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Lexmark X500n-X502n MFP 7100 Service Manual

1. RIP card voltages Connector Pin Voltage Signal J PNL 1 Pin 1 45V J ADF 1 Pin 5 2 5V J FB1 Pin1 45V J CCD Pin 8 12V J CCD Pin 10 5V J CCD Pin12 3 3 J CCD Pin 16 3 3V J CCD Pin 20 5V Locations and connectors 5 15 7100 XXX Engine controller board MCN9 MCN8 MCN7 MCN6 5 16 Service Manual 7100 High voltage power supply HVPS board Locations and connectors 5 17 7100 XXX Modem Card voltages and signals Pin Number Signal 1 3 3 V 2 3 3V 3 Signal 4 Signal 5 Signal 6 Signal 7 Signal 8 Signal 9 Signal 10 Signal 11 Signal 12 Signal 13 Signal 14 Signal 15 Signal 16 Signal 17 SCS3
2. 7 1 INDEX e ec su l 1 number INGO asse ui 5554550505 5595555555 PIANO E 1 5 Table of contents Vii 7100 XXX viii Service Manual 7100 XXX Notices and safety information The following laser notice labels may be affixed to this printer Laser notice Laser 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 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 Der Drucker erf llt gem 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 I der die Anforderungen der IEC international Electrotechnical Commission 60825 1 gemaB amtlicher Bestatigung erf llt
3. 4 6 Fuss assembly 4 6 Waste teer faroval aeri qu PIG 4 7 PPholodeveloper cart dge TOImIOVBl sci mision xm Ron Saxa dro qa s eim RU E Ra RR 4 8 Secondary paper feed assembly removal esee hh hh 4 9 DOVSFTGITOVAlS ag dese eda cea cess qax US qe 4 10 Top cover TOlTIOVl saei pasar ced rimas ae SEQ SPP a PRAE Ede apad qs 4 10 Fight covar assembly TEITIOVE 19 2 2 gr ao edendo ccc aab doc desea green pd 4 12 Fig Cover TainoVal M QW REG SES Qe 4 13 Roar covor as emnon TeioVal sse aqaxdaseexssneisTred ser erasesesQedeeesesrrdsqQed gs 4 14 Egit foni COVOPTORNIOVEIL REGE EFE RR PIA PEU ERA EN 4 15 Leia COVBI au s neqoe ure Rc acd eee Sch 4 16 Upper right rear Cover uos iR E rh Red qx tas M Ed Nd RU E 4 17 Upper lett teal CoOVOr reroyvdl 24 23 ow qs ERR ESQ NW ERES SNR E USE GNE M E Rud mE 4 17 Laser unit assembly printhead FOITIOVa arua 4 18 Brass P Pme 4 20 ssa eic me s e x tte see
4. 4 21 Frontdoor interlock Swich with DIOCKGE desu dw 4 21 Waste toner bottle holoer removal 22 2 323 Ger IU PERS RES PATER RES 4 22 Developer drivo assembly teimoVal suum e ux rar o penc si m oe d 4 22 Toner sensor sondon OG RR A EN RN Cd xp ENS 4 24 Table of contents V 7100 XXX Cleaning Toller s suos dia ween hows d Queer pesi xdi 4 25 Main motor assembly a can Gun ad 4 26 CLIC us DR au el ee Qd 4 27 Main drive goar assembly removal 2 cece Sade RR dd 4 27 Waste odor feeder removal 4252224993 Pxe PRETEREA RE EE EN SP MESE 4 28 Ecl c PPP DDR 4 30 Bracket assembly removal 222222 d md RR RR NN mq Rd Sd 4 30 Papel guide assembly TeinoVal us sas ace ics maa ark Red da Rm eae acria du qi aha e rio 4 31 Paper guide GC assembly Tem Oval asia E Up Sd a aae indigere A pM is 4 31 Papar LIC FOUN TOITIOVUI uia aec e nonsi eed dao Re RR Sn sh a
5. 7 15 Guide cable 7 7 Cable ADF boc tee Ee eee Sete eo ee oes Sie 7 7 Cable modem 7 15 Cover legal extender 7 3 7 5 Cover ADF mechanism 7 7 CP CIPIT 7 11 Parts packet harness 7 19 Parts packet screw rrr 7 19 Power supply 110 V low voltage 7 15 Power supply 220 V low voltage 7 15 Bezel operator panel X500 7 7 Bezel operator panel X502 7 7 Field relocation 7 19 l 6 Service Manual
6. 7 5 Cover front eem le tee ee Ree eee ee seas tee ee Me eue etuer 7 5 Motor assembly main 7 11 Clutch paper feed 7 11 Clutch registration 7 11 Clutch transfer roller 7 44 Clutch cleaning roller 7 44 Gear assembly main drive 7 11 Waste toner feeder 7 11 Drive assembly developer 7 11 Assembly waste toner holder 7 11 Sensor toner receiver TTR This is a two piece sensor system Ordering of this part number includes both the right and left side 7 15 Sensor toner sender TPD This is a two piece sensor system Ordering of this part number includes both the right and left side 7 44 Laser unit assembly printhead 7 9 Right tray guide 7 9 Au
7. 5 Disconnect the ADF cable from the system board 4 54 Service Manual 7100 XXX 6 Remove the ADF cable cover from the rear of the flatbed unit 8 Lift the flatbed cover to a vertical position and up from the flatbed Repair information 4 55 7100 XXX 9 With a flat blade screwdriver press against the tab on the ADF unit retainer ALTTITTTTTTPERNS 10 Lift the ADF unit up and away from the flatbed unit Note Remove the ADF paper tray from the old ADF unit It will be used on the new ADF unit ADF mechanism cover removal 1 Open the ADF top cover and remove the ADF separator roll and ADF separator pad 2 Open the flatbed cover 3 Remove the screw A which secures the ADF front cover to the flatbed cover A Note When replacing this screw do not overtighten it 4 56 Service Manual 7100 4 Remove the ADF front cover 5 Remove the screw B which secures the ADF separator roll lock to the ADF 6 Remove the ADF separator roll lock 7 Remove the two screws C which secures the ADF mechanism cover to the ADF 8 Remove the ADF mechanism cover Repair information 4 57 7100 XXX Operator panel removal 1 Remove the operator panel bezel by prying it off the operator panel cover 2 Remove the two screws A 4 58 Service Manual 7100 3 Using flat blade screwdriver carefully pry the operator panel away from the scanner assembly in four
8. Cleaning LT Note If the cleaning roller is not positioned properly it will not contact the transfer unit surface correctly This results in waste toner remaining on the transfer unit and will cause residual images or ghost images in other words the remaining toner from one page will carry over to the next page as a light ghosted image on the printed page 3 18 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Printer Components The following graphic illustrates all the EP and paper transport processes in the X500 Developer motor RIP board Paper exit unit Belt cleaner unit Engine board controller Belt cleaning I F control Sequence control Transfer belt Laser control 6 Transfer roller Laser unit assembly Lp Sc Paper feed Paper tray Registration roller Paper feed roller Diagnostic aids 3 19 7100 XXX Lexmark confidential until announce edited 1 4 2007 Paper path components in order for an image to be printed the media has to be moved from the paper tray to the printer and eventually exit into the output area The most important component in this process is this media itself Old damaged or out of specification media can and will cause feed and transport problems If you encounter problems you should a
9. 8 Slide the rear cover assembly toward the right side until the captured end of the rear cover assembly clears the mounting bracket 9 Remove the rear cover assembly by pulling it away from the MFP 4 14 Service Manual 7100 Left front cover removal A 1 Remove the top cover assembly See Top cover assembly removal on page 4 10 2 Remove two screws A from the bottom of the left front cover 3 Remove the left cover from the MFP Repair information 4 15 7100 XXX Left rear cover removal 1 Remove the screw A that secures the left rear cover to frame A 2 Slide the left rear cover back and remove it from the printer 4 16 Service Manual 7100 Upper right rear cover removal 1 Open the rear cover See Rear cover assembly removal on page 4 14 2 Remove the screw A that secures the upper right rear cover to the frame 3 Remove the upper right rear cover Upper left rear cover removal 1 Remove the left rear cover See Rear cover assembly removal on page 4 14 2 Remove the screw A that secures the upper left rear cover to the frame um m umm um 3 Remove the upper left rear cover Repair information 4 17 7100 XXX Laser unit assembly printhead removal Open the front cover Remove the toner cartridges Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Open the top cover a
10. ASF Standard tray 2 530 sheet tray 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 Paper Jam A1 Rear tray 1 Paper Jam 1 rear tray 1 on page 3 24 Paper Jam A2 Rear tray 2 Paper Jam A2 rear tray 2 on page 3 26 Paper Jam B Rear Paper Jam B rear on page 3 27 Paper Jam C Rear Paper Jam C rear on page 3 29 Diagnostic aids 3 23 7100 XXX Lexmark confidential until announce edited 1 4 2007 Paper Jam A1 rear tray 1 A PAPER JAM A1 message indicates the media is jammed in tray 1 To clear a jam from the standard tray Tray 1 1 Pull the tray out Remove the tray completely Fora misfeed of the media the single piece of media is laying on top of the stack Pull it straight out 3 24 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX For media jammed behind the tray area locate the jam on the bottom surface of the tray housing 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 the problem see Paper feed service checks on page 2 44 Diagnostic aids 3 25 7100 XXX Lexmark confidential until announce edited 1 4 2007 Paper Jam A2 rear tr
11. Service Manual Lexmark X500n X502n MFP 7100 XXX e Table of contents e Start diagnostics e Safety and notices e Trademarks Index LEXMARK 7100 Edition May 1 2007 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 ServiceinfoAndTraining 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 referen
12. 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 23 7100 XXX 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 6 Does error clear 2 Check fuser connector 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 6 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 6 Does error clear 3 Check fuser connector for damage Replace Problem solved Go to s
13. o 4 Remove the system board cage cover 4 36 Service Manual 7100 5 Remove the screw B securing the two ground wires 6 Disconnect all the cables from the system board 7 Remove the four screws C securing the system board to the system board cage 3 MM Repair information 4 37 7100 XXX 8 Remove two screws D securing the system board to the system board cage 9 Slide the system board out of the MFP 4 38 Service Manual 7100 System board cage removal Remove the left front cover See Left front cover removal on page 4 15 Remove the three screws A securing the engine card shield Remove the engine card shield Disconnect all the cables from the engine card Disconnect the modem speaker cable from the RIP card Remove the three screws B which secure the card cage to the printer frame 7 Carefully remove the cage from the printer Note The engine controller board and system RIP board do not need to be removed to perform this removal Repair information 4 39 7100 XXX High voltage power supply HVPS removal AN 1 Remove the RIP board cage See System board cage removal on page 4 38 2 Disconnect all the connectors from the HVPS Note When reinstalling flat cables ensure that the blue side of the cable is opposite of the pins on the connectors Flat cable pins are exposed on onl
14. Maintenance mode Maintenance mode contains information and settings that can be used in servicing the X5xx series MFPs The maintenance mode menu is entered by holding down the key when performing a POR The various items in maintenance mode are accessed by using the and w keys to navigate within a submenu to each item and pressing the to select the item Press the key to move up a level WARNING These settings should not be used without the supervision of your secondary support center Display info The default menu displayed when in maintenance mode is the Display info menu To select this menu item press the key The Display info menu item contains printer specific information The information in this menu is described below Press to exit this menu Model Name Model Name is the default menu item in the Display info submenu This item displays the MFP model name The options are X500 and X502 This item cannot be changed Press 5 to exit this item FW Version The FW Version submenu displays three different firmware related items While in the Display info menu use the A and w keys to navigate to FW Version and press the key to enter the submenu FW Version menu items are accessed by using the and w keys to navigate within the submenu to each item CTL FW Ver CTL FW Ver displays the system board firmware version It cannot be changed in the menu This is the default menu item in the FW Version sub
15. 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 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 14 Transfer roller is not properly installed Remove transfer roller and reinstall See Transfer roller removal on page 4 6 Ensure transfer roller bias pole is touching spring contact on left side as viewed from front of printer of roller 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 8 Open glass cover Clean glass There are foreign particles adhering to laser beam opening of printhead Clean laser beam opening Toner cartridge has insufficient amount of toner Replace toner cartridge Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Problem area 1 Rear cover assembly 2 Transfer roller 3 Laser unit assembly printhead 4 Toner cartridge 5 Photodeveloper cartridge 6 Transfer belt unit Replace faulty transfer belt unit See Transfer belt unit removal on page 4 5 2 68 Service Manual 7100
