Tonerssnmsor receher SMOOVE E RD CREE UERBO E xx FE Exe de xs 4 40 Lett tray guide assembly removal 2 2 22 xk t Rhe x TERT ER REY 4 40 Tob Edad equae wed due eda 4 42 Marker sensor assembly removal 22 2 2222 9 9e ee 3 3 e ore rer boda 4 42 Wasto ions uge ENN bomo E REDE E UNE E E RE ERN RE a a Res 4 43 Waste toner agitatorqgemoval i uui Rue ker Rad RR EFE EE nes 4 43 esse nexa b End ex E Exe end dE KE 4 44 Locations 222222 42252 2 6142 5649 5 1 Pier S Wd ERN EE NI ERRARE ERR E ER IEEE 5 1 Electronic COMPONEMS 22 2 5 2 creas 5 3 SensorlocallOns 466 eee eee 5 3 Printe
86. ease from transfer belt onto paper during second transfer process Locations andconnectors 5 7 5023 110 Symbol and part name table Symbol Part name Symbol Part name BR Back up roller MCTL Main engine MCTL P W B board CTFAN Control fan motor cooling fan MM Main motor PS DM Developer motor Optical unit Optical unit DPJ Drum jam sensor PANEL Operator panel P W B DSW1 Interlock switch front PBS Belt sensor DSW2 Interlock switch top PCLU Upper paper feeding clutch DSW3 Interlock switch rear PDU PDU P W B Erase lamp Erase lamp PEU Upper paper empty sensor FBCL Cleaning roller solenoid PFUL Exit paper full sensor FBSOL Cleaning cam clutch PSU Upper paper size sensor FCS Cleaning roller sensor PT1 Paper feed sensor FUSER unit Fuser unit PT2 Paper exit sensor HPSEN Drum encoder sensor RECL Registration clutch HR Heater roller SCM Scanner motor HTFAN Heater fan motor cooling fan EX TBLE Waste toner sensor WT holder TBFL assembly HVU High voltage unit TFU1 Thermal fuse TFU2 LCD LCD P W B TH Themistor LDU Laser drive unit P W B TNK Toner key sensor LFU Lower paper feeding unit TPD Toner empty sensor TTR LVPS Power supply unit TRCM Transfer cam clutch 5 8 Service Manual Wiring diagram 1 of 4 Toner empty sensor TPD sender receiver Transfer unit sensor Loe Toner density sensor Registration sensor tia
87. easured using a simple text single character page Note Warm up time 45 seconds maximum is the time elapsed from when the power is turned on to when the ready status is reached Processor ARM 9 200 MHz General information 1 5 5023 110 Duty cycle Maximum duty cycle 35 000 pages one month s usage Printer memory Memory configuration Standard DRAM 64MB Optional SDRAM N A Max DRAM 64MB Paper and media specifications Print area The printable area is up to 4 0 mm 0 158 in from the top and bottom of the media and up to 3 0 mm 0 118 in from the left and right edges Any information placed outside this specified printable area will not print Note For envelopes the printable area is up to 4 0 mm 0 158 in of the left and right edges and 3 0 mm 0 118 in of the top and bottom edges Input and output configurations The following table shows the standard number of input sources and output destinations as well as the estimated capacity of each Capacity may vary and is subject to media specifications and printer operating environment The capacities listed are based on plain paper at 75 g m Sources and capacities C500n Input sources Number of standard sources 1 Number of optional input drawers 1 Maximum number of input sources 2 Maximum input capacity 780 Input capacities Standard input Primary tray capacity 2
88. ebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder pa belgelaengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser XiV Service Manual 5023 110 Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia kayttajalle Kirjoittimessa on sis inen luokan 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometria Laserj rjestelm ja kirjoitin on suunniteltu siten etta kayttaja ei altistu luokan I m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan kayttajan tekemien huoltotoimien tai muiden huoltotoimien yhteydessa VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers te
89. ence control Controls print sequence of printer 2 Temperature control Controls temperature of fuser unit 3 Consumables life control Controls toner empty status for each toner cartridge and life of periodic replacement parts 4 Operator panel control Controls operator panel indication and operator signals 5 Error processing control Senses errors occurring as well as stop procedures 6 Interface control Controls receipt and transmission of interface signals from external controller 7 Laser control Controls laser scanning and laser power Note A micro CPU mounted on the engine board controls the print processes General information 1 35 5023 110 Print sequence diagram OPERATION PANEL ENGINE CONTROL G A Engine board CPU Sequentia Control 8bit CPU Fuser Temperature Control Operator Panel Control Error Clearance Program Laser Power Control I F Control LASER ASM PDU PWB Scanner Motor 1 36 Service Man ual Lower 1 I Feed Unit YMCK INTERLOCK SWITCH Developer Motor Main Motor Developer Clutch Registration Clutch Laser Fi Fuser Clut Board 5 B gt BD 5 amp ERASE 3 3 amp LAMP amp PBS TES 5 3 E 2 3 B 3 E 5 E 2 a X 3 P E 5 5 HV POWER SUPPLY Paper Feed Clutch Transfer
90. engine controller 7 13 Power supply high voltage 7 13 Power supply 110 V low voltage 7 13 Power supply 220 V low voltage 7 13 Bracket 110 V power supply 7 13 Fan power supply includes top cover and rear cover assembly interlock switches 7 15 Sensor toner present 7 13 Bracket 220 V power supply 7 13 Transfer unit 7 3 Paper guide C assembly includes registration sensor tray empty sensor 7 11 Roller paper feed 7 11 Pad separator Atrina ee Rain NT Re ee ee ie HAMA men Ia 7 11 Lamp erase 7 7 Rear cover assembly 7 5 Transfer roller assembly 7 3 5023 110 40X3419 40X3420 40X3421 40X3423 40X3424 40X3425 40X3426 40X3428 40X3429 40X3430 40X3431 40X3432 40X3433 40X3434 40X3436 40X3440
91. ensor away from printer disconnect cable and remove sensor 4 22 Service Manual 5023 110 Cleaning roller clutch removal 1 Remove transfer belt cleaning roller See Transfer belt cleaning roller removal on page 4 5 2 Remove right cover See Right cover removal on page 4 14 3 Using a flat tip tool pry and remove cleaning roller clutch gear from inside of printer 4 Disconnect cleaning roller clutch cable A 5 Remove three screws B from cleaning roller clutch 6 Remove cleaning roller clutch from printer Repair information 4 23 5023 110 Main motor assembly removal 1 Remove right cover See Right cover removal on page 4 14 2 Disconnect main motor assembly cable A from main motor 3 Remove 4 screws B from the main motor assembly 4 Remove main motor assembly from printer 4 24 Service Manual 5023 110 Clutch removal Note This procedure applies to the transfer roller clutch registration clutch and the paper feed clutch Shown is the transfer clutch removal This removal is typical for the others 1 Remove right cover See Right cover removal on page 4 14 2 Disconnect clutch cable A 3 Remove clip from clutch B 4 Slide clutch away from printer to remove Main drive gear assembly removal 1 Remove cleaning roller clutch See Toner sensor sender removal on page 4 22 2 Remove main motor assembly See Main motor assembly removal on
92. enzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona piu elevato personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Safety information XiX 5023 110 Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt Wahrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine gefahrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit groBer Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu Pautas de Seguridad La seguridad de este producto se basa en pruebas y apro
93. er i J Separator Paper guide C Paper exit Registration assembly assembly assembly contains Registration sensor Tray empty sensor System board removal Warning Before replacing the system board save the onboard settings See Saving the system RIP board settings on page 3 3 1 Disconnect any attached cables 2 Remove two screws A 3 Slide system board out of printer 4 28 Service Manual 5023 110 Bracket assembly removal Remove erase lamp See Erase lamp removal on page 4 18 Remove two screws A Disconnect connector B from transfer belt marker sensor Disconnect connector C from toner density sensor moo m B A C 5 Lift and remove bracket assembly Repair information 4 29 5023 110 Paper guide assembly removal 1 Remove lower cover from rear cover assembly 2 Remove two screws A that attach paper guide assembly to printer Screws are located in holes 3 Open rear cover assembly 4 30 Service Manual 5023 110 4 Lift and remove paper guide assembly B from printer Paper guide C assembly removal Remove paper guide assembly See Paper guide assembly removal on page 4 30 Remove transfer belt unit See Transfer belt unit removal on page 4 6 Remove support pin disconnecting support cable A from printer Remove two screws B that attach paper guide C assembly to printer POS B A 5 Disconnect two sen
94. ervice error code appears while you are working on the printer go to the Service error codes on page 2 2 and take the appropriate action Diagnostic information 2 1 5023 110 Service error codes Error code Action SVC 110 ERROR Memory Read Write is abnormal SVC 111 ERROR Memory Read Write is abnormal SVC 112 ERROR Memory Read Write is abnormal SVC 113 ERROR Memory Read Write is abnormal SVC 180 ERROR CPUIF part cache register read write test is abnormal SVC 160 ERROR DMA RAM read write test is abnormal SVC 251 ERROR DMA circuit interruption is abnormal SVC 25 ERROR DMA circuit test is abnormal SVC 411 ERROR IRQ timer 1 is abnormal SVC 412 ERROR IRQ timer 2 is abnormal SVC 140 ERROR MII interface is abnormal SVC 141 ERROR LAN loop back test is abnormal SVC 090 ERROR Check sum is abnormal Replace the controller board See Engine controller board removal on page 4 34 SVC 11 ERROR Communication error between the RIP and the engine controller SVC 31 ERROR Download error Memory locating error Replace the RIP board See System board removal on page 4 28 Or replace the engine controller board See Engine controller board removal on page 4 34 2 2 Service Manual 5023 110 Error code Action SVC 32 ERROR Download error Flash ROM erasing writing error SVC 33 ERROR Do
95. et on ohmmeter check switches When switch is page 4 20 for front interlock open cover open resistance between pin switch see Power supply 1 and pin 3 is 0 pin 1 and 2 is infinite fan removal on Closing switch will show 0 resistance page 4 44 for rear and top between pins 1 and 2 and infinite resistance interlock switches between pins 1 and 3 Are switches good 3 Turn printer on Check for 5 VDC between Go to step 5 Go to step 4 front cover interlock switch pin 1 top pin and ground Is 5 VDC present 4 Turn printer off and check cable for Replace LVPS See Low Replace cable continuity between LVPS ACN2 pin 1 and voltage power supply cable that connects to front cover interlock LVPS with cage switch pin 1 Is cable okay removal on page 4 38 5 Check the following cables for continuity Replace cable Replace engine controller board See Engine controller board removal 4 34 Engine controller board MCN4 pin to top interlock switch pin 3 Top cover interlock switch pin 1 to front cover interlock switch pin 2 Top cover interlock switch pin 2 to rear cover interlock switch pin 1 e LVPS 2 pin 2 to rear cover interlock Switch pin 2 Are any cables defective Diagnostic information 2 39 5023 110 OPC belt photodeveloper cartridge drive service check Step Questions actions Yes No 1 Check photodeveloper cartr