16. Reconnect operator panel Turn printer on Touch negative lead of voltmeter to metal frame to obtain ground Touch positive lead to engine controller board MCNS 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 14 Is 5 VDC present Go to step 6 Go to step 7 Remove paper tray fill with paper and reinsert Check voltage level on MCNO9 14 Is 0 VDC present 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 engine controller board See Engine controller board removal on page 4 34 Replace paper guide C assembly See Paper guide C assembly removal on page 4 31 Replace paper guide C assembly See Paper guide C assembly removal on page 4 31 Replace cable Check cable continuity between LVPS ACN1 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 41 Replace cable Diagnostic information 2 29 7100 XXX Paper tray missing service check Step Questions actions Yes No 1 Turn pri
17. and ensure charging unit on bottom cartridge See of photodeveloper cartridge is not Photodeveloper cartridge damaged Is charging unit removal on page 4 8 damaged Note photodeveloper 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 8 Has error cleared Note photodeveloper cartridge is a customer ordered part 4 Check cable for continuity between Go to step 5 Replace cable engine controller board connector 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 40 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 ACNA 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 41 Does problem persist Go to step 3 Problem solved
18. o fF WwW N Clean Erase the photodeveloper and transfer Unit in summary the printer RIP board receives the command to print The RIP board then sends a signal to the engine controller board to start the print process The engine controller board is the command center for the EP process The engine card coordinates the various clutches motors and signals The high voltage power supply sends a charge to various components in the EP process The laser fires on the photodeveloper and creates an invisible image on the surface One toner cartridge is pushed against the photodeveloper for each rotation of the OPC and toner is developed on the surface of the OPC The image is then transferred to the transfer unit and the photodeveloper is cleaned and electrically erased This process continues until all four colors have been transferred to the transfer unit Media is picked up from the tray and carried to the registration rollers where it stops and it is timed to enter the EP process at just the right moment Next it is carried to the transfer roller where the image is transferred from the Transfer Unit to the media The media is carried to the fuser rollers where heat and pressure are applied to the page to permanently bond the toner to the page The fuser rollers push the media into the output bin The transfer unit is cleaned and the process begins again for the next page Diagnostic aids 3 9 7100 XXX Summary of the EP process on
19. 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 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 MCN1 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 Fan motor and assembly See Rear cover interlock switch locations on page 5 6 assembly removal on Reconnect operator panel Turn printer on page 4 14 Retest printer If and check for 24VDC between engine error clears problem controller board MCN1 pin 4 and power solved otherwise go to step ground you can touch negative lead of 3 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 MCN1 and power board See Engine supply fan Check cable for continuity and controller board removal pin shorts Is cable okay on page 4 34 2 22 Service Manual High voltage power supply HVPS service check 7100 XXX Step Questions actions Yes No 1 Remove photodeveloper cartridge Replace photodeveloper Go to step 2
20. 18 Signal 19 SRD 20 IRQN 21 SWR 22 Signal 23 Reset 24 GND 25 Signal 26 Signal 27 GND 28 GND 29 Signal 30 SSD_PWM 5 18 Service Manual 6 Preventive maintenance There is no preventive maintenanc e the X5xx series MFPs are installed by the customer 7100 XXX performed by a service technician for this printer Maintenance parts for y Preventive maintenance 6 1 7100 XXX 6 2 Service Manual 7100 XXX T 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 7100 XXX Assembly 1 Base printer DM Z Ny q 4 N 7 1 f Y if 1 AN NS JX n 1 x 1 1 1 7 2 Service Manual 7100 XXX Assembly 1 Base printer index P N Units Description 1 1 40X4702 1 ADF separator roll assembly 2 40X4703 1 ADF separator pad 3 40X3383 1 Cover cleaning roller 4 40X3382 1 Roller cleaning 5 40X3412 1 Transfer unit 6 40X3418 1 Transfer roller assembly 7 40X4694 1 Paper tray universal 8 40X0297 1 Power cord USA 8 40X
21. Laserprodukte der Klasse gelten als unschadlich Im inneren des Druckers 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 Klasse bersteigen w rde Menschen keinesfalls erreicht 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 Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe 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 prodott
22. Pin Voltage Signal Pin Voltage Signal 1 LFCN RET 8 PSCST1 2 24 F2 9 PEL1 P 3 PKCLL10N N 10 OCST1 N 4 NC SGND 11 SGND 5 PSL1 12 5V S 6 PSL2 13 LFCN CHK N PSL3 14 5V 1 MCN8 12 Pin Toner Sensor TTR TDP Pin Voltage Signal Pin Voltage Signal 1 LEDON P 7 NC SGND 2 TLES K P 8 TLES C P 3 TLESCHK 9 TLESSCN N 4 TLES Y P 10 SGND 5 SGND 11 ELON N 6 TLES M P 12 24V F2 LVCN 14 Pin LVPS Pin Voltage Signal Pin Voltage Signal 1 5V 8 ACSYNC N 2 5V 9 24V 3 24V 10 PGND 4 NC SGND 11 24V 5 HON 12 PGND 6 ACOFF P 13 CN CHK LVPS 14 SGND FUCN 6Pin Pin Voltage Signal Pin Voltage Signal 1 TH1 4 TH2 2 5 FUTEMP 3 6 SGND Locations and connectors 5 13 7100 XXX POCN 30 Pin LVPS Pin Voltage Signal Pin Voltage Signal 1 5V CNT 16 SGND 2 PSGNT CNT 17 5V 1 3 5V CNT 18 SGND 4 PSGNT CNT 19 PGND 5 5V CNT 20 PGND 6 PSGNT CNT 21 24V 1D 7 3 3V 2 22 PGND 8 PSGND 23 24V 1D 9 3 3V 2 24 PGND 10 PSGND 25 24V 11 3 3 2 26 PGND 12 PSGND 27 24V 1D 13 5V 1 28 PGND 14 SGND 29 24V 15 5V 1 30 PGND 5 14 Service Manual RIP board 7100 XXX
23. 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 8 cable and toner empty sensor receiver TTR cable See Toner sensor receiver removal on page 4 43 for steps to gain access to sensor cable MCN8 Toner empty sensor sender pin 2 pin 1 pin 4 pin 2 pin 6 pin 3 pin 8 pin 4 pin 9 pin 5 pin 10 pin 6 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 receiver TTR See Toner sensor receiver removal on page 4 43 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 Diagnostic information 2 27 7100 XXX Lower feed unit secondary paper assembly 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 ste
24. on page 4 25 2 54 Service Manual 7100 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 6 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 40 Diagnostic information 2 55 7100 XXX Residual image service check PE Mottle amp TPE Mottl Image of preceding page appears on every other page Problem area Action 1 Transfer unit cleaning roller 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 4 2 HVPS Replace faulty HVPS See High voltage power supply HVPS removal on page 4 40 2 56 Service Manual Ribbing service check 7100 XXX Light print occurs in right or left side of image Problem area Action 1 Printer is not level Table printer is sitting
25. 3 Replace registration clutch Measure resistance between two outer pins See Clutch removal on on paper feed clutch Does resistance page 4 27 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 27 persists replace faulty registration clutch See Clutch removal on page 4 27 Diagnostic information 2 19 7100 XXX OPC belt marker sensor service check Step Questions actions Yes No 1 Remove photodeveloper cartridge and Go to step 2 Replace photodeveloper check for defects Does photodeveloper cartridge appear okay 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 in
26. 5 Remove the paper feed clutch See Clutch removal on page 4 27 Repair information 4 27 7100 XXX 6 Remove five screws A that secure the main drive gear assembly to the MFP Note screw A B shown removed 7 Remove two screws B that secure the lower right frame 8 Remove the main drive gear assembly from the MFP 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 the main drive gear assembly See Main drive gear assembly removal on page 4 27 2 Loosen the two screws A of the sensor base to allow free movement of the waste toner feeder 4 28 Service Manual 7100 3 Remove screw B from the waste toner feeder pipe 4 Remove the waste toner feeder pipe from the waste toner bottle holder 5 Pull and remove the waste toner feeder from the MFP Repair information 4 29 7100 XXX Rear removals Bracket assembly removal Remove the erase lamp See Erase lamp removal on page 4 20 Remove two screws A Disconnect connector B from the transfer belt marker sensor Disconnect connector C from the toner density sensor C 5 Lift and remove the bracket assembly 4 30 Service Manual 7100 Paper guide assembly removal 1 Remove the registration assembly See Registration assembly removal on page 4 33 2 Remove
27. Check the op panel cable continuity Is there Go to step 4 Replace the flatbed unit continuity See Flatbed assembly removal on page 4 50 4 Check Voltages on J PNL1 located on the Replace the operator panel Replace the system board RIP card Pin 1 voltage should measure 5V See Operator panel See System board Is it correct removal on page 4 58 removal on page 4 36 USB service check Step Questions actions Yes No 1 Is the USB cable properly connected to the Go to step 2 Properly connect the cable MFP and host PC at both ends 2 Try a different USB cable Does this fix the Issue fixed Go to step 3 issue 3 Connect a different device to the USB cable Replace the RIP system There is an issue with the Did the host PC see the device board See System board host machine removal on page 4 36 Network service check Step Questions actions Yes No 1 Ping the using the address on the Go to step Go to step 2 op panel Is it responding 2 Is the ethernet cable properly connected to Go to step 3 Properly connect the cable the network card RJ 45 connector to the RJ 45 jack 3 Check to see if DHCP is being used on the Go to step 4 Go to step 5 network Is DHCP used 4 Does the MFP IP address match the ports Go to step 5 Have the network admin IP address on the driver create a port on the host PC matching the IP address on the
28. Is there continuity cable 4 Check the voltages from connector J Replace the modem card Replace the system board FAX10n the RIP card Check pins 1 and 2 See Modem card See System board for 3 3V Pins 24 27 and 28 are grounds removal on page 4 46 removal on page 4 36 Are there signals or voltages present Diagnostic information 2 43 7100 XXX 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 See 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 and replace if necessary See Transfer roller removal on page 4 6 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 uni
29. MFP Assign the new port to the driver 5 Have the network admin try a new network Problem resolved Replace the system board cable to the MFP Did this fix the problem See System board removal on page 4 36 2 40 Service Manual 7100 XXX Scanner Copy Fax service checks Black page copy service check Step Questions actions Yes No 1 Print a menu page or a page from the host See High voltage power Go to step 2 Is the page black supply HVPS service check on page 2 23 2 Is the CCD ribbon cable properly connected Go to step 3 Properly connect the ribbon to J CCD on the system board cable to J CCD 3 Check for 3 3VDC on pins 12 and 16 on Replace the flatbed unit Replace the system board connector J CCD Pins 10 and 20 are See Flatbed assembly See System board 5VDC Pin 8 is 12VDC Are the voltages removal on page 4 50 removal on page 4 36 present Flatbed service check Step Questions actions Yes No 1 Check to see if the flatbed is locked Is it Unlock the flatbed Go to step 2 locked 2 Ensure that the flatbed motor cable JFB1 Go to step 3 Properly connect the cable is connected Is the cable connected 3 Check pin 1 in J FB1 for voltage The Replace the flatbed unit Replace the system board voltage is only present when a copy job is See Flatbed assembly See System board running The voltage should measure 5V Is removal on pa
30. Manual 7100 7 Route the cables through the RIP cage and around the fuser fan 8 Remove the ribbon cable guide from the ribbon cable and flatbed unit 9 Remove the four screws C that attach the flatbed to the scanner arms Repair information 4 51 7100 XXX 10 Tilt the scanner assembly vertically carefully pulling the white slides off of the flatbed 11 Lift the flatbed assembly off of the printer engine base 4 52 Service Manual 7100 Scanner arm removal 1 Remove the flatbed assembly See Flatbed assembly removal on page 4 49 2 Remove the screw A securing the scanner armlock to the printer top cover 3 Tilt the top of the scanner arm to the center of the MFP and remove the armlock B Note Save the armlock for the new scanner arm 4 Continue tilting the scanner arm and pull the arm outward and up 5 Lift the scanner arm up and away from the printer top cover Repair information 4 53 7100 XXX 6 Repeat steps 3 4 and 5 for the other arm if needed Note If you are replacing the scanner arm remove the spring from the old scanner arm The spring will go on the new arm ADF unit removal Remove the upper left rear cover See Upper left rear cover removal on page 4 17 Remove the left rear cover See Left rear cover removal on page 4 16 Remove the system board cover Remove the screw B that secures the ADF and flatbed ground wires to the RIP cage
31. Photo 13 Shift Press to access the other 10 speed dial settings 14 Speed Dial One Scan mode One touch key for Push Scan with one shift key to switch to 20 sets touch dial Fax mode One touch key for Fax with one shift key to switch to 20 sets 15 Re dial Pause Scan mode Display the latest push scan profile Fax mode Redial or pause a Fax job 16 Hook Fax mode Hook 17 Directory Scan mode Search Push Scan profile by name for a Push Scan job Fax Mode Search Fax phone numbers by name or speed dial code 3 2 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Retrieving printing and restoring the MFP settings Printing the maintenance and configuration pages Before replacing the engine controller board or the system RIP board print out the maintenance and configuration pages These page contain the MFP setting information that will need to be reset on the new board Printing the maintenance page 1 in Ready mode press 4 The MFP will enter the admin menus 2 Press A twice to scroll to the Reports menu 3 4 5 Press Press W once to scroll to the Maintenance Page item Press and hold J The maintenance page will print out Printing the configuration page in Ready mode press 4 The will enter the admin menus 1 2 Press A twice to scroll to the Reports menu 3 4 5 Press V Press W XX times to scroll to C
32. Rear cover assembly 7 5 Panel operator X500 4 Paper tray universal cccccccmcmIIII III III 7 3 Panel operator X502 7 7 Board Network RIP US 7 15 Cover top left 7 5 Cover top right 7 5 Assembly flatbed 7 7 Assembly ADF 7 7 Assembly ADF separator roll 7 3 Assembly pick roll 7 7 Pad ADF separator rrr rrr rrr rrr rere 7 3 7 7 Power supply 110 V low voltage 7 45 Power supply 220 V low voltage 7 15 Arm right left scanner 7 5 Tray ADF input 7 7 Speaker modem 7 17 Card modem US
33. Remove the cleaning roller clutch from the MFP Repair information 4 25 7100 XXX Main motor assembly removal 1 Remove the right cover See Right cover removal on page 4 13 2 Disconnect the main motor assembly cable A from the main motor 3 Remove 4 screws B from the main motor assembly 4 Remove the main motor assembly from the MFP 4 26 Service Manual 7100 Clutch removal Note This procedure applies to the transfer roller clutch registration clutch and the paper feed clutch The transfer clutch removal is shown This removal is typical for the others 1 Remove the right cover See Right cover removal on page 4 13 2 Disconnect the clutch cable A 3 Remove the clip B from the clutch 4 Slide the clutch away from the MFP to remove Main drive gear assembly removal 1 Remove the cleaning roller clutch See Toner sensor sender removal on page 4 24 2 Remove the main motor assembly See Main motor assembly removal on page 4 26 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 beginning of this procedure because the main drive gear assembly FRU does not include the clutches 3 Remove the transfer roller clutch See Clutch removal on page 4 27 4 Remove the registration clutch See Clutch removal on page 4 27
34. SE NM NEUEN Rs 3 6 Fax tists EE Qe ded MGR E E mee 3 6 Density aspi ave teens QAM Secaucus 3 8 Panor thean or Operon 323i ma dia swa pap e drea pau d aq ds teaser ema dd PR dpa Pd 3 9 Eloctrophetographic Pracsss EP DIODOSS mp Rep ears cadence wedge 3 9 EMI du RE DRUG AGES ee 3 9 Summary of the EP process on the XbOD a isse ex exu x Rs Rx xcu dw WIR x Roma cx x Re am n 3 10 AVO EFP SERS IN dolall z35 24 34 phe ape 3 11 Printer ERE 3 19 Paper Pall COMPONGMS P RUE RUNE 3 20 ASUUI WON aod aci cQ Ga MOSES Sega qud cq au sd eed 3 20 Pape aiti Messa O aiios eiae quee cdd dac 3 22 TOIT edad diane d ecsegracnn osos dd dap imams adam eae 3 23 Papadam ds qus Reap RS RES Nome MEN 3 24 Paper Jam e OA lay 2o use qoe dde quee i dtd qe 3 26 Paper d
35. X X X X A5 148 x 210 5 83 x 8 27 X X JIS B53 182 x 257 7 17 x 10 1 X X X Letter 216 x 279 4 8 5 x 11 X X X X Legal 216 x 356 8 5x14 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 5x8 5 X X Universal X X X Standard 250 sheet letter tray 104 8 x 210 to 215 9 x 4 425 x 8 27 to 8 5 x 297 11 7 Optional 250 sheet legal tray 104 8 x 210 to 215 9 x 4 425 x 8 27 to 8 5 x 14 355 6 Envelope sizes Dimensions Dimensions 9 Envelope 98 4 x 225 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 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 3 B5 may be supported in optional tray 1 but size sensing must be turned off Output capacity by media and 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 Facedown General information 1 9 7100 XXX Scan specifications Resolution 1200 X 2400 Scan size 216mm X 297 mm flatbed Window size 220mm X 300mm Scan depth 48 bits Lamp warm up time Less than
36. XXX Spacing table Roller specifications Repeating defect on Name of roller ma ni of rotations Pr n Registration assembly rubber roller g 14 283 43 Registration assembly steel roller g 12 321 38 Transfer roller 20 194 63 Developer roller g 18 345 35 bok oni belt drive roller part of transfer 30 128 95 Transfer belt cleaning roller 26 182 67 OPC belt charge brush part of d 256 47 photodeveloper charging system di ss belt drive gear shaft 5 256 47 OPC belt drive roller g 30 128 95 Fuser roller part of fuser g 41 95 128 Fuser belt part of fuser 30 128 95 Paper exit roller part of paper exit 16 246 50 assembly Diagnostic information 2 69 7100 XXX 2 70 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX 3 Diagnostic aids This chapter explains the tests and procedures to identify MFP failures and to verify repairs have corrected the problem Understanding the MFP operator panel Stop Clear Y The use of the buttons and the layout of the operator panel is described in the following table Number Button Function 1 LCD Display All modes Displays messages and prompts during operation Displays settings when new settings are specified 2 Alpha Numeric Enters numbers and letters in the setting menu Keys Copy mode Enter copy quantity Scan mode E
37. amie heic GO asa a bg og od 2 32 Missing photodeveloper cartridge service check 2 33 Trangier roller missing serdea CHBOK wha EN 2 34 GVBl BDOU ilic a cp Pers eq e ESI RE NE PES 2 35 OPC belt photodeveloper cartridge drive service 2 36 Misang Tuser Service CHECK 55 dene xd sage mcd me ANE NGC 2 36 Paper size sensing service alee exes 2 37 Printer nopdwel servico GDIBCE unus eu sa x aed SP RM d Schola A pe dus Gee 2 38 Toner iced Service da deer Aedes n qas mad Re e aem 2 39 Waste toner food Servia check ausus ma rim pic d DS RET GM RM RARE PN E ES ERAN EE as 2 39 Operator panel seice ChBDK RR E PT ES desse NET 2 40 USE comi aeh ssoads etd PRAE PAM 2 40 S9IVIOE sug arat i d wed ae dosi a uon d ah udi wera du ado d wo 2 40 Black paga copy servito CHECK oues esce e seas ad amd aq rs eos 2 41 Flatbed Servi S CODEC asa quamdgad Nader EN qaad s qd qudd MG 2 41 SEIVICE CHOC ua supe qu
38. be used on the new top cover See Scanner arm removal on page 4 52 Repair information 4 11 7100 XXX Front cover assembly removal 1 Open the front cover assembly 2 Remove the 8 screws A from the inner front cover A 3 Disengage the support strap from the MFP 4 Release the tabs on the front cover 5 Remove the front cover from the inner front cover 6 Raise the inner front cover 4 12 Service Manual 7100 7 Rotate the support pin away from the and slide toward the center of the to remove Repeat for the other support pin 8 Remove the front inner cover from the MFP Right cover removal 1 Remove the waste toner bottle See Waste toner bottle removal on page 4 7 2 Remove the top cover assembly See Top cover assembly removal on page 4 10 3 Remove 2 screws A from the bottom of the right cover y 4 Remove the right cover from the MFP Maneuver the front cover for easy removal Repair information 4 13 7100 XXX Rear cover assembly removal Remove the fuser assembly See Fuser assembly removal on page 4 6 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 Remove the right cover See Right cover removal on page 4 13 Disconnect the rear cover assembly connector A Remove the support pin B disconnecting the support cable from the MFP Remove two screws C from the rear cover assembly EW Ox gr deco mor cm
39. board removal on page 4 34 Engine controller board MCNA pin 3 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 LVPS ACN pin 2 to rear cover interlock switch pin 2 Are any cables defective Diagnostic information 2 35 7100 XXX OPC belt photodeveloper cartridge drive 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 8 Note photodeveloper 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 26 on page 4 27 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
40. 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 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 Repair information 4 3 7100 XXX MFP 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 removal 1 Raise the scanner unit 2 Open the top cover 3 Depress the tabs and remove the cleaning roller cover Transfer belt cleaning roller removal 1 Remove the cleaning roller cover See Cleaning roller cover removal on page 4 4 2 Lift and remove the transfer belt cleaning roller 4 4 Service Manual 7100 Transfer belt unit removal 1 Open the rear cover assembly 2 Rotate the
41. is not installed Paper is jamming at feeding area Ensure transfer roller is properly installed If problem persists see Transfer roller missing service check on page 2 34 See Paper Jam 1 rear tray 1 on page 3 24 or Paper Jam 2 rear tray 2 on page 3 26 for instructions to clear the jam Paper Jam B Paper is jamming inside See Paper Jam B rear on page 3 27 for the MFP instructions to clear the jam Paper Jam C Paper is jamming at paper See Paper Jam C rear on page 3 29 for exit area instructions to clear the jam Cover Open The back front or OPC Close specified cover if open If not open open Close Front Rear OPC cover is open the cover and close If the problem persists see Cover open service check on page 2 35 TR Belt Life Replace Transfer Belt The transfer belt is at its end of life Replace the transfer belt See Transfer belt unit removal on page 4 5 TR Kit Life Replace PQ Kit The transfer roll and transfer belt cleaning roll have reached the end of life Replace the transfer roll See Transfer roller removal on page 4 6 Also replace the transfer belt cleaning roller See Transfer belt cleaning roller removal on page 4 4 PF1 Kit Life Replace PF Kit 1 The paperfeed roll and separator pad in tray 1 are at the end of life PF2 Kit Life Replace PF Kit 2 The paperfeed roll and separator
42. pad in tray 2 are at the end of life Replace the paperfeed roll and the separator pad for the respective paper tray 1 or 2 See Paper feed roller removal on page 4 32 ADF Jam Open ADF cover and Clear Jam A sheet of paper is jammed in the ADF Clear the ADF jam If the message persists see ADF streak service check on page 2 41 ADF Cover Open Close ADF cover The ADF cover is open Close the ADF cover If the cover is already closed see ADF streak service check on page 2 41 Scan Calibration Error Scanner is out of calibration Perform scanner calibration Scan Lock Error Unlock Scanner The scanner lock is in the locked position Unlock the scanner If the scanner lock is in the unlocked position see Flatbed service check on page 2 41 Diagnostic information 2 9 7100 XXX Message Description Action Scan USB Disconnect The USB connection is disconnected See USB service check on page 2 40 Scan Network Disconnect The network connection is disconnected See Network service check on page 2 40 Duplicate IP Address Found Another device using an identical IP address has been detected on the network Contact the network administrator E mail Size Limit Exceeded E mail memory buffer full Retry the job Break it up if needed Out of Memory Memory depleted Retry the print job Break it up if need
43. page 2 14 Transfer belt unit makes noise when rotated or does not rotate at all See Transfer belt unit service check on page 2 17 The transfer roll is not transferring images or does not turn See White band service check on page 2 63 No power See Printer no power service check on page 2 38 Waste toner feed problems See Waste toner feed service check on page 2 39 Fans not working or making noise See Service error codes on page 2 3 Find the failing fan and follow the action suggested Print image problems See Print quality symptom table on page 2 13 Photodeveloper cartridge does not rotate or makes noise See OPC belt photodeveloper cartridge drive service check on page 2 36 Black copies from scanner See Black page copy service check on page 2 41 Fail to scan from the flatbed See Flatbed service check on page 2 41 Paper jams in the ADF See ADF paper feed service check on page 2 42 Paper skews when fed into the ADF See ADF paper feed service check on page 2 42 Paper fails to feed into the ADF See ADF paper feed service check on page 2 42 Op panel failure See Operator panel service check on page 2 40 Fax fails to transmit See Modem fax card service check on page 2 43 Fax appears stretched or compressed Issue with sending fax machine Streaks down the middle of a copy fax or s