96. extend the wiring harness Confirm the wiring harness connector is connected properly Be sure to handle the fuser carefully as it remains hot for a while after the printer stops running Always unplug connectors by holding the connector housing Remember to install the ground wire or ground plate to ensure positive conduction Install the screw with a toothed washer in the correct position at reassembly Repair information 4 1 5023 110 Handling the printed circuit boards with MOS ICs The following precautions must be observed when handling circuit boards with MOS Metal Oxide Semiconductor ICs During transportation storage Do not remove new circuit boards from their protective conductive bags until needed Do not store or place circuit boards in a location exposed to direct sunlight When it becomes necessary to remove a board from its conductive bag or case always place it on its conductive mat in an area as free as possible from static electricity Do not touch pins of the ICs with your bare hands During replacement Before you unplug connectors from the circuit boards be sure the power cord has been unplugged from the power outlet When you remove a board from its conductive bag or case do not touch the pins of the ICs or the printed pattern Place it in position by holding only the edges of the board Before you plug connectors into the board be sure the power cord has been unplugged from the power
97. f black yellow magenta and cyan 1 Toner adheres to the developer roller The developer roller makes contact with the surface of the OPC belt which begins the developing process Toner 2 The developer roller has been biased to DBV V potential The first illustration shows the relationship between the toner the Vo V at the non exposed area of the OPC belt and the VR V at the exposed area of the OPC belt Dev roller CBV DBV General information 1 25 5023 110 3 Developing is processed by toner adhering to the OPC belt due to the attraction between the toner and the VR V charge at the exposed area of OPC belt The toner image becomes visible on the OPC belt Toner M gt X VW lt lt gt 0000000 W OW Exposing Developing Note No developing takes place on the non exposed area because the potential of toner and that of the non exposed area of the OPC belt is an identical pole and therefore repels First transfer drum process The first transfer process consists of toner images on the OPC belt being transferred to the transfer belt The transfer belt is composed of a special rubber See Printer theory of operation on page 1 14 for transfer belt location 1 After the development process the OPC belt rotates making contact and synchronizing with the transfer belt and the
98. f the jammed media Pull it to the rear of the printer and then out Fuser pressure release lever Fuser pressure release lever Note Gently pull the media out so you do not tear it 5 Close the rear door 6 Check registration sensor and its actuator Replace if damaged See Paper guide C assembly removal on page 4 31 7 Ensure connector MCN9 on the engine controller board is connected If connector is attached and error persists replace the engine controller board See Engine controller board removal on page 4 34 2 14 Service Manual 5023 110 JAM C rear A JAM C Rear message indicates the media is jammed behind the rear door above the fuser 1 Push the rear door release latch and gently lower the rear door 2 Pull the fuser pressure release levers to release tension on the media 3 Grasp each corner of the jammed media and pull it up and out Fuser pressure release lever A Fuser pressure release lever Note Gently pull the media out so you do not tear it Whenever possible pull the media towards the bottom of the printer to avoid contamination of the fuser 4 Close the rear door 5 Check fuser exit sensor located in paper exit assembly and its actuator Replace if damaged See Paper exit assembly removal on page 4 32 6 Ensure connector MCN1 on the engine controller board is connected If connector is attached and error persists replace engine controller
99. fice environment is supported Only PN 12A5940 and 12A5941 should be used There is no automatic paper type sensing These settings should be manually set in the operation panel General information 1 7 5023 110 Media sizes Media sizes Dimensions Input Output gt E S o s js o o mm in A4 210 x 297 8 27 x 11 7 X X X X A5 148 x 210 5 83 x 8 27 X X JIS B5 182 x 257 7 17 x 10 1 x x X Letter 216 x 279 4 8 5x 11 X X X X Legal 216 x 356 8 5 x 14 X X Executive 184 2 x 266 7 7 25 x 10 5 X X X X Folio 216 x 330 8 5 x 13 X X Statement 139 7 x 215 9 5 5 x 8 5 X X Universal X x X Standard 250 sheet letter tray 104 8x210 to 4 125x8 27 to 8 5x11 7 215 9x297 Optional 250 sheet legal tray 104 8x210 to 4 125x8 27 to 8 5x14 215 9x355 6 Envelope sizes Dimensions Dimensions 9 Envelope 98 4x225 4 3 875 x 8 9 X X X COM 10 Envelope 104 8 x 241 3 4 12 x 9 5 X X X DL Envelope 110 x 220 4 33 x 8 66 X X X C5 Envelope 162 x 229 6 38 x 9 01 x X X B5 Envelope 176 x 250 6 93 x 9 84 X X X Select Universal when using a non standard size sheet of print material The printer formats the page for the maximum size 8 5 X 14 in 215 9 X 355 6 mm Set the actual size from your software application Supported through the driver 3B5 may be supported in optional tray 1 but size sensing must be turned off Output capacity by media and
100. from hazardous voltage the area of the AN product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit e La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es e Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la tache exige que le produit reste sous tension Norme di sicurezza Lasicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti Leinformazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manut
101. ge 2 28 SVC H1 ERROR Fuser lamp error Circuitry that controls the fuser temperature has failed See Fuser assembly service check on page 2 28 SVC H2 ERROR Fuser temperature error warming up Fusing temperature is not reached within the warming up time period See Fuser assembly service check on page 2 28 SVC ERROR Fuser temperature error printing Fusing temperature drops below fusing threshold during the printing process and does not reach fusing temperature again within alloted time See Fuser assembly service check on page 2 28 SVC H4 ERROR Fuser temperature high error Fusing temperature rises above limit during printing process and does not return within the alloted time period See Fuser assembly service check on page 2 28 2 4 Service Manual 5023 110 Error code Action SVC HA ERROR Fuser AC OFF error relay off AC relay turned off due to an abnormal temperature See Fuser assembly service check on page 2 28 SVC L1 ERROR Beam detector error BDT error Laser scanning beam is not detected by beam sensor See Laser unit assembly service check on page 2 29 SVC L2 ERROR Scanner motor error Scanner motor SM is rotating abnormally See Laser unit assembly service check on page 2 29 SVC LL ERROR Laser power error Laser power is lower than the output limit See Laser unit assembly service c
102. ge 4 32 Replace the tray 2 separator pad 40X3415 004 Replace the paperfeed roller 40X3414 in both trays See Paper feed roller removal on page 4 32 Replace the separator pad 40X3415 in both paper trays 010 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 011 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 Replace the tray 1 paperfeed roller 40X3414 See Paper feed roller removal on page 4 32 Replace the tray 1 separator pad 40X3415 012 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 Replace the tray 2 paperfeed roller 40X3414 See Paper feed roller removal on page 4 32 Replace the tray 2 separator pad 40X3415 014 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 Replace the paperfeed roller 40X3414 in both trays See Paper feed roller removal on page 4 32 Replace the separator pad 40X3415 in both trays 100 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 101 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the tray 1 paperfeed roller 40X3414 See Paper feed roller removal on
103. heck on page 2 29 SVC N3 ERROR HVU HVPS connection error Improper connection between engine controller board and HVPS See HVPS connection service check on page 2 29 SVC N4 ERROR Toner empty sensor error 1 Improper connection between engine controller board and toner sensor sender board See Toner empty sensor sender TPD service check on page 2 30 SVC N5 ERROR Toner empty sensor error 2 Improper connection between engine controller board and toner sensor receiver board See Toner empty sensor receiver TTR service check on page 2 31 SVC N6 ERROR Lower paper feed unit LFU connection error Improper connection between engine controller board and lower paper feed unit See Lower feed unit secondary paper assembly service check on page 2 32 SVC P6 ERROR Pick up paper feed clutch L LFU error Data communication error between engine controller board and LFU paper feed clutch See Lower feed unit secondary paper assembly service check on page 2 32 Diagnostic information 2 5 5023 110 Parts replacement maintenance codes Operator panel code Recommended actions 001 Replace the tray 1 paperfeed roller 40X3414 See Paper feed roller removal on page 4 32 Replace the separator pad 40X3415 in tray 1 002 Replace the tray 2 paperfeed roller 40X3414 See Paper feed roller removal on pa
104. idge for proper Go to step 2 Install properly installation Is cartridge installed properly 2 Check photodeveloper cartridge for Replace photodeveloper Go to step 3 damage Is cartridge damaged cartridge See Photodeveloper cartridge removal on page 4 9 Note Photo developer cartridge is a customer ordered supply 3 Check main motor assembly for damage Is Replace main motor Replace main drive main motor assembly damaged assembly See Main assembly See Main drive motor assembly removal gear assembly removal on page 4 24 on page 4 25 Missing fuser service check Step Questions actions Yes No 1 Check photodeveloper cartridge for proper Go to step 2 Install properly installation Is cartridge installed properly 2 Check photodeveloper cartridge for Replace photodeveloper Go to step 3 damage Is cartridge damaged cartridge See Photodeveloper cartridge removal on page 4 9 Note Photo developer cartridge is a customer ordered supply 3 Check main motor assembly for damage Is Replace main motor Replace main drive main motor assembly damaged assembly See Main assembly See Main drive motor assembly removal gear assembly removal on page 4 24 on page 4 25 2 40 Service Manual Paper size sensing service check 5023 110 Step Questions actions Yes No 1 Turn printer off and remove engine Go to step 2 Properly connect cable controller bo