44. page 2 48 Vertical line Vertical staggering image See Vertical line service check on page 2 60 See Vertical staggering image service check on page 2 61 Banding See Banding service check on page 2 47 White band See White band service check on page 2 63 Toner drop See Toner drop service check on page 2 59 White spots and black spots See White spot black spot service check on page 2 65 Mixed color image See Mixed color image service check on page 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 66 Insufficient fusing See insufficient fusing service check on page 2 50 Diagnostic information 2 13 7100 XXX 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 13 cartridge Open top cover and override top cover interlock switch Restart printer and observe Note photodeveloper main motor and photodeveloper
45. page 4 10 Remove the transfer belt cleaning roller See Transfer belt cleaning roller removal on page 4 4 Remove two screws A from the waste toner auger remove the waste toner auger op oO No Waste toner agitator removal 1 Remove the waste toner auger See Waste toner auger removal on page 4 47 2 Remove gear A from the cleaning roller clutch 3 Pull the agitator off the shaft lift and remove 4 48 Service Manual 7100 Power supply fan removal 1 Remove the top cover assembly See cover assembly removal on page 4 10 2 Disconnect the modem speaker cable from the system board and carefully route the cable through the engine board cage 3 Remove screw A from the power supply fan 4 While holding the fan disconnect the cables B from the interlock switches and remove the power supply fan Repair information 4 49 7100 XXX Scanner assembly removals Flatbed assembly removal Remove the left rear cover See Left rear cover removal on page 4 16 Remove the RIP System board cover See System board removal on page 4 36 Open the MFP rear cover Remove the screws A securing the upper left and right covers AT 5 Remove the ADF unit See ADF unit removal on page 4 53 6 Disconnect the CCD ribbon cable the operator panel cable and the flatbed motor cable from the System board 4 50 Service
46. 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 if defective See Waste toner auger removal on page 4 48 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 28 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 5 Replace cleaning roller See Transfer belt cleaning roller removal on page 4 4 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 Diagnostic information 2 59 7100 XXX Vertical line service check A vertical line appears in printed image Problem area 1 Photodeveloper cartridge OPC belt and transfer belt Action Foreign particles dust and so on adhere to parts located around photodeveloper cartridge and transfer belt unit which consequently contact toner image on
47. places B 5 Remove the operator panel Repair information 4 59 7100 XXX 4 60 Service Manual 7100 5 Locations and connectors Printer front and rear views Top cover assembly y Rear cover assembly Paper stopper Right cover Front cover Paper ever Upper left Left front cover cover Left rear cover USB connection Modem jack S Network en connection AC input q inlet Power switch Locations and connectors 5 1 7100 XXX Part name Description Paper stopper Stopper for exited papers 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 Front cover Covers the right side of the printer where the motors and drives are located Printer front enclosure that opens allowing toner cartridge or waste toner bottle replacement Paper tray Left front cover Standard paper tray that holds printer paper Covers the left side of the printer over the MFP engine card Left rear cover Covers the left side of the prin
48. 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 6 2 Transfer roller clutch Replace faulty transfer roller clutch See Clutch removal on page 4 27 Diagnostic information 2 63 7100 XXX 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 Printing the maintenance and configuration pages on page 3 3 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 White line Il service check amp Vertical white line appears from leading edge to trailing edge of printed image 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 8 Open dust proof glass cover Clean glass There are foreign particles adhering to laser beam opening of printhe
49. removal on page 4 8 Fuser Life Replace Fuser Replace with a new fuser unit See Fuser assembly removal on page 4 6 TR Belt Life Replace Transfer Belt Replace with a new transfer belt unit See Transfer belt unit removal on page 4 5 Missing install 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 2 8 Service Manual 7100 Message Description Action Toner Error install Supported Cartridge An invalid toner cartridge is installed install a supported cartridge If the problem persists see Missing toner cartridge service check on page 2 32 Missing install Toner C M Y K A toner cartridge is not keyed properly install proper brand of toner cartridge If problem persists see Missing toner cartridge service check on page 2 32 Missing install OPC Belt The OPC 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 33 Missing install Transfer Roller Paper Jam A 1 2 The transfer roller
50. sensor Scanner motor p Fuser connection Fuser unit MCN3 MCN3 Locations and connectors Exit fan Waste toner sensor sender Laser assembly 5 9 7100 XXX Engine controller board connections HVCN 21 pin Connects to HVPS Pinz Voltage Signal Pin Voltage Signal 1 HVUCNCHK N 12 BRVPWM N 2 PGND 13 PWMON N 3 ID PGND 14 DCVP N 4 FCBVPWM N 15 BRVON N 5 THV I 16 24V 1D 6 DBV KY PWM N 17 24V 1D 7 THVPWM N 18 24V 1D 8 DBV MC PWM N 19 PGND 9 THVRON 20 PGND 10 CBVPWM N 21 PGND 11 BRVERR LCN 24 Pin Connects to LSU assembly Pinz Voltage Signal Pin Voltage Signal 1 45V 1R 13 BDT P 2 LCONT 1 14 LDREF 0 3 LREADY 15 BDT N 4 LCONT2 16 VCC 5 SGND 17 SGND 6 LDREF 4 18 SGND 7 VIDEO N 19 SCMRDY N 8 LDREF 3 20 SCMCLK 9 VIDEO P 21 PGND 10 LDREF 2 22 SCMON N 11 SGND 23 24V 1 12 LDREF 1 24 3 3V 5 10 Service Manual MCN9 14 Pin Connects to transfer unit toner density registration and paper sensors Pinz Voltage Signal Pinz Voltage Signal 1 5V S 8 V02 k 2 VCC 9 PTI N 3 TBEN N 10 V01 YMC 4 LED 11 SGND 5 SGND 12 5V S 6 SGND 13 SGND 5V S 14 PEV P MCN2 3 Pin Toner present sensor Pin Voltage Signal Pin Voltage Signal 1 Toner OK N 3 SGND 2 5V S MC
51. set the fax compression setting The options are JBIG MMR MR and MH This can also be changed in the user menus When Encoding is selected use the A and w keys to navigate to the desired encoding and press to select the new setting Press 3 to exit Protocol Definition Timer These settings affect the time duration before a protocol used to transmit a fax is switched This setting is country or region dependent and should not be changed without supervision of a second level support person TO Timer T1 Timer T4 Timer RX Settings Silence Detection Time CNG Tone Detection Time CNG Cycles Tone Sound Monitoring Stop Clear Key This makes the key functional or non functional Diagnostic aids 3 7 7100 XXX Lexmark confidential until announce edited 1 4 2007 Density Tune Up These settings adjust the density of the separate color planes for the copy scan and fax functions These settings should not be adjusted without second level support center supervision The density tune up menu items can be accessed using the and w keys to navigate to the individual settings When the desired modem setting is displayed press S to select the item Copy The COPY settings submenu items can be accessed using the and W keys to navigate to the individual settings When the desired modem setting is displayed press J to select the item Each individual density setting can be adjusted by using the and W to increment or decrement
52. shorted pins on cable that connects MCNS to developer motors Is cable okay 2 16 Service Manual 7100 XXX Step Questions actions Yes No 7 Disconnect cable from engine controller Replace engine controller Replace cable that board 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 8 board Remove RIP board Pin 21 to pin 22 24VDC cage to gain access to Pin 13 to pin 14 5VDC cable See System board cage removal on Are voltages present page 4 39 Go to step 8 8 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 5 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 f
53. the density value When the desired value is displayed press to accept and set the value Press 5 to exit the submenu item Density Notch 1 0 255 127 is the default Density Notch 2 0 255 127 is the default Density Notch 3 0 255 127 is the default Density Notch 4 0 255 127 is the default Density Notch 5 0 255 127 is the default Scan The SCAN settings submenu items can be accessed using the and w keys to navigate to the individual settings When the desired setting is displayed press to select the item Each individual density setting can be adjusted by using the and w to increment or decrement the density value When the desired value is displayed press 4 to accept and set the value Press 5 to exit the submenu item Density Notch 1 0 255 127 is the default Density Notch 2 0 255 127 is the default Density Notch 3 0 255 127 is the default Density Notch 4 0 255 127 is the default Density Notch 5 0 255 127 is the default Fax The FAX settings submenu items can be accessed using the and W keys to navigate to the individual settings When the desired setting is displayed press to select the item Each individual density setting can be adjusted by using the and W to increment or decrement the density value When the desired value is displayed press to accept and set the value Press to exit the submenu item Normal 0 255 127 is the default Dark 0 255 127
54. 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 it Reinstall cleaning roller 2 60 Service Manual 7100 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 Upper right rear cover removal on page 4 17 Diagnostic information 2 61 7100 XXX Vertical white band service check White band appears in vertical direction of printed image Problem area Action 1 Toner cartridge Replace faulty toner cartridge 2 Photodeveloper cartridge Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 3 Transfer belt unit Replace faulty transfer belt unit See Transfer belt unit removal on page 4 5 2 62 Service Manual 7100 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
55. two screws A that attach the paper guide assembly to the MFP Screws are located in holes 3 Lift and remove the paper guide assembly B from the MFP Paper guide C assembly removal Remove the paper guide assembly See Paper guide assembly removal on page 4 31 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 Remove the support pin disconnecting the support cable A from the MFP Remove the two screws B that attach the paper guide C assembly to the MFP Boo m oL B A 5 Disconnect two sensor cables from the sensors located on the paper guide C assembly and remove the paper guide C assembly Repair information 4 31 7100 XXX Paper feed roller removal 1 Remove the paper guide C assembly See Paper guide C assembly removal on page 4 31 2 Slide the paper feed roller off the shaft to remove Paper exit assembly removal 1 Remove two screws A 4 32 Service Manual 7100 2 Disconnect the cable B 3 Remove two screws C Registration assembly removal 1 Remove the transfer roller See Transfer roller removal on page 4 6 2 Remove three metal screws A and three plastic screws B 3 Lift and remove the registration assembly Repair information 4 33 7100 XXX Left side removals A Warning Before replacing the engine controller board save the onboard settings See Printing the maintenance and configuration pages on pag
56. 00 XXX Assembly 8 Top m GC S 7 Y VG S SS 7 16 Service Manual Assembly 8 7100 XXX index P N Units Description 8 1 40X3402 1 Auger waste toner 2 40X3403 1 Agitator waste toner 3 40X3434 1 Assembly marker sensor OPC includes bracket 4 40X4691 1 Assembly fuser fan 5 40X4690 1 Fan power supply includes top cover interlock switch and rear cover assembly interlock switch 6 40X4710 1 Speaker modem Parts catalog 7 17 7100 XXX Assembly 9 Miscellaneous Options 7 18 Service Manual Assembly 9 Miscellaneous Options 7100 XXX index P N Units Description 9 1 40X3421 1 Assembly secondary paper feed NS 40X4717 1 Parts packet harness NS 40X3442 1 Cable 120V fuser NS 40X3443 1 Cable 240V fuser NS 40X4718 1 Parts packet screw NS 7372640 1 Field relocation kit NS 14D0403 1 Cable USB 2 meter Parts catalog 7 19 7100 XXX 7 20 Service Manual Index A Accessing jam areas 3 23 acronyms 1 17 ADF mechanism cover removal 4 55 ADF paper jams 3 30 ADF unit removal 4 53 bracket assembly removal 4 30 C cleaning roller clutch removal 4 25 cleaning roller cover removal 4 4 clearances 1 4 clutch removal 4 27 copy specifications 1 11 CRU FRU and supplies removals 4 4 D developer drive assembly removal 4 22 diagnostic aids 3 1 diagnostic information printer service checks 2 14 service e
57. 1766 1 Power cord LV USA APG Bolivia Canada Columbia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Nicaragua Panama Peru Venezuela 8 40X0301 1 Power cord HV Argentina 8 40X1767 1 Power cord HV Brazil 8 40X0273 1 Power cord HV Chile 8 40X0286 1 Power cord HV UK Ireland 8 40X0278 1 Power cord HV Austria Belgium Euro English Finland France Germany Greece Netherlands Norway Poland Portugal Russia Slovakia Czech Hungary Spain Sweden Turkey 40X0275 1 Power cord HV Israel 8 40X0274 1 Power cord HV Switzerland French Switzerland German Switzerland Italian 8 40X0276 1 Power cord HV South Africa 8 40X0287 1 Power cord HV Italy 8 40X0279 1 Power cord HV Denmark NS 40X4716 1 Cover Legal Extender Parts catalog 7 3 7100 XXX Assembly 2 Covers 7 4 Service Manual Assembly 2 Covers 7100 XXX index P N Units Description 2 1 40X4686 1 Cover assembly top 2 40X4706 1 Arm scanner contains the left and right arms 3 40X4698 1 Cover top left 4 40X4699 1 Cover top right 5 40X4692 1 Rear cover assembly includes 40X3428 and 40X3430 6 40X3428 1 Assembly paper exit contains fuser exit sensor and flag 7 40X4718 1 Packet parts 8 40X3430 1 Assembly registration 9 40X3385 1 Cover right 10 40X3388 1 Cover front 11 40X3387 1 Cover inner front 12 40X4687 1 Cover front left 13 40X4688 1 Cover rear left NS 40X4716 1 Cover legal extende
58. 2 24 H2 Service Call Fuser Unit Fusing temperature is not reached within the warming up time period See Fuser assembly service check on page 2 24 H3 Service Call Fuser Unit 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 24 2 4 Service Manual 7100 XXX Error code Action H4 Service Call Fuser Unit 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 24 HA Service Call Fuser Unit AC relay turned off due to an abnormal temperature See Fuser assembly service check on page 2 24 L1 Service Call Laser Unit Assembly Laser scanning beam is not detected by beam sensor See Laser unit assembly service check on page 2 25 L2 Service Call Laser Unit Assembly Scanner motor SM is rotating abnormally See Laser unit assembly service check on page 2 25 LL Service Call Laser Unit Assembly Laser power is lower than the output limit See Laser unit assembly service check on page 2 25 N3 Service Call HVPS Connection N4 Service Toner Empty Sensor Improper connection between engine controller board and HVPS See HVPS connection service check on page 2 25 Improper connection between engine controlle
59. 2 36 missing photodeveloper cartridge 2 33 missing toner cartridge 2 32 modem fax card 2 43 network 2 40 OPC belt photodeveloper cartridge drive 2 36 OPC belt marker sensor 2 20 operator panel 2 40 paper feed 2 44 paper feed clutch 2 19 paper size sensing 2 37 paper tray missing 2 30 power supply fan 2 22 print quality 2 45 back stain 2 46 background 2 45 banding 2 47 black line 2 48 color misregistration 2 49 insufficient fusing 2 50 insufficient gloss 2 51 jitter 2 52 missing image at edge 2 53 mixed color image 2 54 mottle 2 55 residual image 2 56 ribbing 2 57 smear 2 58 toner drop 2 59 uneven density right and left 2 68 vertical line 2 60 Index 3 7100 XXX vertical staggering image 2 61 vertical white band 2 62 white band 2 63 white line 2 64 white line 1 2 64 white print 2 66 white spot black spot 2 65 wrinkle image migration 2 67 printer 2 14 printer no power 2 38 printer paper feed 2 44 registration clutch 2 19 toner empty sensor receiver TTR 2 27 toner empty sensor sender TPD 2 26 toner feed 2 39 toner low empty 2 31 transfer belt cleaning roller clutch 2 18 transfer belt unit 2 17 transfer roller clutch 2 18 transfer roller missing 2 34 tray empty 2 29 USB 2 40 waste toner bottle 2 31 waste toner feed 2 39 service error codes 2 3 Setting the country code 3 3 spacing table 2 69 specifications 1 2 supported operating systems 1 2 symptom tables MFP 2 11 print quality 2 13 system boar
60. 3 seconds MTF More than 3096 Depth of focus 2 mm to 2 mm Magnification Less than 0 596 Scanning TWAIN Connectivity USB 2 0 and Ethernet 10 100 Base TX TCP IP only Push scan Scan to E mail scan to FTP scan to host PC Web status monitor Yes Scanner driver TWAIN features Scan mode True color grayscale black amp white Contrast adjustment Yes Brightness adjustment Yes Color Mono switch Yes Scan to E mail feature Network requirements TCP IP and an SMTP gateway Authorization function SMTP authentication POP3 before SMTP Register E mail address By Web page Scan destination Set up in scan profile E mail address maintenance By Web page Job Search By profile name Subject input 20 characters maximum Entered by the Web page interface Maximum E mail data size Supported file formats TIFF JPEG PDF 1 10 Service Manual Copy specifications 7100 XXX Resolution 600 dpi X 600 dpi flatbed 600 X 300 dpi ADF Print from copy 600 X 600 dpi 9600 dpi X 9600dpi w software interpolation Original paper sizes A4 Letter Legal ADF only B5 JIS Executive Copies per minute Mono up to 21 Color up to 7 Time to first copy Less than 30 seconds Multiple copies 99 copies maximum Output paper sizes A4 Letter Legal optional cassette only Imag
61. 8 Note photodeveloper 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 26 on page 4 27 2 36 Servi ce Manual Paper size sensing service check 7100 XXX 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 7 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 41 4 If paper tray is removed set paper tray for Replace engine controller Go to step 5 desired paper size and insert paper tray board See Engine into printer Using table below check for controller board removal proper paper size sensor action by taking on page 4 34 voltage readings between ground and engine controller board MCN7 pins 4 6 8 and 10 Is paper size sensor working properly 5 Check c
62. 8 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 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 Print engine 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 MFP operating environment The capacities listed are based on plain paper at 75 g m Sources and capacities X500n X502n Input sources Number of standard sources 1 Number of optional input drawers Maximum number of input sources 2 Maximum input capacity 780 Input capacities Standard input Primary tray capacity 250 Total standard capacity 250 Optional input Optional tray 1 capacity 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 MFP supports top output facedown as standard No additional output options are available Note All capacities are based on use of 20 Ib paper G
63. 9 mm ADF length 5 5 to 14 inches 139 7 to 355 6 mm ADF capacity 35 sheets Flatbed width 8 5 inches 216 mm Flatbed length 11 7 inches 297 mm Scanning width 215 9 mm maximum Printing width Legal 215 9 mm X 355 6 mm Letter 215 9 mm X 279 4 mm A4 210 0 X 297 0 mm Fax scan resolutions Horizontal Fixation 200 dpi 8 dot mm Vertical Standard 100 dpi 3 85 dot mm Fine 200 dpi 7 7 dot mm Photo 200 dpi 7 7 dot mm Miscellaneous FAX specifications Halftone error diffusion Error diffusion Speed dial 50 entries name 20 characters number 40 digits Quick dial 20 entries name 20 characters number 40 digits On hook dial Yes Direct Fax number entry Yes Re dial Yes Transmission Immediate transmission Yes Memory transmission Yes Page retransmission Yes Error correction mode Yes Broadcasting Yes 100 entries Reception FAX only mode Yes Manual mode Yes Auto reduction Yes Threshold 74 Error correction mode Yes Reports Activity report Yes Transmission verification report Yes Power failure report Yes Phone book list Yes Quick dial list Yes Speed dial list Yes Memory manage list Yes User parameter list Yes Clear memory transmission file Memory job clear Standard All clear Standard 1 12 Service Manual 7100 XXX Media guidelines Paper desi
64. CP BOOTP WINS SNMP MIB 2 host resources MIB printer MIB enterprise MIB SNMP traps HTTP LPR LPD FTP IPP1 SLP DDNS e AppleTalk This MFP with standard Ethernet supports an Embedded Web Server The current status of the operator panel is viewable using the resident Web pages Processor ARM 11core running at 366mhz Supported operating systems This MFP is compatible with applications running under the following operating systems for either local or network connections Macintosh e Macintosh OS X version 10 2 40 4 and above Power PC and Intel The software applications that operate with most Apple LaserWriter printers will generally operate with this printer Download the latest Lexmark printer PPD files or printer drivers from www lexmark com 1 2 Service Manual 7100 XXX Microsoft Windows Microsoft Windows Me 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 Microsoft Windows Vista 32 64 bit Download the latest printer drivers from http www lexmark com The Windows software applications which operate in the operating systems listed above are best suited to run with the drivers supplied with this MFP The drivers for Windows take advantage of the MFP s functions and increase the MFP s performance wherever possible Memory configuration Standar
65. German Switzerland Italian 7 3 Power HV Israel 7 3 Power cord HV South Africa 7 3 Power cord HV Austria Belgium Euro English Finland France Germany Greece Netherlands Norway Poland Portugal Russia Slovakia Czech Hungary Spain Sweden Turkey 7 3 Power cord HV Denmark 7 3 Power cord HV UK 7 3 Power cord HV Italy 7 3 Power cord USA ie Se NSS Se mabe te oye SRS Seid mabye 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 right 7 5 Cover inner front
66. Image migration Service GNEC uu meae gta ine rt sn te Rea a RR 2 67 Uneven density ight Sandell cn m a RR ee 2 68 SPACING AIG ia secede ETE 2 69 PONGPSHECKIICANONG eeu did pauses d Ups es 2 69 Diagnostic 2 3 1 Hnderstandingtha MEP eperator parl a su 3 1 Retrieving printing and restoring the MFP settings eee eee 3 3 Printing the maintenance and configuration pages 3 3 Soul Ine COUNUY Tess PERS S one Meena ee wns eames 3 3 iV Service Manual 7100 Scanner calibration ana registration 25232 Ru ara qe Sea TESI RETE 3 3 Malltelgice NOUS cri waa dco wicca M d apa eae 3 4 Display WO ac spes pre S sque Pede S MORGEN ox 3 4 3 5 Engine MANONI Kip S 3 6 ic otek Ged S
67. MFPs for presentations business graphics line art and text They use laser diode electrophotographic technology to deliver remarkable quality print images and text The scan and copy functions work with A4 letter and legal ADF only size paper Photographic quality images are possible with scan function The FAX function delivers a wide range of functionality to the office user The MFPs can be used as shared network or desktop devices Models The Lexmark X5xx MFPs are available in the following models Model Configuration Machine type X500n Print copy scan network 7100 010 X502n Print copy scan fax network 7100 110 General information 1 1 7100 XXX MFP Specifications General device technical specifications Interfaces X500n X502n USB 2 0 X X Ethernet 10 100 Base T X X Note The USB 2 0 and network interfaces can be used simultaneously The USB interface supports Windows 98 SE e Windows Me e Windows NT Windows 2000 Professional e Windows XP Operating Systems Windows Server 2003 Operating Systems Windows Vista 32 64 bit e Macintosh OS X version10 1 10 4 Power PC and Intel Note For USB attachment a USB cable P N 12A2405 is recommended and must be ordered separately 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 DH
68. N10 3Pin Power supply fan Pin Voltage Signal Pin Voltage Signal 1 CTFANON P 3 CTFANERR 2 PGND MCN7 12 Pin Marker paper size room thermistor Pinz Voltage Signal Pin Voltage Signal 1 PBSEN N 7 NC SGND 2 VCC 8 PSU3 3 5V S 9 SGND 4 PSU1 10 PSU4 5 SGND 11 TH3 6 PSU2 12 SGND MCN1 6 Pin Exit Fan Pin Voltage Signal Pin Voltage Signal 1 5V S 4 HTFANON P 2 PT2 N 5 PGND 3 SGND 6 HTFANERR 7100 XXX Locations and connectors 5 11 7100 XXX 4 20 Pin Clutches waste toner sensor Pin Voltage Signal Pin Voltage Signal 1 24V 1DF3 11 TBFULL N 2 FBCLON N 12 SGND 3 13 WTLEDON 4 14 SGND 5 24V 1DF3 15 5V S 6 TRSLON N 16 DM1SENin 7 24V 1DF3 17 SGND 8 RECLON N 18 9 24V 1DF3 19 10 PKCLU10N N 20 MCN5 26 Pin Dev motors 1 amp 2 main motor Pin Voltage Signal Pin Voltage Signal 1 DM1 OUT 14 MMGAin 2 24V 1D B COM 15 MMREV N 3 DM1 OUT 16 MMENC 4 DM1 OUT 17 VCC 5 24V 1D A COM 18 SGND 6 DM1 OUT 19 PGND 7 DM2 OUT 20 PGND 8 24V 1D B COM 21 24V 1D 9 DM2 OUT 22 PGND 10 DM2 OUT 23 24V 1D 11 24V 1D A COM 24 MMCLK 12 DM2 OUT 25 MMON N 13 NC SGND 26 MMRDY N 5 12 Service Manual 7100 XXX MCN6 14 Pin LFU