105. ield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN10 2 Ensure rear cover assembly cover is shut Replace power supply fan Go to step 3 Override top and front cover interlock assembly See Power switches For location see Interlock supply fan removal on switch locations on page 5 6 Reconnect page 4 44 Retest printer If operator panel Turn printer on and check error clears problem for 24VDC between engine controller board solved otherwise go to step MCN10 pin 1 and power ground you can 3 touch negative lead of voltmeter to metal frame to obtain ground Is voltage present and correct 3 Turn printer off and disconnect cable from Replace engine controller Replace cable engine controller board MCN10 and power board See Engine supply fan Check cable for continuity and controller board removal pin shorts Is cable okay on page 4 34 Fuser fan service check Step Questions actions Yes No 1 Turn printer off and remove engine controller board board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly connected to engine controller board connector MCN1 Go to step 2 Properly connect cable engine controller board MCN1 and power supply fan Check cable for continuity and pin shorts Is cab
106. ilylle Ala katso s teeseen VARNING Osynlig laserstr lning nar denna del ar ppnad och sp rren ar urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass I 1 I andra lander uppfyller skrivaren kraven f r laserprodukter av Klass I enligt kraven i IEC 60825 1 Laserprodukter i Klass I anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass I niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser notices XV 5023 110 Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og eri andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke a betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i belgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niv under vanlig bruk vedlikehold som utf res av br
107. irection Problem area Action 1 Photodeveloper cartridge Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Note Photodeveloper cartridge is a customer order supply 2 Main motor assembly Irregular rotation of main motor assembly Main motor assembly gear unit failure Variation of OPC belt running speed due to failing main motor assembly Replace main motor assembly See Main motor assembly removal on page 4 24 3 Developer drive assembly Replace faulty developer drive assembly See Developer drive assembly removal on page 4 21 2 52 Service Manual 5023 110 Missing image at edge service check Image has missing or peeling toner at edge Problem area Action 1 Toner cartridge Too small a toner mass amount and charging amount in the development process Replace toner cartridge 2 Photodeveloper cartridge OPC belt is deformed and wavy Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Note Photodeveloper cartridge is a customer order supply Diagnostic information 2 53 5023 110 Mixed color image service check Mixed color image appears Problem area Action 1 Toner cartridge Ensure toner cartridge moves in and out of printer without a lot of resistance Compare toner cartridge in question with one of the other known working cartridges Replace t
108. it assembly gt Registration assembly Paper tray Paper feed roller LJ Erase lamp Cleaning blade OPC charge system 1 14 Service Manual 5023 110 Printer paper path The following illustration shows the paper path and the associated paper jam messages for jams at specific points in the paper path The printer depicted in the illustration has a duplex unit and secondary paper feed assembly installed Top Cover Paper Exit Roller Fuser Exit Sensor Rear Cover Assy Fuser Unit Transfer Roller Assy Registration Roller Registration Sensor Paper Feed Roller General information 1 15 5023 110 Printer systems description See the illustration Printer component systems on page 1 17 for more information Basic principles of color printing Color printing is made through the subtractive process of combining the three primary colors yellow magenta and cyan Mechanical and electrical structures This color laser printer consists of five engineering systems print transfer optical paper transport and control system Print system The print system consists of six functional parts located around the optical photoconductor OPC belt and forms a toner image on the OPC belt charge expose develop first transfer discharge and clean Transfer system The transfer system consists of three functional parts that transfers the toner image formed on the transfer belt to paper transfe
109. ive assembly E eq ede madre a iie werd 4 21 Toner sensor sender asses rper x 5 dedo 4 22 Cleaning toller TOMOVal uus aua aite m Rab ene Sp aa op erem d eus 4 23 Mail motor assembly removal ilia Rx eA Be xxx ex aed sees ne 4 24 een ee FR quedes apr du T Mere 4 25 Main drive gear assembly removal sisi ke 9 3 er e no Pe RESI RES 4 25 Waste toner Sele ENN rn x REVUE DU EE KE a Eum RE d eus 4 26 HearrcSlnpvals smectite des Sed he RE RI Gre ee Ri dreper REN cee dee sees 4 28 SEE s edere we i ace ra dw rd qe T 4 28 Bracket assembly removal 2 2 ecl 34e 3e o eo peg uo 4 29 Paper guide Assembly ETG asas edu dpi ara erai po x s o Ro 4 30 Paper guide C assembly remove ia me a aber ee Seer one dee Gorg REG RE 4 31 Papel cedex dee Fave c hanks Sieg VES baie 4 32 Paper exit assembly removal i iac td ons cates aa ges 4 32 Hegislradon desse nb TOMOVA ugar qp Eo bw E xd a KL Ha app ac p d 4 33 Leitside FONMIOVALS 25 54 cows odo cesses tu tose see wee ew Seen eee ena 4 34 Engine concer boda remoyal PER du mug eie a und rds 4 34 System board cag
110. k for shorted pins See pin2 black K Toner sensor sender pin4 yellow Y removal on page 4 22 pin6 magenta M and Toner sensor 8 cyan C receiver removal on Slightly remove toner cartridge in question page 4 40 for steps to Voltmeter should read approximately 4 8 expose cable If cable is VDG Continue to slowly slide toner okay replace toner sensor cartridge out of printer while noting system voltmeter reading Voltage should slowly decrease until it reads approximately 0 VDG Is toner sensor system working properly Waste toner bottle service check Step Questions actions Yes No 1 Remove waste toner bottle from printer Go to step 2 Replace waste toner bottle Inside waste toner bottle holder check holder See Waste toner sensor flag Does flag work properly and is it bottle holder removal on not damaged page 4 20 2 Reinstall waste toner bottle Does error Problem solved Go to step 3 clear 3 Replace waste toner bottle holder See Problem solved Replace engine controller Waste toner bottle holder removal on board See Engine page 4 20 Does error clear controller board removal on page 4 34 Diagnostic information 2 35 5023 110 Missing toner cartridge service check Step Questions actions Yes No 1 Remove toner cartridge in question Holding Replace toner cartridge Go to step 2 toner cartridge with developer roller
111. lace faulty transfer roller clutch See Clutch removal on page 4 25 2 62 Service Manual 5023 110 White line service check Vertical white line appears in a specific color area when print quality test print is run Problem area Action 1 Test print Print the maintenance page See Maintenance page printout on page 3 2 White line appears on specific color 2 Toner cartridge Developer roller of specific toner cartridge is dirty Remove foreign particle adhering to specific toner cartridge developer roller Developer roller surface is damaged Replace problem toner cartridge Vertical white line appears from leading edge to trailing edge of printed image White line Il service check Problem area Action 1 Laser unit assembly printhead Dust proof glass of laser unit is smeared with toner or foreign particles Clean glass Remove toner cartridges and photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Open dust proof glass cover Clean glass There are foreign particles adhering to laser beam opening of printhead Clean laser beam opening 2 Toner cartridge Foreign particles mixed in toner cartridge Replace faulty cartridge Diagnostic information 2 63 5023 110 White spot black spot service check A white spot and black spot appear on paper Problem area Action 1 Photodevelo
112. le okay board See Engine controller board removal on page 4 34 2 Ensure rear cover assembly cover is shut Potentially faulty fuser fan Go to step 3 Override top and front cover interlock Replace rear cover switches For location see Interlock assembly See Rear switch locations on page 5 6 Reconnect cover assembly removal operator panel Turn printer on and check on page 4 15 Retest for 24VDC between engine controller board printer If error clears MON 1 pin 4 and power ground you can problem solved else go to touch negative lead of voltmeter to metal step 3 frame to obtain ground Is voltage present and correct 3 Turn printer off and disconnect cable from Replace engine controller Replace cable 2 26 Service Manual High voltage power supply HVPS service check 5023 110 Step Questions actions Yes No 1 Remove photodeveloper cartridge Replace photodeveloper Go to step 2 and ensure charging unit on bottom cartridge See of photodeveloper cartridge is not Photodeveloper cartridge damaged Is charging unit removal on page 4 9 damaged Note Photo developer cartridge is a customer ordered part 2 Check charging unit high voltage Go to step 3 Clean contacts If problem contacts in printer Are they clean persists go to step 3 3 Replace photodeveloper cartridge Problem solved Go to step 4 See Photodeveloper cartridge removal on page 4 9 Has err
113. lification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Power On Reset Power On Self Test Print Quality Enhancement Technology Raster Image Processor Volts alternating current Volts direct current General information 1 3 5023 110 Specifications Resolution 600 x 600 dpi 2400 image quality Model differences C500n C500tn USB 2 0 X X Parallel Ethernet X X Memory MB 64 64 Options available 530 sheet drawer tray 2 X Technical specifications Color Balance Settings This printer offers color balance control It is a color correction option that allows you to increase or decrease the amount of toner going to the page for the cyan magenta yellow and black color planes The scale ranges from 10 to 10 Physical specifications and weight The following table contains the dimensions and weights for each printer model and option This does not include packaging but does include the print cartridge that ships with the printer Width Depth Height Weight inch inch inch Ib mm mm mm kg Printers Lexmark C500n 18 9 16 5 15 2 66 0 480 420 385 29 0 Paper options 530 Sheet drawer 18 1 18 5 7 3 13 3 460 470 185 6 0 530 Sheet tray 11 2 14 4 4 5 4 2 285 365 115 1 9 Standard
114. ms 1 3 B Back button 3 2 button back 3 2 stop 3 1 C control system 1 35 control of print process 1 35 electrical system and function 1 35 laser drive control circuit 1 37 CRU FRU and supplies removals 4 4 D diagnostic aids 3 1 diagnostic information operator messages 2 8 printer service checks 2 18 symptom tables 2 16 display panel 3 2 E error codes operator messages 2 8 Indicator light 3 1 J jam messages JAM A tray rear tray 1 2 11 JAM A tray rear tray 2 2 12 JAM B Rear 2 13 JAM B rear 2 13 JAM C Rear 2 15 JAM C rear 2 15 L locations 5 1 circuit boards 5 4 engine controller board 5 13 fans and motors 5 5 high voltage supply board 5 14 interlock switches 5 6 low voltage power supply board 5 14 printer 5 1 RIP board 5 13 sensors 5 3 solenoids and clutches 5 7 wiring diagram and cable harness reference 5 9 5 10 5 11 5 12 maintenance approach 1 1 maintenance page printout 3 2 5023 110 messages operator 2 8 N Navigation buttons 3 2 NVRAM settings saving the engine controller board settings 3 3 saving the system RIP board settings 3 3 O optical system 1 31 P panel display 3 2 paper jam messages 2 9 paper path 1 15 paper transportation system 1 32 fusing process 1 34 fusing unit 1 33 part number index X 3 preventive maintenance 6 1 print sequence diagram 1 36 print system belt cleaning process 1 27 belt discharge erase lamp process 1 27 charging process
115. n front cover assembly 2 Remove 8 screws A from inner front cover 3 Disengage support strap from printer 4 Release tabs on front cover N 4 i 4 r4 d bans Vel 5 Remove front cover from inner front cover 6 Raise front inner cover Repair information 4 13 5023 110 7 Rotate support pin away from printer and slide toward center of printer to remove Repeat for other support pin 8 Remove front inner cover from printer Right cover removal 1 Remove waste toner bottle See Waste toner bottle removal on page 4 8 2 Remove top cover assembly See Top cover assembly removal on page 4 12 3 Remove 2 screws A from bottom of right cover 4 Remove right cover from printer Maneuver front cover for easy removal 4 14 Service Manual 5023 110 Rear cover assembly removal Remove fuser assembly See Fuser assembly removal on page 4 7 Remove transfer belt unit See Transfer belt unit removal on page 4 6 Remove right cover See Right cover removal on page 4 14 Disconnect rear cover assembly connector A Remove support pin B disconnecting support cable from printer Remove two screws C from rear cover assembly ooRQOM 8 Slide rear cover assembly toward right side until captured end of rear cover assembly clears mounting bracket 9 Remove rear cover assembly by pulling away from printer Repair information 4 15 5
116. n is acceptable for laser printers Envelopes Should be fed with short edge first flap down and to the right If envelope wrinkling occurs refer to the User s Reference for correct loading and stacking of envelopes All envelopes should be new unused and without damage Envelopes with excessive curl or twist exceeding 6 0 mm those stuck together those with bent corners or nicked edges or those that interlock should not be used Minimum weight 90 g m 24 Ib The following envelopes should not be used Envelopes with windows holes perforations cutouts or deep embossing Envelopes with metal clasps string ties or metal folding bars Envelopes with exposed flap adhesive when the flap is in the closed position Self seal envelopes Under high humidity conditions over 60 the envelopes may seal during printing For best results print on new 90 g m 24 Ib sulfite or 25 cotton bond envelope Transparencies Labels Use letter 12A5940 or A4 size 12A5941 sheets only Transparencies are only supported in tray 1 standard or legal trays Labels should be selected using guidelines found in the User s Reference Complete Printer Reference or the Card stock amp Label Guide located at www lexmark com and tested for acceptability Vinyl labels are not supported Labels are only supported in tray 1 standard or legal trays Glossy Paper Use letter 12A5950 or A4 size 12A5951 sheets only Gl
117. n printer off and check transfer roller contacts Are contacts present and not damaged Yes Go to step 2 No If contact A has slipped off frame put it back on If you cannot see it remove HVPS cage see HVPS cage removal on page 4 39 and put it back in place If B is damaged replace registration assembly See Registration assembly removal on page 4 33 4 Replace engine controller board See Engine controller board removal on page 4 34 Does error clear Problem solved Replace HVPS See High voltage power supply HVPS removal on page 4 37 2 38 Service Manual Cover open service check 5023 110 Step Questions actions Yes No 1 Turn printer off and remove right cover See Go to step 2 Replace appropriate Right cover removal on page 4 14 actuator Check all interlock switch top rear and front actuators for proper operation Are 9 actuators good Front cover assembly removal on page 4 13 Top cover assembly for top cover interlock switch See Top cover assembly removal on page 4 12 Rear cover actuator for rear cover interlock switch Actuator is contained in parts packet 2 Check each interlock switches top rear Go to step 3 Replace switch in question and front for proper operation and damage See Front door interlock Listen for switching action Using an switch with brack
118. nce contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples Conventions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software There are several types of caution statements CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface gt gt CAUTION This type of caution indicates a tipping hazard XXii Service Manual 5023 110 1 General information This Lexmark C500 color laser printer is the ideal printer for presentations business graphics line art and text It uses laser diode electrophotographic technology to deliver remarkable quality print images and text The printer can be used as a shared network or desktop printer Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part U
119. ng retract of toner cartridge Replace toner cartridge Diagnostic information 2 47 5023 110 Black line service check A fine black line appears in printer image Problem area Action 1 Toner cartridge Toner cartridge blade is deformed Replace toner cartridge 2 Photodeveloper OPC cartridge OPC belt s surface is damaged Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 3 Debris Foreign particles paper dust and so on have adhered to perimeter parts of OPC belt and transfer unit belt Clean perimeter of mounting area of OPC belt and transfer belt 2 48 Service Manual 5023 110 Color misregistration service check Color misregistration between two colors Problem area Action 1 Transfer roller and transfer belt cleaning roller Transfer belt fails to maintain regular and proper rotation due to impact caused when transfer roller or transfer belt cleaning roller contacts transfer belt Ensure transfer roller and transfer belt cleaning roller are properly installed 2 Toner cartridge Developer cartridge OPC belt fails to maintain regular and proper rotation due to impact caused when toner cartridge contacts OPC belt Ensure toner cartridge is properly installed 3 Photodeveloper cartridge OPC belt is off track Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Note
120. ns on connectors Flat cable pins are exposed on only one side opposite blue side and must make contact with metal pins on connectors Repair information 4 35 5023 110 System board cage removal 1 Remove engine controller board See Engine controller board removal on page 4 34 2 Remove screw A from power supply fan 3 Lay power supply fan to side 4 Remove ducting 4 36 Service Manual 5023 110 5 Remove three screws B from system board cage 6 Remove system board cage High voltage power supply HVPS removal 1 Remove RIP board cage See System board cage removal on page 4 36 2 Disconnect all connectors from HVPS Note When reinstalling flat cable ensure blue side of cable is opposite pins on connector Flat cable pins are exposed on only one side opposite blue side and must make contact with metal pins on connector 3 Remove 11 screws A 4 corner screws are gold in color metal inner screws are silver plastic remove HVPS Repair information 4 37 5023 110 Low voltage power supply LVPS with cage removal Remove transfer belt unit See Transfer belt unit removal on 4 6 Remove RIP board cage See System board cage removal on page 4 36 Remove grounding terminal screw A Disconnect power supply bracket connector B Remove three screws C that attach power supply bracket remove power supply bracket groom a lt 4
121. oard cage removal on Are voltages present page 4 36 Go to stepO 2 20 Service Manual 5023 110 Step Questions actions Yes No 9 Reassemble and retest printer Does error Problem solved Contact next level of clear support Transfer belt unit service check Step Questions actions Yes No 1 Open rear cover assembly and check Clean belt marker area with Go to step 2 transfer belt unit markers for stains Are cotton cloth If problem markers stained persists go to step 2 2 Remove transfer belt unit and observe Replace transfer belt unit Reinstall transfer belt unit markers on side Are belt markers deformed See Transfer belt unit Go to step 3 or does transfer belt seem hard to rotate removal on page 4 6 3 Turn printer off and remove engine Go to step 4 Properly connect cables If controller board shield See Engine problem persists go to step controller board removal on page 4 34 4 for steps to remove engine controller board shield Are cables properly connected to engine controller board connectors MCN9 and POCN 4 Ensure rear cover assembly and front cover Engine controller board is Go to step 5 assembly are closed Override top interlock providing 5 VDC to marker switch and turn printer on Wait until printer Sensor Replace transfer displays error and remove 9 from belt marker sensor Marker engine controller board Check for 5 VDC sensor is part of
122. ohmmeter ensure power switch is cage removal on good Is power switch good page 4 38 for steps to remove power supply bracket 7 Check LVPS ACN1 ACN2 and ACN4 for Replace LVPS See Low Properly connect cables proper connection Are cables properly voltage power supply connected to LVPS LVPS with cage removal on page 4 38 2 42 Service Manual Toner feed service check 5023 110 Step Questions actions Yes No 1 Check toner cartridge for damage Check to Replace toner cartridge Go to step 2 see if toner cartridge moves easily into and out of printer Is toner cartridge damaged or is there resistance moving in and out of printer 2 Is developer motor damaged Replace developer drive Go to step 3 assembly See Developer drive assembly removal on page 4 21 3 Is developer drive assembly damaged Replace developer drive Contact higher level assembly See Developer technical support drive assembly removal on page 4 21 Waste toner feed service check Step Questions actions Yes No 1 Is transfer belt unit cleaning roller properly Go to step 2 Properly install cleaning installed roller 2 Check cleaning roller clutch gear located Replace cleaning roller Go to step 3 inside printer for damage Is cleaning roller clutch clutch damaged 3 Check waste toner bottle for overflow Is Go to Waste toner bottle Go to step 4 waste toner
123. oller 012 321 38 Transfer roller 20 194 63 Developer roller g 18 345 35 Transfer belt drive roller part of transfer belt unit 128 89 Transfer belt cleaning roller 026 182 67 OPC belt charge brush of photodeveloper charging system om 299 at OPC belt charge roller part of photodeveloper charging system gm 89s R OPC belt drive gear shaft 05 256 47 OPC belt drive roller 030 128 95 Fuser roller part of fuser 41 95 128 Fuser belt part of fuser 30 128 95 Paper exit roller part of paper exit 16 246 50 2 68 Service Manual 3 Diagnostic aids 5023 110 This chapter explains the tests and procedures to identify printer failures and to verify repairs have corrected the problem Understanding the printer operator panel The display panel is a two line gray scale display that shows text The Go and Stop buttons are located below the display panel and the Back Navigation and Select buttons are located below the Go and Stop buttons Display panel ERROR Error light Stop H gt X GE with indicator light Back 4 Navigation buttons pr 5s Select The use of the buttons and the layout of the operator panel is described in the following table Button Function Go with indicator light A green LED is used on the operator panel The light indicates whether the printer power is on the printer is busy idle offline o