69. OST PQET PSTN RIP SMTP SDRAM SNMP TAD TCP IP VAC VDC WINS Automatic document feeder Application specific integrated circuit Boot protocol Charge coupled device Dynamic domain name service Dynamic host configuration protocol Dots per inch Dynamic random access memory Electrophotographic process Electrostatic discharge Field replaceable unit Hypertext transport protocol High voltage High voltage power supply Joint Bi Level Image Experts Group Local area network Light amplification by simulated emission of radiation Liquid crystal display Light emitting diode Low voltage Low voltage power supply Multiple function printer Nonvolatile random access memory Message handling Modified modified read Modem ready Original equipment manufacturer Private automatic branch exchange Power on reset Power on self test Print quality enhancement technology Public switched telephone network Raster image processor Simple mail transport protocol Synchronous dynamic random access memory Simple network management protocol Telephone answering device Transmission control protocol Internet protocol Volts alternating current Volts direct current Windows internet name service General information 1 17 7100 XXX 1 18 Service Manual 7100 2 Diagnostic information Start CAUTION Remove power from the printer before you connect or disconnect any cable electronic board or assembly for personal safe
70. X Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charts symptom index and service checks to determine the symptom and repair the failure The removals in the repair information chapter may help you identify parts Printer messages e Symptom tables Service checks Repair information After you complete the repair perform tests as needed to verify the repair See Diagnostic aids on page 3 1 Standard inspection and cleaning procedure Switch off printer power and disconnect the AC power cord from the electrical outlet e Remove and inspect the photodevelopers and toner cartridges shielding them from strong light Inspect the interior of the printer removing foreign matter such as paper clips staples pieces of paper or transparencies paper dust hair oil grease or toner Clean the printer interior using a lint free cloth Do not use solvents or chemical cleaners to clean the printer interior Use only the specified oil or lubricant on printer parts some service parts are lubricated at the factory Inspect and if necessary clean all rubber plastic rolls with a lint free cloth Dry the rolls with a lint free cloth While cleaning inspect the interior of the printer for damaged wires loose connections toner leakage loose springs and damaged or worn parts Be sure the printer is on a single flat str
71. X Safety information 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 from hazardous voltage in 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 e 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 symbole
72. 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 40 Diagnostic information 2 45 7100 XXX Back stain service check Backside of paper is stained Action Fuser roller and back up roller are stained Fusing offset error occurred Replace fuser assembly See Fuser assembly removal on page 4 6 Note Fuser assembly is a customer ordered supply Problem area 1 Fuser assembly 2 Transfer roller Transfer roller is stained Replace transfer roller See Transfer roller removal on page 4 6 2 46 Service Manual Banding service check 7100 XXX A banding line appears in horizontal direction Problem area 1 Photodeveloper cartridge Action 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 8 2 Toner cartridge OPC belt and transfer belt fail to maintain regular and proper rotation due to impact created during retract of toner cartridge Replace toner cartridge Diagnostic information 2 47 7100 XXX Black line service check A fine black line appears in printer image Problem area 1 Toner cartridge Action Toner cartridge blade is def
73. a suia Nd pem dad do due aw ae e GV M A e a eus 2 41 ADI papel reed SBIVIGE BHO s sco eec aree Care s qoae Goes GO qe d oor grado 2 42 Modem Tax Cald CHECK ue e RISO xg mc Resa eda qais mq qa aus 2 43 Paper SOL VIDE EIGCRS su xd arcs m aid eased qua uS a Mc ur pala Genes m aid MR Rc 2 44 Printer paper feed service Chek auus PEG P NA GREG P PEE PESE Se 2 44 Pat qualite Service a coa crn e aoa ern arn tt 2 45 Background Servico CROCK acs es ee NN GEM Rd UE 2 45 Back stain Service DISC aasxawezesbescesassearedescadqevesesxxwe de qaad exa 2 46 Bangin ONOR 3 52 39 92 queppra dap pa qi ed dp Eau ip RR Iq qup eee de qup ed e Spass 2 47 Saret6B CHOC s da maps goa SO gos doa gab 2 48 Calor misregistratiom sgrvice CHECK ues SR GR Rie REGE ENS QE NE Pus 2 49 HSUMICISNT TUS SONOS CHECK 2 50 Irisufficigit gigas Sorvico CHECK os ease iram repe ki 2 51 Jor SEIVIOH CHECK oou area rep ero n secus E as aeRO e eod acie pO V ebd ao mcd a 2 52 Missing image at edge service check e
74. able 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 43 assembly removal on page 4 43 Paper tray setting MCN7 all voltages measured from pin to ground Standard tray 4 pin 6 pin 8 pin 10 A4 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 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 37 7100 XXX 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 1 Reset printer and listen for any activation of Go to 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 the 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 e
75. ad Clean laser beam opening 2 Toner cartridge 2 64 Service Manual Foreign particles mixed in toner cartridge Replace faulty cartridge White spot black spot service check 7100 XXX A white spot and black spot appear on paper Problem area Action 1 Photodeveloper cartridge There are foreign particles adhering to photodeveloper OPC belt Remove photodeveloper cartridge see Photodeveloper cartridge removal on page 4 8 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 5 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 6 Diagnostic information 2 65 7100 XXX White print service check Mottle amp TPE gt 3 E Blank page no 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 othe
76. al for the repeating marks table Note If the charge roller is severely damaged the surface of the photodeveloper will not be charged properly and heavy amounts of toner will be deposited on the photodeveloper This will cause the printed page to be saturated with 10096 of each color Diagnostic aids 3 11 7100 Lexmark confidential until announce edited 1 4 2007 Step 2 Expose During the expose step the laser fires a focused beam of light at the surface of the photodeveloper and writes an invisible image called a latent image or electrostatic image This is repeated for each color printed This is the expose process The laser beam actually discharges the surface only where the beam hits the photodeveloper This creates a difference in charge potential between the exposed area and the rest of the photodeveloper surface Look at callout 2 in the picture below This is the where the laser beam hits the photodeveloper in Step 2 of the EP process Note The laser beam passes through a glass lens as it exits the laser unit If this lens gets contaminated with toner or other debris it will cause vertical streaking of white lightness on the page Cleaning the lens will solve the problem Note Never touch the surface of the photodeveloper with your bare hand The oil from your skin may cause a charge differential on the surface and to
77. al gebruik 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 belgeleengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstraling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser X Service Manual 7100 XXX Laserilmoitus Tama tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J standardin mukaiseksi luokan 1 1 lasertuotteeksi ja muualla IEC 60825 1 standardin mukaiseksi luokan lasertuotteeksi Luokan lasertuotteita ei pidet haitallisina Tulostimen sis ll on luokan IIIb 3b laser joka on nimellisteholtaan 5 mW n galliumarsenidilaser ja toimii 770 795 nanometrin aallonpituuksilla Laserjarjestelma ja tulostin ovat rakenteeltaan sellaisia ett k ytt j ei joudu alttiiksi luokkaa 1 suuremmalle s teilylle normaalin k yt n yll pidon tai huollon aikana Huomautus laserlaitteesta T m kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen
78. ali B TOO APA sqq qa qm E E SES p qas 3 27 Paper HR RE eee ede gari ERR 3 29 ADF paparia essc edad es Rd pad Cee eam eK dada qa 3 30 Repair informalloh 4 1 Removal and cleaning precautiorS cecccccccccce sac dsdi iddi 4 1 Handing ESD sensltiVe EO CROR SR AUR NOE dae es 4 2 dl a ele Photodeveloper cartridge 4 3 During transportation StOrage n mac 4 3 Handing 4 3 ramovalS iua X GXCR OR RON GE RA R R E 4 4 Cleaning roller cover removal RR a E ER 4 4 Transfer belt cleaning roller removals 4 4 Transter belt unit removal be ce PRG RP PR E 4 5 Transter roller removal 22222222 uuu
79. ar 3 27 paper jam C rear 3 29 paper jam messages 2 11 3 22 ADF paper jam 3 30 paper jam A1 3 24 paper jam 2 3 26 paper jam B rear 3 27 paper jam C rear 3 29 part number index X 5 photodeveloper handling precautions 4 3 photodeveloper cartridge removal 4 8 physical specifications and weight 1 3 power and electrical specifications 1 4 power supply fan removal 4 48 preventive maintenance 6 1 print engine specifications color balance 1 6 emulations 1 6 print resolution 1 6 speed and performance 1 6 time to first print 1 6 printer theory of operation 3 9 Printing the maintenance and configurationn pages 3 3 R rear cover assembly removal 4 14 registration assembly removal 4 33 removals ADF mechanism cover 4 55 ADF unit 4 53 bracket assembly 4 30 cleaning roller clutch 4 25 cleaning roller cover 4 4 clutch 4 27 covers 4 10 developer drive assembly 4 22 engine controller board 4 34 erase lamp 4 20 flatbed assembly 4 49 front cover assembly 4 12 front door interlock switch 4 21 front door interlock switch with bracket 4 21 fuser assembly 4 6 fuser fan assembly 4 43 high voltage power supply HVPS 4 39 HVPS cage 4 41 laser unit assembly printhead 4 18 left cover 4 15 left rear cover 4 16 left side 4 34 left tray guide assembly 4 42 low voltage power supply LVPS 4 40 main drive gear assembly 4 27 main motor assembly 4 26 modem 4 45 modem speaker 4 43 operator panel 4 57 paper exit assembly 4 32 paper e
80. area and print jobs appear smudged see Smear service check on page 2 58 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 9 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 3 28 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Paper Jam C rear A PAPER JAM C 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 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 the 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 the connector is attached and the error persists replace the engine controller board See Engine controller board removal on page 4 34 Diagnostic aids 3 29 7100 Lexmark confidential until announc
81. ay 2 A PAPER JAM A2 message indicates the media is jammed in tray 2 To clear a jam from the optional 530 sheet tray Tray 2 1 Pull the tray out Remove the tray completely Fora 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 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 the problem replace the secondary paper feed assembly See Secondary paper feed assembly removal on page 4 9 3 26 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Paper Jam B rear CAUTION A When clearing paper jams inside of the printer may be hot Allow printer to cool before touching any internal components A PAPER JAM B message indicates the media is jammed behind the rear door To clear this type of jam do the following 1 Push the rear door release latch Diagnostic aids 3 27 7100 Lexmark confidential until announce edited 1 4 2007 3 Pull the fuser pressure release levers to release tension on the media 4 Grasp each side of the jammed media Pull it to the rear of the printer and then out Note Gently pull the media out so you do not tear it Note If there is no media present in the fuser
82. 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 22 Does error clear controller board removal on page 4 34 Diagnostic information 2 31 7100 XXX 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 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 42 toner present sensor flag operate correctly 3 Turn printer off and remove engine Go to step 4 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 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 t
83. can when using the ADF See ADF streak service check on page 2 41 Scanner locked Check the scanner lock switch If it is unlocked see Flatbed service check on page 2 41 Scanner fails to communicate with the host PC If the MFP is USB attached see USB service check on page 2 40 If the MFP is network attached see Network service check on page 2 40 Diagnostic information 2 11 7100 XXX Symptom Action No dial tone when sending a fax See Modem fax card service check on page 2 43 Lines on outbound fax documents Check the flatbed glass for scratches or marks Words and images on inbound fax documents are stretched out The sending machine had a temporary jam 2 12 Service Manual Print quality symptom table 7100 XXX 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 67 White line See White line Il service check on page 2 64 White line See White line Il service check on page 2 64 Vertical white band See Vertical white band service check on page 2 62 Black line See Black line service check on