124. on i xix saving NVRAM settings for hardware replacement 3 3 service checks paper feed 2 44 print quality 2 45 printer 2 18 service error codes 2 2 spacing table 2 68 specifications 1 4 Stop button 3 1 symptom tables print quality 2 17 printer 2 16 T theory of operation printer 1 14 transfer system 1 29 second transfer paper process 1 29 transfer belt cleaning process 1 30 1 2 Service Manual 5023 110 Part number index P N 14D0403 40X0273 40X0274 40X0275 40X0276 40X0278 40X0279 40X0286 40X0287 40X0297 40X0301 40X1766 40X1767 40X3382 40X3383 40X3384 40X3385 40X3386 40X3387 40X3388 40X3389 40X3390 40X3391 40X3393 40X3394 40X3395 40X3396 40X3397 40X3398 40X3399 40X3399 40X3400 40X3401 40X3402 40X3403 40X3404 40X3405 40X3406 40X3407 40X3408 40X3409 40X3410 40X3411 40X3412 40X3413 40X3414 40X3415 40X3416 40X3417 40X3418 Description page Cable USB 2 meter 7 17 Power cord HV Chile 7 3 Power cord HV Switzerland French Switzerland German Switzerland Italian 7 3 Power cord HV Israel 7 3 Power cord HV South Africa 7 3 Power cord HV Austria Belgium Euro English Finland France Germany Greece
125. on page 4 38 If Note Fuser is a customer ordered supply error does not clear replace engine controller board See Engine controller board removal on page 4 34 2 28 Service Manual Laser unit assembly service check 5023 110 Step Questions actions Yes No 1 Check LCN connection on laser assembly Go to step 2 Properly connect LCN LDU board Is connector properly cable If error clears connected problem solved otherwise go to step 2 2 Check LCN connection on engine controller Go to step 3 Properly connect LCN board Is cable properly connected cable If error clears problem solved otherwise go to step 3 3 Check cable that connects engine controller Replace laser unit Replace cable Go to step board LCN and LDU LCN connectors for assembly Laser unit 4 continuity and shorted pins Is cable okay assembly printhead removal on page 4 16 Go to step 4 4 Does error clear Problem solved Replace engine controller board See Engine controller board removal on page 4 34 HVPS connection service check Step Questions actions Yes No 1 Turn printer off and remove engine Go to step 2 Properly connect cable controller board shield See Engine Retest printer If error controller board removal on page 4 34 clears problem solved for steps to remove shield Is cable properly otherwise go to step 2 connected to engine controller board HVCN
126. oner cartridge if defective 2 Transfer roller clutch Replace transfer roller clutch See Clutch removal on page 4 25 3 Transfer belt unit cleaning roller clutch Replace transfer belt unit cleaning roller clutch See Cleaning roller clutch removal on page 4 23 2 54 Service Manual 5023 110 Mottle service check Variation of optical density is found in image Problem area Action 1 Rear cover assembly Rear cover assembly is not fixed in place Open rear cover assembly and close properly 2 Transfer roller Transfer roller is not properly installed Remove and reinstall transfer roller See Transfer roller removal on page 4 7 3 Paper Replace deformed paper 4 Toner cartridge Replace defective toner cartridge 5 HVPS Replace faulty HVPS See High voltage power supply HVPS removal on page 4 37 Diagnostic information 2 55 5023 110 Residual image service check Mottle amp TPE Mottl Image of preceding page appears on every other page Action Cleaning roller is not installed properly Remove and reinstall Ensure left side of cleaning roller is making good contact with HVPS contact If error continues to occur after reinstallation replace cleaning roller See Transfer belt cleaning roller removal on page 4 5 Problem area 1 Transfer unit cleaning roller 2 HVPS Replace faulty HVPS See High voltage power suppl
127. or cleared Note Photo developer cartridge is a customer ordered part 4 Check cable for continuity between Go to step 5 Replace cable engine controller board connector HVCN and HVPS BCN1 connector and for shorted pins Is cable okay 5 Replace HVPS See High voltage Problem solved Go to step 6 power supply HVPS removal on page 4 37 Has error cleared 6 Replace engine controller board Problem solved Contact higher level support See Engine controller board removal on page 4 34 Has error cleared Low voltage power supply LVPS service check Step 1 Questions actions Check cable for continuity between engine controller board connector LVCN and LVPS ACN4 connector Also check for shorted pins Is cable okay Yes Go to step 2 No Replace cable Replace LVPS See Low voltage power supply LVPS with cage removal on page 4 38 Does problem persist Go to step 3 Problem solved Replace engine controller board See Engine controller board removal on page 4 34 Does problem persist Contact higher level support Problem solved Diagnostic information 2 27 5023 110 Fuser thermistor service check Step Questions actions Yes No 1 Remove and reinstall fuser assembly See Problem solved Go to step 2 Fuser assembly removal on page 4 7 Does error clear 2 Check fuser connecto
128. or disconnect any cable electronic board or assembly for personal safety and to prevent damage to the printer Always use the hand grips on the side of the printer and be sure your fingers are not under the printer when you set the printer down Use the service error codes user status messages user error messages symptom tables service checks and diagnostic aids to determine the corrective action necessary to repair a malfunctioning printer Service error codes are indicated by a two character alphanumeric error code If a service error code displays go to the Service error codes on page 2 2 User status messages provide the user with information on the current status of the printer Ready displays on the first line of the display unless Power Saver is invoked then Power Saver is displayed If a user status message displays go to the Operator messages on page 2 8 User error messages are indicated by a two or three digit error code which provides the user with information explaining a problem with a print cartridge paper jam option port and so on If a user error message displays go to the Operator messages on page 2 8 The User Messages section sometimes allows a servicer to isolate printer problems This section also gives actions to be taken when they do not set or clear If you have a failing symptom go to the Symptom tables on page 2 16 Locate your symptom and take the appropriate action If a s
129. ossy paper is only supported from tray 1 standard or legal trays General information 1 9 5023 110 Sensing by source Input Paper size Paper out Tray present Integrated 250 sheet x X X Optional 530 sheet X X X Connectivity Cables Personal computers For USB attachment a USB cable P N 12A2405 is recommended and must be ordered separately Operating systems This printer is compatible with applications running under the following operating systems for either local or network connections Apple Macintosh Mac OS 8 6 9 x OS X Download the latest Lexmark printer PPD files or printer drivers from the Lexmark Web Site Microsoft Windows Microsoft Windows 98 2nd Edition Microsoft Windows Me Microsoft Windows NT 4 00 Microsoft Windows NT 4 00 Server Microsoft Windows 2000 Professional Microsoft Windows 2000 Server Microsoft Windows 2000 Advanced Server Microsoft Windows XP Home Microsoft Windows XP Professional Microsoft Windows Server 2003 Download the latest printer drivers from the Lexmark Web Site The Windows software applications which operate in the operating systems listed above are best suited to run with the drivers supplied with this printer The drivers for Windows take advantage of your printer functions and increase the printer performance wherever possible The software applications that operate with most Apple LaserWriter printers will generally opera
130. otodeveloper cartridge Toner cartridge OPC belt OPC charging unit Laser assembly Electrode Photoconductor OPC Aluminum deposit layer Insulator material 1 20 Service Manual 5023 110 Basic structure of the print system The print system process consists of the following 1 The OPC belt is biased to the CBV V by power supply CBV 2 The OPC belt is then evenly charged to the negative high voltage by the OPC charging system The charging system consists of a charging brush that is biased by power supply CHV and a discharge roller that is biased by power supply DCV 3 The developer roller in the toner cartridge is biased to DBV V by power supply DBV 4 Frame potential of transfer drum is GND Paper exit unit o Photodeveloper cartridge Toner cartridge Developer roll Cleaning roller OPC belt Fuser unit Transfer belt Drm gt 47 GND Laser assembly printhead BRV charging unit General information 1 21 5023 110 5 Variation of the OPC belt potential a b The OPC belt is biased to CBV V The OPC belt surface is evenly charged to Vo V during the charging process During the exposing process the optical unit emits a laser beam that strikes the OPC belt surface forming an electrostatic image The electrostatic image is at VR V potential The negatively charged toner is moved to the OPC belt in the development process due to the
131. over touch meter Erase lamp removal on positive lead to left LED connection and page 4 18 Retest printer If meter negative lead to right LED error clears problem connection LED should illuminate Check solved otherwise go to step all LEDs on erase lamp board Do any LEDs 4 fail to illuminate 4 Remove engine controller board board Go to step 5 Properly connect cable shield See Engine controller board Retest printer If error removal on page 4 34 for steps to remove clears problem solved engine controller board shield Is cable otherwise go to step 5 properly connected to engine controller board connector MCN8 5 Disconnect cable from erase lamp and Replace engine controller Replace cable Retest engine controller board MCN8 Check for board See Engine printer Go to step 6 continuity between cable pin that controller board removal corresponds to MCN8 11 and erase on page 4 34 Go to step 6 lamp cable connector pin 3 Also check for continuity between cable pin that corresponds to MCN8 pin 12 and erase lamp cable connector pin 1 Check for shorted pins on both sides of cable Is cable okay 6 Retest printer Does error clear Problem solved Contact higher level support Diagnostic information 2 25 5023 110 Power supply fan service check Step Questions actions Yes No 1 Turn printer off and remove engine Go to step 2 Properly connect cable controller board board sh
132. ow printer to cool before touching any internal components Diagnostic information 2 9 5023 110 Accessing jam areas Open doors and covers and remove trays to access jam areas The illustration shows the location of sources and possible jam areas Standard tray Tray 1 an 530 sheet tray Tray 2 BA Rear door Use the following table to locate instructions for a particular jam however to resolve any message you must clear all media from the media path Jam message Go to page JAM A Tray Rear tray 1 JAM A tray rear tray 1 on page 2 11 JAM A Tray Rear tray 2 JAM A tray rear tray 2 on page 2 12 JAM B Tray Rear JAM B rear on page 2 13 JAM C Tray Rear JAM C rear on page 2 15 2 10 Service Manual 5023 110 JAM A tray rear tray 1 JAM A Tray Rear message indicates the media is jammed in either tray 1 or tray 2 The affected tray is indicated by the Tray x message Tray x could be the 250 sheet letter size tray or the optional 250 sheet legal size tray Tray 1 or the optional 530 sheet tray Tray 2 1 Pull the tray out Remove the tray completely e For a misfeed of the media the single piece of media is laying on top of the stack Pull it straight out For media jammed behind the tray area locate the jam on the bottom surface of the tray housing
133. page 4 32 Replace the tray 1 separator pad 40X3415 112 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 Replace the tray 2 paperfeed roller 40X3414 See Paper feed roller removal on page 4 32 Replace the tray 2 separator pad 40X3415 114 Replace the transfer roller 40X3418 See Transfer roller removal on page 4 7 Replace the cleaning roller 40X3382 See Transfer belt cleaning roller removal on page 4 5 Replace the transfer unit 40X3412 See Transfer belt unit removal on page 4 6 Replace the paperfeed roller 40 3414 in both trays See Paper feed roller removal on page 4 32 Replace the separator pad 40X3415 in both trays Note If an OW kit replacement message is displayed order the cleaning roller 40X3382 and the transfer roller 40X3418 These parts should be replaced every 120 000 pages Note The expected yield of the separator pad and paperfeed role are 120 000 pages The transfer unit has an expected yield of 48 000 pages Diagnostic information 2 7 5023 110 Operator messages Message Description Action Tray x paper size Tray x Load paper size The upper or lower paper tray is empty or the media in the trays is inconsi
134. paper from the printer 1 32 Service Manual Fusing unit 5023 110 The fusing unit utilizes a thermal fusing system that contains a heated fusing roller and a belt like backup roller The heated roller contains an inner heating element The backup roller contains three pressure members located behind the belt Paper carrying a toner image passes between the rollers where heat and pressure are applied to the paper to fuse the toner to the paper The fusing unit consists of the following components No Part Function 1 Fusing roller Used for fusing containing a heater 2 Back up roller Pressure roller 3 Fusing heater Heating device heated by a halogen lamp 4 Thermistor Sensor that detects the temperature of the fuser roller s surface 5 Thermal fuse Protective device that prevents the fuser roller from being excessively heated General information 1 33 5023 110 Fusing process 1 When the paper reaches the fuser the toner image is transferred on the paper but not yet fused to the paper 2 The transported paper passes between the heated roller and the back up roller The heated roller s temperature is approximately 338 F 170 C 3 When the paper with toner image pas
135. per cartridge There are foreign particles adhering to photodeveloper OPC belt Remove photodeveloper cartridge see Photodeveloper cartridge removal on page 4 9 Lightly wipe off foreign particles using a cotton cloth If problem persists replace photodeveloper cartridge 2 Transfer belt unit There are foreign particles adhering to transfer belt unit Remove transfer belt unit see Transfer belt unit removal on page 4 6 Lightly wipe off foreign particles using a cotton cloth If problem persists replace transfer belt unit 3 Toner cartridge Foreign particles mixed in toner Replace toner cartridge 4 Transfer roller There are foreign particles adhering to transfer roller or transfer roller is deformed Replace transfer roller See Transfer roller removal on page 4 7 2 64 Service Manual White print service check Mottle amp TPE 5023 110 gt 2 Blank page print at all is printed or a specific color is missing Problem area Action Solid white print 1 Optical Unit Printhead Laser light path is blocked by paper or other material stuck at the opening of the optical unit Ensure there are no foreign particles stuck at the opening of the optical unit 2 Transfer roller Transfer roller is not properly installed Remove transfer roller and reinstall See Transfer roller removal on page 4 7 Ensure transfer rolle
136. place toner cartridge 3 Photodeveloper OPC cartridge Photodeveloper cartridge has reached life or is failing Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Note Photodeveloper cartridge is a customer ordered supply 4 High voltage power supply HVPS HVPS has failed Replace HVPS See High voltage power supply HVPS removal on page 4 37 Diagnostic information 2 45 5023 110 Back stain service check pu Backside of paper is stained Problem area Action Fuser roller and back up roller are stained 1 Fuser assembly Fusing offset error occurred Replace fuser assembly See Fuser assembly removal on page 4 7 Note Fuser assembly is a customer order supply Transfer roller is stained Replace transfer roller See 2 Transfer roller Transfer roller removal on page 4 7 2 46 Service Manual Banding service check 5023 110 A banding line appears in horizontal direction Problem area Action 1 Photodeveloper OPC cartridge Transfer failure due to uneven rotational speed caused by a shock which occurs when the seam of the OPC belt passes over the cleaning blade Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 2 Toner cartridge OPC belt and transfer belt fail to maintain regular and proper rotation due to impact created duri
137. problem persists see Missing toner cartridge service check on page 2 36 Set Belt CG The belt cartridge is not installed Correctly install the photodeveloper cartridge to clear message and continue printing If error persists see Missing photodeveloper cartridge service check on page 2 37 Set Transfer Roll The transfer roller is not installed Ensure transfer roller is properly installed If problem persists see Transfer roller missing service check on page 2 38 Tray x paper size JAM A Tray Rear Paper is jamming at feeding area See JAM A tray rear tray 1 on page 2 11 or JAM A tray rear tray 2 on page 2 12 for instructions to clear the jam exit area JAM B Rear Paper is jamming inside See JAM B rear on page 2 13 for instructions the printer to clear the jam JAM C Rear Paper is jamming at paper See JAM C rear on page 2 15 for instructions to clear the jam Close Back Front Top Cover The back front or top cover is open Close specified cover if open If not open open the cover and close If the problem persists see Cover open service check on page 2 39 2 8 Service Manual 5023 110 Paper jam messages The following illustration lists paper jam messages indicating where the paper jam occurred Nee eee lll JAM B CAUTION When clearing paper jams inside of the printer may be hot All
138. r belt unit second transfer and cleaning roller Optical system The optical system consists of two functional parts that forms an electrostatic latent image on the OPC belt using a laser light optical unit and scanner motor SCM Paper transport system The paper transport system consists of five functional parts that picks up paper from the paper tray separates the transported paper from the transfer belt and exits it from the printer after fusing the toner image on the paper paper tray transport fuser and paper exit Control system The control system consists of four control parts and runs the printer by processing the interface signals transmitted from the computer and the other printer systems such as the print transfer optical and transport system sequence control laser control fusing temperature control and interface control 1 16 Service Manual 5023 110 Printer component systems qa Developer motor RIP board Paper exit unit Belt cleaner unit Engine board Fuser unit C Fix gt controller Belt cleaning I F control Sequence control Transfer belt Laser control Laser unit assembly Paper feed General information 1 17 5023 110 Basic process of color printing 1 This printer has a toner cartridge for each color yellow magenta cyan and black 2 The toner image is developed with primary colors and then transferred to the transfer belt for
139. r bias pole is touching spring contact on left side as viewed from front of printer of roller 3 HVPS Replace faulty HVPS See High voltage power supply HVPS removal on page 4 37 One color missing 4 Toner cartridge Replace faulty toner cartridge Diagnostic information 2 65 5023 110 Wrinkle image migration service check Banding shadows of different optical density appear due to wrinkle image migration and color misregistration occurring on paper Problem area Action 1 Non recommended paper Paper being used is not recommended for printer Replace paper with recommended paper 2 Rear cover assembly Open rear cover assembly and reclose ensuring that both sides properly latch 3 Fuser assembly Ensure fuser assembly is properly installed and that both locking levers are locked See Fuser assembly removal on page 4 7 Replace faulty fuser assembly Note Fuser assembly is a customer order supply 2 66 Service Manual 5023 110 Uneven density right and left Optical density is different between right and left side of printed image Problem area Action 1 Rear cover assembly Open rear cover assembly and reclose ensuring that both sides properly latch If rear cover assembly will not properly latch ensure that white door actuators located at top of rear cover assembly are not damaged If damaged replace These items are part of
140. r circuit board 122 22 euet hh hh Rh RR ERE RR 5 4 Fan motor locations s2 csuushkasek RR 5 5 interlock Switch lOCALONS eau eau hh hh 5 6 GIUteh locations UE ERR 5 7 Symbol and name table 2 sc ccccccsccreesereseiseeeseseereeeereaaieesecaasoeeas 5 8 Wiring diagram 1 044 2 2 2 5 4 44 ss eeedeweraenedewaes sed 5 9 vi Service Manual 5023 110 RIP iiszcasinzku Reha sisan test GREASE RIXA E RIEGO ERROR RR RA eas 5 13 Engine ceritellir Baal seus qx x Roi 5 13 Low voltage power supply LVFS Boald suisses e re xr E eru REFERT ER 5 14 Figli voltage power supply IHVPS bodd usns sc Eger TEE S REESE SES 5 14 Preventive maintenance 2 452 225 nn RAS EXRARERSSASERRAPRRASERRASERRRSASTERSEEE 6 1 Parts Catalog 7 1 Dads ENN 554005084556 eee 7 1 ldeX 22228 2221 8 e X uc e aas geceuUsesrei c 33 Gd eas 1 1 Part number akser
141. r clutch service checK ci 0cccceete ee mue mu vad 2 22 Transfer belt cleaning roller clutch service check 2 22 Paper feed clutch service Check 4 4 4444 444 xxu RXRURRRRRRRREKRRERGOGE ek 2 23 Registration clutch service CHECK 2 2 2 2 4 2 4 4 4 44 44 2 23 OPC belt marker sensor service 22 2444 4 ee eee ee 2 24 Erase lamp service Check cc cccccscceeccececeecesad se eases kebab a h n 2 25 Power supply fan service Check 2 444 seve see w ese demand en 2 26 Fuser fan service Chek bc cee eene anu 2 26 High voltage power supply HVPS service 2 27 Low voltage power supply LVPS service check 2 27 Fuser thermistor service 4 4 44 444 444 eee 2 28 Fuser assembly service 5 2 2 4 2 2 422 4 44 ee 64 444 44 4 2 2 28 Laser unit assembly service check sees eee eee eee eee eee ee 2 29 HVPS connection service CheCK 2 29 Toner empty sensor sender TPD service