84. 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 6 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 4 26 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 26 switches For location see Fan motor and Go to step 9 interlock 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 shield See Go to step 8 Replace cable Retest Engine controller board removal on printer If error clears page 4 34 for
85. ce 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 paper 4 Fuser Replace failed fuser See Fuser assembly removal on page 4 6 Note The fuser is a customer order supply 2 50 Service Manual insufficient gloss service check Gloss on paper is not sufficient 7100 XXX 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 6 Note The fuser is a customer order supply Diagnostic information 2 51 7100 XXX Jitter service check Uneven optical density appears periodically in horizontal direction Problem area 1 Photodeveloper cartridge Action Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Note Photodeveloper cartridge is a customer order supply 2 Main motor assembly Irregular ro
86. ce to 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 is a trademark of Lexmark international inc registered in the United States and or other countries All other trademarks are the property of their respective owners 2007 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 12G9738 7100 Table of contents Notices and safety information ee eee ee ix Pe CP nS xix General dE Re o Ves pa eua parait edad Se 1 1 e ee ee ee 1 1 Specifications caes uu e quar rm eT ER RARE Ad AR qu Ed RR RA WEAR M 1 2 General device technical specificatiorn amp suu a me xx eee ewe n 1 2 Pr
87. ch top rear and front actuators for proper operation Are 9 actuators good Front cover assembly removal on page 4 12 Top cover assembly for top cover interlock switch See Top cover assembly removal on page 4 10 Rear cover actuator for rear cover interlock switch Actuator is contained in parts packet 2 Check each interlock switch top rear and Go to step 3 Replace switch in question front for proper operation and damage See Front door interlock Listen for switching action Using an switch with bracket on ohmmeter check switches When switch is page 4 21 for front interlock open cover open resistance between pin switch see Power supply 1 and pin 3 is 0 and pin 1 and 2 is infinite fan removal on Closing switch will show 0 resistance page 4 49 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 41 5 Check the following cables for continuity Replace cable Replace engine controller board See Engine E wl ids Pd puta controller
88. 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 coloraS on page 4 34 toner sensor system both dictated by list below sender and receiver Also MCN8 check for shorted pins See pin2 black K Toner sensor sender pin4 yellow Y removal on page 4 24 pin6 magenta M and Toner sensor pin8 cyan C receiver removal on Slightly remove toner cartridge in question page 4 43 for steps to Voltmeter should read approximately 4 8 expose cable If cable is VDC 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 VDC 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 bottle holder removal on it not damaged page 4 22 2 Reinstall waste toner
89. crapes the remaining toner from the surface of the photodeveloper while an erase lamp discharges the remaining voltage This is the clean erase process The photodeveloper surface is prepared to begin the EP cycle once again This cleaning erasing cycle happens after each plane of color is transferred to the transfer unit Look at callout 6 in the picture below This is where the photodeveloper is cleaned and erased in the photodeveloper phase of the clean erase step of the EP process i Cleaning blade Diagnostic aids 3 17 7100 Lexmark confidential until announce edited 1 4 2007 Transfer unit cleaning Once the toner image on the transfer unit has been transferred to the page the transfer unit rotates around and is cleaned by the cleaning roller This cleaning happens after each page is printed A clutch engages a cam to lower the cleaning brush on the surface of the transfer unit and another clutch rotates the brush The high voltage power supply sends a charge to the cleaning brush so the toner will want to stick to the cleaning brush instead of the transfer unit surface The waste toner is kicked into a containment area and moved by an auger system into the waste toner bottle This is the transfer unit clean process Look at callout 6 in the picture below This is the where the transfer unit is cleaned by the cleaning roller
90. d removal 4 36 system board cage removal 4 38 T theory of operation epbasic 3 9 printer components 3 19 X500 paper path components 3 20 X500 steps in detail 3 11 X500 summary 3 10 time to first print 1 6 toner present sensor removal 4 41 toner sensor sender removal 4 24 tonser sensor receiver removal 4 42 top cover assembly removal 4 10 transfer belt cleaning roller removal 4 4 transfer belt unit removal 4 5 transfer roller removal 4 6 4 Index U Understanding the operator panel 3 1 upper right rear cover removal 4 17 uuper left rear cover removal 4 17 W waste toner agitator removal 4 47 waste toner auger removal 4 47 waste toner bottle removal 4 7 4 22 waste toner feeder removal 4 28 7100 XXX Part number index P N 14D0403 40X0273 40X0274 40X0275 40X0276 40X0278 40X0279 40X0286 40X0287 40X0297 40X0301 40X1766 40X1767 40X3382 40X3383 40X3385 40X3387 40X3388 40X3389 40X3390 40X3391 40X3393 40X3394 40X3395 40X3396 40X3397 40X3398 40X3399 40X3399 40X3400 40X3401 40X3402 40X3403 40X3405 40X3410 40X3412 40X3413 40X3414 40X3415 40X3416 40X3418 40X3420 40X3421 40X3428 40X3429 40X3430 40X3431 40X3432 40X3433 40X3434 Description page Cable USB 2 meter ee 7 19 Power cord HV Chile 7 3 Power cord HV Switzerland French Switzerland
91. d DRAM 128MB Optional SDRAM N A Max DRAM 128MB Physical specifications and weight WIP The following table contains the dimensions and weights for each MFP model and option This does not include packaging but does include the print cartridge that ships with the MFP Width Depth Height Weight inch inch inch Ib mm mm mm kg MFP Lexmark X500n 18 9 17 2 21 77 0 X502n 480 437 531 35 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 tray 10 8 13 0 2 2 2 2 275 330 55 1 0 Tray set to legal 10 8 15 9 2 2 2 4 275 405 55 1 4 1 Comes with standard input tray and starter cartridges 2 Weight does not include packaging or pubs General information 1 3 7100 XXX Operating clearances MFP sides X5xxn X5xxn 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 700 mm Rear 10 in 254 mm 10 in 254 mm Top 16 in 400 mm 16 in 400 mm Packaging and shipping dimensions Width Depth Height Weight MFP in in in Ib mm mm mm kg X500n X502n 23 4 22 6 29 9 77 595 575 760 42 0 Options 530 Sheet drawer 21 9 22 4 10 9 18 7 556 570 277 8 5 Includes start up kit supplies Power and electrical s
92. d removal on page 4 34 for steps to remove engine controller board shield Disconnect cable 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 13 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 roller clutch Does resistance removal on page 4 27 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 on engine controller board I ae page 4 27 Check cable continuity from MCNA pins 5 petit Clutch removal on and 6 cable to connector that attaches to page 4 27 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 13 Is cable properly connected to 2 cleaning roller clutch 2 D
93. e 3 3 Engine controller board removal 1 Remove the left front cover See Left front cover removal on page 4 15 2 Remove the system board See System board removal on page 4 36 3 Remove three screws A from the engine controller board shield remove the shield 4 34 Service Manual 7100 4 Disconnect all the connectors from the engine controller board Note When reinstalling flat cables ensure that the blue side of the cable is opposite of the pins on the connectors Flat cable pins are exposed on only one side opposite blue side and must make contact with the metal pins on the connectors Repair information 4 35 7100 XXX System board removal CAUTION AN There is a lithium battery on your system board RISK OF EXPLOSION IF REPLACED BY AN INCORRECT TYPE The battery is non replaceable Do not replace recharge disassemble or incinerate a lithium battery Discard used batteries according to the country state or local regulations Warning Before replacing the system board save the onboard settings See Printing the maintenance and configuration pages on page 3 3 Warning When replacing the System RIP board be sure to set the country code See Setting the country code on page 3 3 1 Disconnect any attached USB or network cables 2 Remove the left rear cover See Left rear cover removal on page 4 16 3 Remove the screw A securing the system board cover
94. e density adjustment 5 levels manual only Image quality modes Text Photo and Mixed Zoom 2596 to 40095 in increments of 196 Present reduction ratio US 25 65 78 93 EU 25 71 86 93 Present enlargement ratio Advanced copier features US 129 155 200 400 EU 122 141 200 400 Combine multiple copies into one copy 2 into 1 4 into 1 Can be toggled between landscape and portrait Electronic sort Yes Scan once print many Yes Limitless paper feed Yes Memory copy Standard Copy counter indicator Standard Jam recover auto restart For print jams only Buzzer to finish job Yes ADF ADF width 5 5 to 8 5 inches 139 7 to 215 9 mm ADF length 5 5 to 14 inches 139 7 to 355 6 mm ADF capacity 35 sheets 1 assumes 50 coverage 2 Does not include scanner and printer warm up time Fax specifications Phone network connectivity Phone networks types supported Both PSTN and PABX are supported Compatibility T30 ITU T Super G3 is supported Color fax is not supported Modem speed Automatic fallback 33600 bps V34 V17 V29 and V27ter are supported for image transmission V8 and V21 are supported for control channels Compression MH MR MMR and JBIG General information 1 11 7100 XXX Document Sizes supported ADF width 5 5 to 8 5 inches 139 7 to 215
95. e edited 1 4 2007 ADF paper jams An ADF JAM Open ADF Cover and Clear Jam message indicates a jam in the ADF WARNING Do not clear any ADF jams until the release lever on the ADF pick roller assembly is opened 3 30 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX 1 Open the ADF top cover To clear an ADF paper jam follow these steps OS e gt lt 2 Lift the green separator roll release lever to the up position Do not remove the separator roll Diagnostic aids 3 31 7100 Lexmark confidential until announce edited 1 4 2007 4 Lower the separator roller release lever until it locks in place 3 32 Service Manual 7100 XXX 4 Repair information Removal and cleaning precautions Observe the following precautions whenever you service the MFP Prior to starting any repair read and understand the warnings in this manual Be sure to unplug the from the outlet before attempting to service the To reassemble the MFP reverse the order of removal unless otherwise specified Do not operate the MFP anytime during removals If it is absolutely necessary to run the MFP 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 gro
96. ed Scan Memory Full Memory for the scan job is full Break the scan job into smaller segments Communication Error Communication with host machine failed Retry the job Check all connections with the host device Server Connection Failed Communications with the server failed Retry the job Check all connections with the host device TX RX Comm Error There is a data transmission or reception error Resend the fax CPU fan locked The CPU fan is no longer running on the RIP card See CPU fan service check on page 2 16 Note The expected yield of the separator pad and paperfeed roll are 120 000 pages 2 10 Service Manual 7100 XXX Symptom tables MFP 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 User attendance messages on page 2 8 and follow the action suggested Paper jam messages do not reset after removing paper See User attendance 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 39 Developer motor makes noise or continuously runs See Developer drive assembly service check on page 2 16 Main motor makes noise or continuously runs See Main motor service check on
97. ee eee eee 2 53 Mixed color mage Service GnebK eee 2 54 Metis SOIVICOCNECK 2 55 Figsiciual mago SONICS gw gin aad RE Ra do 2 56 Filbbirig SONICS CHECK PAPE GIG GGG eda as 2 57 Smear Semice CHECK 2 58 Tone drop SEVIER CHECK uu pesa 2 59 Vertical Service CHECK a4 4 5 eed ud sd acp oU ag m eae eerie hed we 2 60 Vertical staggering image service Check 20 00 eee eee eee 2 61 Vertical while Dand CIBOK SET E EGG demque x edema eq e Rad 2 62 While Dand CHECK addu eese a qa Pd SIR d peau Eua M PRA MEUS 2 63 Walo Mme ca quisuam d dog m ecu aes dac ced cn wi ee ed aes dap 2 64 White line T service chok ea dun 2 64 White Spot black spat Service COO ac css x EE oaks SV Eae deaeque 2 65 White pim Service CHECK eap qe Pam GR PME sacar a 2 66 Vibe