142. r for damage Problem solved Go to step 3 Replace if necessary Does error clear 3 Turn printer off and check cable that Go to step 4 Properly connect cable or connects engine controller board connector replace if damaged If error FUCN to fuser for proper connection clears problem solved continuity and pin shorts Is cable okay otherwise go to step 4 4 Replace fuser assembly See Fuser Problem solved Replace engine controller assembly removal on page 4 7 Does board See Engine error clear controller board removal on page 4 34 Note Fuser is a customer order supply Fuser assembly service check Step Questions actions Yes No 1 Check for proper input line voltage Is line Go to step 2 Provide proper line voltage voltage correct 2 Remove and reinstall fuser assembly See Problem solved Go to step 3 Fuser assembly removal on page 4 7 Does error clear 3 Check fuser connector for damage Replace Problem solved Go to step 4 if necessary Does error clear 4 Turn printer off and check cable that Go to step 5 Properly connect cable or connects engine controller board connector replace if damaged If error FUCN to fuser for proper connection clears problem solved continuity and pin shorts Is cable okay otherwise go to step 5 5 Replace fuser assembly See Fuser Problem solved Replace LVPS See Low assembly removal on page 4 7 Does voltage power supply error clear LVPS with cage removal
143. r processing a job q E Pressing Go switches the status of the printer between online and offline it allows access to menus Status Indicates Off Printer is offline and the menus are available Solid green Printer is on but idle Flashing green Printer is warming up processing data or printing a job Stop XxX Press the Stop button to stop the mechanical operation of the printer After pressing Stop the message Stopping appears When the printer has stopped the status line in the operator panel will show Stoppea and a list of options will appear Diagnostic aids 3 1 5023 110 Button Function Back J Press the Back button to return to the last screen viewed Note Changes made on a screen will not be applied if you press the Back button Navigation buttons The Left and Right buttons are used to move within a screen such as 4 gt moving from one menu index item to another d gt V J The Select button is used to initiate an action on a selection Press Select to select a menu item or to submit a configuration item Display panel The display panel shows messages describing the current state of the printer and indicating possible printer problems you must resolve The top line of the display is the header line Trayl Letter Ready ERROR Error light The error light appears whenever a service message occurs Trayl Letter Set K Toner CG ERROR
144. remove photodeveloper cartridge A 4 Lay photodeveloper cartridge as shown in a clean area Repair information 4 9 5023 110 Secondary paper feed assembly removal 1 Remove left secondary paper feed assembly cover Repeat for the right side 2 Loosen thumbscrew A on left bracket and remove bracket Repeat for right side A 3 With aid from another person lift printer by recessed handholds and remove from secondary paper feed assembly 4 10 Service Manual 5023 110 Cover removals Top cover Operator assembly Rear cover assembly Paper Release stopper Release Front lever cover Right cover Front view Left cover AC input inlet Power switch Back view Repair information 4 11 5023 110 Top cover assembly removal Remove cleaning roller cover See Cleaning roller cover removal on page 4 5 Remove photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Open rear cover assembly Open top cover Remove screw A from operator panel Rotate rear of operator panel and operator panel cover up Pull operator panel forward and turn it over Disconnect operator panel cable Remove two screws B from top cover assembly 10 Release tabs on front of top cover assembly 11 Lift top cover assembly and remove 4 12 Service Manual 5023 110 Front cover assembly removal 1 Ope
145. rmal load on developer motor 1 1 Replace black and magenta toner cartridge 2 If error persists see Developer drive assembly service check on page 2 20 SVC E1 ERROR Developer motor 2 over current error An over current signal is detected due to an abnormal load on developer motor 2 1 Replace yellow and cyan toner cartridge 2 If error persists see Developer drive assembly service check on page 2 20 SVC E2 ERROR Main motor MM error A NOT READY signal rotation error signal is detected because of abnormal main motor rotation See Main motor service check on page 2 18 Diagnostic information 2 3 5023 110 Error code Action SVC ERROR Transfer belt error transfer unit Unstable transfer belt rotation color matching cannot be secured See Transfer belt unit service check on page 2 21 SVC E5 ERROR Transfer roller clutch error Improper transfer roller clutch cable connection or a shorted or cut cable See Transfer roller clutch service check on page 2 22 SVC E6 ERROR Transfer unit cleaning solenoid cleaning roller clutch error Improper cleaning roller clutch cable connection or a shorted or cut cable See Transfer belt cleaning roller clutch service check on page 2 22 SVC E7 ERROR Pick up paper feed clutch error Improper paper feed clutch cable connection or a shorted or cut cable See Paper feed clutch servic
146. roller clutch Does resistance removal on page 4 25 measure between 119 and 145 ohms 3 Remove engine controller board shield See Replace engine controller Replace cable If problem board See Engine controller board removal on page 4 34 If problem persists replace faulty transfer roller clutch See Clutch removal on from MCN4 on engine controller board 5 eg page 4 25 Check cable continuity from MCN4 pins 5 EAR E i Clutch removal and 6 cable to connector that attaches to page 4 25 transfer roller clutch Ensure that pins are not shorted Is cable okay Transfer belt cleaning roller clutch service check Step Questions actions Yes No 1 Turn printer off and remove printer right Go to step 2 Properly connect cable If cover See Right cover removal on problem persists go to step page 4 14 Is cable properly connected to 2 cleaning roller clutch 2 Disconnect transfer belt cleaning roller Go to step 3 Replace faulty cleaning clutch from cable Measure resistance roller clutch See between two outer pins on cleaning roller Cleaning roller clutch clutch Does resistance measure between removal on page 4 23 198 and 242 ohms 3 Remove engine controller board shield See Replace engine controller Replace cable If problem Engine controller board removal on page 4 34 for steps to remove shield Disconnect cable from MCN4 on engine controller board
147. ruckers befindet sich ein Laser der Klasse 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daB im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem Ber Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Laser notices X 5023 110 Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe l Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe IIIb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed
148. se the error code charts symptom index and service checks to determine the symptom and repair the failure See Diagnostic information on page 2 1 for location of each section You may find that the removals in the Repair information chapter will help you identify parts After you complete the repair perform tests as needed to verify the repair Tools required for service The removal and adjustment procedures described in this manual require the following tools and equipment e Analog volt ohmmeter a digital volt ohmmeter may also be used Flat blade screwdrivers Needle nose pliers e 1 Phillips screwdriver 2 Phillips screwdriver Slotted screwdriver 1 Slotted clock screwdriver 1 Tweezers C ring pliers When you make voltage readings always use frame ground unless another ground is specified General information 1 1 5023 110 Serial number Look for serial number information on the right cover and the inside of the front cover of your printer LEXMARK M i 1 2 Service Manual 5023 110 Acronyms ASIC DPI DRAM EP ESD FRU HV HVPS LAN LASER LCD LED LV LVPS NVRAM OEM POR POST PQET RIP VAG VDC Application Specific Integrated Circuit Dots Per Inch Dynamic Random Access Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage High Voltage Power Supply Local Area Network Light Amp
149. sembly from frame Z 7 LAG 4 Remove two B screws that secure left tray guide assembly to printer frame 4 40 Service Manual 5023 110 5 Slide left tray guide assembly out front of printer Repair information 4 41 5023 110 Top removals Marker Waste toner Waste toner sensor assembly auger agitator Marker sensor assembly removal Remove all toner cartridges Remove photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Remove transfer belt unit See Transfer belt unit removal on page 4 6 Remove screw A from bracket PON A 5 Disconnect cable from sensor and remove marker sensor assembly 4 42 Service Manual 5023 110 Waste toner auger removal Remove photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Remove transfer belt unit See Transfer belt unit removal on page 4 6 Remove top cover assembly See Top cover assembly removal on page 4 12 Remove transfer belt cleaning roller See Transfer belt cleaning roller removal on page 4 5 Remove two screws A from waste toner auger remove waste toner auger c ROM Waste toner agitator removal 1 Remove waste toner auger See Waste toner auger removal on page 4 43 2 Remove gear A from cleaning roller clutch 3 Pull agitator off shaft lift and remove Repair information 4 43 5023 110 Power supply fan removal 1 Remove top cover assembly
150. ses between the heated roller and the backup roller the heat from the heated roller in combination with the pressure between the two rollers melts the toner fusing it to the paper 4 The fused paper then separates from the rollers and is transported out of the printer into the output bin or is routed back into the printer for printing on the other side of the duplex print M Magenta toner Y Yellow toner C Cyan toner Toner image a Before fusing Paper R Red M Magenta G Green Fixed toner b After fusing 1 34 Service Manual 5023 110 Control system structure Electrical system and function The engine board controls most of the main electrical parts in this printer No Control process Function 1 Print process control Controls print process from paper feed through paper exit 2 Laser output control Automatically controls laser output to the default 3 Fuser temperature control Controls fuser heater allowing heated roller to reach default temperature 4 Toner sensing control Controls sensing of toner empty status 5 Interface control video signal Processes the input and output signal with external controller computer 6 Operator panel indicator Displays printer operation status 7 Error control Controls safe stop procedures when errors occur Control of print process Control block diagram No Control process Function 1 Sequ
151. sor cables from sensors located on paper guide C assembly and remove paper guide C assembly Repair information 4 31 5023 110 Paper feed roller removal 1 Remove paper guide C assembly See Paper guide C assembly removal on page 4 31 2 Slide paper feed roller off shaft to remove Paper exit assembly removal 1 Remove two screws A NN 4 32 Service Manual 5023 110 2 Disconnect cable B 3 Remove two screws C 4 Remove paper exit D Registration assembly removal 1 Remove transfer roller See Transfer roller removal on page 4 7 2 Remove three metal screws A and three plastic screws B 3 Lift and remove registration assembly Repair information 4 33 5023 110 Left side removals Engine controller board shield Engine controller board present sensor Engine controller board removal Warning Before replacing the engine controller board save the onboard settings See Saving the engine controller board settings on page 3 3 1 Remove left cover See Left cover removal on page 4 16 2 Remove system board See System board removal on page 4 28 3 Remove three screws A from engine controller board shield remove shield m 4 34 Service Manual 5023 110 4 Disconnect all connectors from engine controller board Note When reinstalling flat cables ensure blue side of cable is opposite pi
152. source Source Media Capacity Orientation Standard output bin top Supports all sizes listed in the Media 250 sheets 20 Ib paper Collated sizes table 50 Transparencies Face down Media guidelines Paper designed for use with xerographic copiers should provide satisfactory print quality and feed reliability Other media types may be suitable We recommend that users test any particular brand for suitability to their applications Refer to the printer User s Reference for additional media specifications 1 8 Service Manual Paper 5023 110 Rough highly textured limp or pre curled papers will result in lower print quality and more frequent paper feed failures Colored papers must be able to withstand 338 F 170 C fusing temperature Preprinted forms and letterheads should be selected using guidelines in the printer User s Reference The chemical process used in preprinting may render some papers unsuitable for use with the printer Unsuitable papers include punched embossed water marked perforated media any kind of inkjet paper or plastic coated paper Recycled paper less than 75 g m 20 Ib may cause unacceptable results The laser printing process heats paper to high temperatures of 170 C 338 F Use only paper able to withstand these temperatures without discoloring bleeding or releasing hazardous emissions Check with the manufacturer or vendor to determine whether the paper you have chose
153. stent Fill up the paper tray s or replace the media with the correct type If the problem persists see Tray empty service check on page 2 33 Tray x NO Set Tray x The upper or lower tray is missing Install the upper or lower tray If the problem persists see Paper tray missing service check on page 2 34 Check Toner C Y M K The specific toner cartridge needs to be replaced In most cases only one of the letters CYMK will appear Install the appropriate toner cartridge If problem persists see Toner low empty service check on page 2 35 Replace WT Pack The waste toner bottle is full or not installed Install the waste toner bottle or replace the full waste toner bottle If problem persists see Waste toner bottle service check on page 2 35 Set Fuser Unit The fuser is not installed If fuser is installed remove it and reinstall If problem persists check the cable that connects engine controller board connector FUCN and fuser If the cable is bad replace the cable Otherwise replace the engine controller board See Engine controller board removal on page 4 34 Set c m y k Toner CG An invalid toner cartridge is installed Install a supported cartridge If the problem persists see Missing toner cartridge service check on page 2 36 Toner CG Error A toner cartridge is not keyed properly Install proper brand of toner cartridge If
154. t sensor Also check for shorted present sensor removal pins Is cable okay on page 4 39 8 Touch positive lead to engine controller Replace engine controller Go to step 9 board connector POCN pins 13 15 and 17 board See Engine to ensure 5 VDC is being supplied to engine controller board removal controller board Is 5 VDC present on page 4 34 9 Check cable continuity between LVPS Replace LVPS See Low Replace cable ACN1 and engine controller board voltage power supply connector POCN Also check for shorted LVPS with cage pins Is cable okay removal on page 4 38 2 36 Service Manual Missing photodeveloper cartridge service check 5023 110 Step Questions actions Yes No 1 Check photodeveloper cartridge for proper Go to step 2 Install properly installation Is cartridge installed properly 2 Check printer contacts A and Replace photodeveloper Replace photodeveloper photodeveloper cartridge contacts B for dirt and damage Are contacts okay cartridge See Photodeveloper cartridge removal on page 4 9 Note Photo developer cartridge is a customer ordered supply If problem persists replace HVPS See High voltage power supply HVPS removal on page 4 37 cartridge See Photodeveloper cartridge removal on page 4 9 Diagnostic information 2 37 5023 110 Transfer roller missing service check Step 1 Questions actions Tur
155. te with this printer Network Connections Internal Network Connections The Lexmark C500n printer comes standard with Ethernet 10 100BaseTX built into the controller board 1 10 Service Manual 5023 110 Internal Print Servers The standard Ethernet connection and optional N2100 Series print servers support the following protocols TCP IP The TCP IP standard set of application services are supported including DHCP BOOTP WINS SNMP mib 2 host resources MIB printer MIB enterprise MIB SNMP traps HTTP LPR LPD FTP IPP1 SLP DDNS e AppleTalk This printer with standard Ethernet supports an Embedded Web Server The current status of the operator panel is viewable using the resident web pages Standard Interfaces This printer ships with the following interfaces Ethernet 10 100 Base TX USB 2 0 supporting full speed 12Mb s data transfer Note The ethernet and USB interfaces may be used simultaneously The USB interface supports Windows 98 SE Windows Me Windows NT e Windows 2000 Professional e Windows XP Operating Systems e Windows Server 2003 Operating Systems Apple Mac OS 9 x 10 1 10 2 10 3 10 4 General information 1 11 5023 110 Power and electrical specifications Printing states C500n Off OW Average power while printing Continuous printing 670 W Power consumption standby Power saver on 35 W Power saver off 200 W Maximum current while printing
156. tion feeder assembly feed clutch clutch Repair information 4 19 5023 110 Front door interlock switch with bracket 1 Remove top cover assembly See Top cover assembly removal on page 4 12 2 Remove right cover See Right cover removal on page 4 14 3 Disconnect interlock switch cable A from interlock switch 4 Remove screw B and disengage locking clip on back of bracket 5 Remove switch with bracket Waste toner bottle holder removal 1 Remove right cover See Right cover removal on page 4 14 2 Disconnect waste toner bottle holder connector A 4 20 Service Manual 5023 110 3 Remove three screws B from waste toner bottle holder Bottom screw is longer than other screws 4 Remove waste toner bottle holder from printer Developer drive assembly removal 1 Remove main motor assembly See Main motor assembly removal on page 4 24 2 Remove waste toner bottle holder See Waste toner bottle holder removal on page 4 20 3 Remove four clips and developer drive gears A from inside of printer 5 Remove four screws from developer drive assembly 6 Remove developer drive assembly from printer Repair information 4 21 5023 110 Toner sensor sender removal 1 Remove developer drive assembly See Developer drive assembly removal on page 4 21 2 Remove two screws A from toner sensor Note Bottom screw is longer than top screw 3 Pull toner s
157. ukeren eller foreskrevne serviceoperasjoner Avis sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe I 1 i segons ha estat certificat en altres llocs s un producte l ser de classe I que compleix els requisits d IEC 60825 1 Els productes l ser de classe I no es consideren perillosos Aquesta impressora cont un l ser de classe 3b d arseni r de gal li nominalment de 5 mil liwats i funciona la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Japanese laser notice L 3 icBiy 1071 9 18 KETADHHS 21 CFRYTFYTY J 07241 1 OMBeMkKLEV V HRCHSCLMIEWS ATVET 8250877 gt ALOV YV WMECHSCEMMMANTIET 29XI0v Vv Wpiifsl amp tEd7vcxxoncozxzv co 7Zyr sZ i72ZzHnb 30 OL P AARMELTIEF CO LF 0 0 95 4 7 0 BH 5LUDybhOAUDAUMILWERHITSL P CF COL LWATACTULS ii BEOR amp 175 MEDI FALTOVANVELELOL ik XVi Service Manual 5023 110 Chinese laser notice OL ae A
158. wnload error Other critical error SVC 41 ERROR Pipeline processing system error DMA error SVC 42 ERROR Pipeline processing system error Time out error SVC 43 ERROR Pipeline processing system error Other critical error SVC 61 ERROR Program processing error Replace the RIP board See System board removal on page 4 28 Or replace the engine controller board See Engine controller board removal on page 4 34 SVC C3 ERROR NVRAM error Incorrect data is detected in the NVRAM during data confirmation process at power on 1 POR the machine 2 If problem persists contact next higher level of support SVC C4 ERROR Engine controller board error Defective engine controller board is causing faulty data transmission between ASIC and CPU POR the printer If error still exists replace the engine controller board See Engine controller board removal on page 4 34 SVC C7 ERROR Process timing error Synchronization signal from main motor is not detected See Main motor service check on page 2 18 SVC D0 ERROR Developer motor error Error detected on developer motor 1 See Developer drive assembly service check on page 2 20 SVC D1 ERROR Developer motor error Error detected on developer motor 2 See Developer drive assembly service check on page 2 20 SVC E0 ERROR Developer motor 1 over current error An over current signal is detected due to an abno
159. y HVPS removal on page 4 37 2 56 Service Manual Ribbing service check 5023 110 Light print occurs in right or left side of image Problem area Action 1 Printer is not level Table printer is sitting on is slightly tilted Tilt should be less than 1 2 inch Confirm the printer table is large enough and the printer is level 2 Toner cartridge Insufficient amount of toner in the toner cartridge Shake the toner cartridge horizontally several times to level the toner 3 Toner cartridge Toner in the toner cartridge is not level and collects on one side Shake the toner cartridge horizontally several times to level the toner If problem persists replace toner cartridge 4 Rear cover assembly Open rear cover assembly and close properly 5 Photodeveloper cartridge Photodeveloper OPC belt is off rack and becomes deformed during operation Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 9 Note Photodeveloper cartridge is a customer order supply Diagnostic information 2 57 5023 110 Toner drop service check Registration A toner spot stain on paper is caused by ambient toner within printer engine Problem area Action 1 Waste toner feed system Waste toner auger Waste toner feeder Toner drops on the transfer drum due to a breakdown of the waste toner feed system Waste toner auger mylar is damaged Examine and replace

Lexmark C500n 5023-110 Service Manual

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