98. elopes 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 Use letter 12A5940 or A4 size 12A5941 sheets only Transparencies are only supported in tray 1 standard or legal trays General information 1 13 7100 XXX Labels Labels should be selected using guidelines found in the User s Guide Complete Printer Guide or the Card stock amp Label Guide located at www lexmark com and tested for acceptability e Vinyl labels are not supported Labels are only supported in tray 1 standard or legal trays Glossy Paper e Use letter 1245950 or A4 size 1245951 sheets only Glossy paper is only supported from tray 1 standard or legal trays Sensing by source Input Paper size Paper out Tray present Integrated 250 sheet X X X Optional 530 sheet X X X 1 14 Service Manual 7100 XX
99. elt the tiny toner particles and bond them permanently to the media The fuser moves the paper from the rollers and into the exit bin This is the Fuse Process Look at callout 5 in the picture below This is the where the Fuser bonds the toner permanently on the page 8 i Note If the fuser rollers are damaged they can cause toner to be pulled off the page or cause paper jams Note Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media setting Always check the paper type setting on the printer and driver before replacing the fuser A common mistake is to print on heavier media such as card stock with the paper type set to plain paper Note When removing paper jams from the fuser be sure to use the fuser release tabs to relieve the pressure on the page in addition never pull unfused toner through the fuser if you can help it try to back the jammed page out of the fuser in the opposite direction it was traveling 3 16 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Step 6 Clean Erase There are two main cleaning processes that take place during the EP Process One process cleans the photodeveloper and the other cleans the transfer unit Photodeveloper clean erase After each plane of color has been transferred to the transfer unit from the photodeveloper a cleaning blade s
100. end E mail Notification An e mail is being sent to a user notifying them of a push scan job being completed Connection Fail Unable to connect to the remote fax No Response The device Busy The remote fax device is currently busy Dial Failed The dial attempt to another device failed Scanning Page The scanner is scanning in the flatbed or ADF Job Fax Job 4 is being processed Dialing A fax number is being dialed Awaiting Re dial The fax is between dialing attempts Transmitting The fax is transmitting data to another fax device Receiving The X502 is receiving fax data from a remote fax device These are the normal operating modes 2 6 Service Manual 7100 XXX Message Description Action TAD Answering A telephone call is being These are the normal operating modes received Answering The fax is answering an in coming call incoming Call There is an incoming call on the phone line Warming Up The MFP is warming up Diagnostic information 2 7 7100 XXX User attendance messages Message Description Action Paper Empty Load Tray Paper Size Load Tray 1 Paper Size Load Tray 2 Paper Size Load Tray Paper The upper or lower paper tray is empty or the media in the trays is inconsistent Fill up the paper tray s or replace the media with the correct type If the problem pers
101. eneral information 1 7 7100 XXX Media input types and weights Source Type Standard tray 530 Sheet tray MFP menu Item Legal tray Paper Paper type weight Paper Xerographic or bond 160 74 60 74 Plain paper Light grain long paper g m g m 16 19 Ib 16 19 Ib Xerographic or bond 75 420 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 80 Envelope Normal g m 20 24Ib 1 Punched embossed water marked perforated punched inkjet paper or plastic coated media should not be used 2 Only occasional use of paper labels in an office environment is supported 3 Only PN 12A5940 and 12A5941 should be used There is no automatic paper type sensing These settings should be manually set in the operator panel 1 8 Service Manual 7100 XXX Media sizes Media sizes Dimensions Input Output ie gt gt E EF gs 595 2 i 938 g aN BB SPs dis E 9 m a gt Ss 5 0 200 o mm in A4 210 x 297 8 27 x 11 7
102. eplacement status of the various maintenance items on the MFP From the top level of the Maintenance mode menu use the A and w keys to navigate to Engine Maintenance Press to select the Engine Maintenance item Use the A and w keys to navigate to the individual settings in the Engine Maintenance menu Press to select the currently displayed item Replace OPC Belt Replace Fuser Replace TR Belt Replace PQ Kit Replace PF1 Kit Replace PF2 Kit Replace ADF Kit Waste Toner Pack Life Setting To change the status of any item use the key to scroll to the desired setting and press the key Press twice to return to the top level of the Maintenance mode menu Scan Maintenance Mono Compression Setting This item lets you change the scan compression settings The options are MH MR and MMR MH is the default setting This is the only item in the Scan Maintenance menu Fax Maintenance Modem Settings The three modem settings submenu items be accessed using the A and w keys to navigate to the individual settings When the desired modem setting is displayed press to select the item RX Level This item allows you to adjust the RX level The options are 16 26 33 and 43 dBm XXX is the default This setting is automatically set when the MFP is initialized at setup Do not change this setting without second level support supervision If the setting needs to be adjusted use the A and w keys to navigate to the sett
103. ere the developer rollers in the toner cartridges touch the surface of the photodeveloper during Step 3 of the EP Process Erase eum ima o e Developer rollers Note If the developer roller is damaged it will not contact the surface of the photodeveloper properly The result could be repeating marks thin vertical voids or thin vertical lines of color on the printed page Check the surface of the developer for damage Note Never touch the surface of the developer roller with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the affected cartridge would need to be replaced Diagnostic aids 3 13 7100 XXX Lexmark confidential until announce edited 1 4 2007 Step 4 Transfer First transfer After the first plane of color is developed on the photodeveloper the high voltage power supply sends voltage to the transfer unit so the image on the photodeveloper is transferred to the transfer unit This takes place by a direct surface to surface contact between the photodeveloper and the transfer unit This is the first transfer process The photodeveloper continues to rotate around and is cleaned and erased Then a new charge is put on the surface The laser exposes the photodeveloper and the next color is deve
104. es LFR Senor IO7ZULZS i CKBHCIADHHS 21 CFRSZT 752 07241 1 ORB MK LEV V HMCHSS CE MAEWS TwcvE 8 2530o BtmK LEFF ALOV VYV WMECHSCEMEWSNTVET EBA oncoEd c 0o 7Zyr Z i 72zHb 30 OL P AAMELTIEF CO T7T95T 72 72 088B8BC BH 5307y RORY a blt COL LvATACTULS ik BORE 2A VPOA YFIHYVAL HH amp 417 wei AGAT FATOVANVE LOL P ik HIM NZCLORWELABHAaANTHEF et ae EI UGE 47 DHHS 21 CFR Subchapter 1 WA 25 1 1 d B tH HE m Hd Hh p Ru SEGA IE S 825 ES dn T I MIC A35 lb 3b AY IE 5 EB EURO 770 795 nm Z 8 E RE VE EAA ARS fi A PRE fh I DE aS RY Xii Service Manual 7100 BLAS 158 sop ASSO CHE DHHS 21 CFR Subchapter 39 FNS ges UZAN 215890 319 9 IEC 825 7138 T lke 158 MOA BORA 05S 158 40 ASSES HNE HOS ZS E HERES 5 AS alo x gA 770 795 mel SScte Class ill 3b alo Xi amp HFA zt S Ecc SB AAMT BREE AA Ae Sol FAL BS SHE HAS MHA 2219 Class 29 alo x H AZo cH Mos So Notices and safety information Xiii 7100 XXX XiV Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XX
105. eveloper motor or developer drive customer ordered supply assembly before error posts Go to step 2 2 Does noise go away Problem solved Replace developer drive assembly See Developer drive assembly removal on page 4 22 Go to step 3 3 Does noise go away Problem solved Go to step 4 4 Turn printer off and remove right cover See Go to step 5 Properly connect cable Right cover removal on page 4 14 Is Retest printer If error cable properly connected to developer drive clears problem solved assembly motor otherwise go to step 5 5 If waste toner bottle is removed reinsert it Replace developer drive Go to step 6 Ensure rear cover assembly is shut assembly See Developer Override top and front cover interlock drive assembly removal switches For location see Interlock on page 4 21 Go to step 8 switch locations on page 5 6 Reconnect operator panel Turn printer on Allow printer to run until error posts Disconnect connector from each developer motor and check for the following on each disconnected cable connector Pin 2 to ground 24VDC Pin 5 to ground 24VDC Are voltages present 6 Remove engine controller board shield See Go to step 7 Replace cable Retest Engine controller board removal on printer If error clears page 4 34 for steps to remove engine problem solved otherwise controller board shield Disconnect MCN5 go to step 7 from engine controller board Check for continuity and
106. ge 4 50 removal on page 4 36 voltage present ADF streak service check Step Questions actions Yes No 1 Do streaks appear on the middle of Clean the ADF glass on the issue to fix scans when using the ADF flatbed using a lint free cloth Also clean the separator roll and pad with a damp cloth Diagnostic information 2 41 7100 XXX ADF paper feed service check Step Questions actions Yes No 1 If the ADF is multi feeding check for dirt Clean them with a lint free Replace the separator pad the ADF separator pad and ADF separator cloth and isopropyl alcohol and ADF pick roll rollers Are they dirty 2 If the paper is skewing when it is fed into the Go to step 3 Set the paper guides so ADF check the paper guide width Is it set they contact the edges of correctly the paper 3 If paper is skewing when fed or jamming Properly close the top If the paper is jamming in check to see if the top cover is open or ajar cover the ADF go to step 6 Is the ADF top cover open or ajar 4 Is paper failing to feed into the ADF Go to step 5 There is no issue 5 Check the leading edge of the paper to Bad media Go to step 6 ensure the paper is not curled or bent in a way that would keep it from contacting the paper sensor actuator Is the paper damaged 6 Is there dirt in the sensors or is the paper Clean the sensors or Go to
107. ger waste toner 7 17 Agitator waste toner 7 17 Power supply high voltage 7 15 Sensor toner present 7 15 Transfer unit 7 3 Paper guide C assembly includes registration sensor tray empty sensor 7 13 Roller paper feed 7 13 separator 7 13 Lamp erase 7 9 Transfer roller assembly 7 3 Packet parts 7 5 Assembly secondary paper feed 7 19 Assembly paper exit contains fuser exit sensor and flag 7 5 Assembly bracket includes marker sensor transfer belt unit toner density sensor 7 13 Assembly registration 7 5 Left tray guide assembly includes paper size sensor and temperature thermistor 7 9 Assembly in
108. gned 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 MFP User s Guide for additional media specifications Paper 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 MFP User s Reference The chemical process used in preprinting may render some papers unsuitable for use with the MFP 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 chosen 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 Env
109. h counter within the submenu Press to select the displayed item Press 5 to exit an item Total Page Total number of pages scanned Total Image Total number of images Black Page Total number of black and white scans Color Page Total number of color scans ADF Used Total number of scans from the ADF ar O N gt Jam Counter This menu shows the number of jams in various areas of the MFP Use the A and w keys to navigate to each counter within the submenu Press to select the displayed item Press 5 to exit an item 1 Total Total number of jams 2 ADF Total number of ADF jams 3 Prt Output Bin Total number of jams in the fuser area 4 internal Total number of jams in the paper path 5 Tray 1 Total number of paper tray jams Press 5 again to exit the Counter menu Print Reports Print Reports is the second top level menu item From the top level of the Maintenance mode menu use the A and W keys to navigate to Print Reports Press to select the Print Reports item G3 Protocol Dump List This is the only menu item in the Print Reports submenu This setting converts inbound fax data into ASCII data to aid in troubleshooting fax issues Press to select this item Press twice to return to the top level of the Maintenance mode menu Diagnostic aids 3 5 7100 XXX Lexmark confidential until announce edited 1 4 2007 Engine maintenance This submenu shows the r
110. ha d estar ne assabentat i prendre les mesures convenients A r i ni o o Di Hu E m r 225 9 Oe ri a FTT 2 H nio nio Ls Oo 2 2 9 x PI 9 J2 jorge H o r TTE r2 HE o o I fo T o U or 4 o of ct H gt rm gt PH 40 Ot pi pi mH Jo o lo g r mim BS ico bi E AS FALSE TIT IER LIS pi ORB ARS XE P i E UA RAAN ANT KEE fA vi o PRECAUCIO aquest simbol indica que 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 rir ox o lo ES 1 fE Wn TED REN IRIS e DUET Pr rf Att GTI 5 D il I WHER AEREE i AR 710 CAE x BRE ETT FF J FYE RET A 1 JFANTSEE AIE Hi BA Pa SED IA E PE 230 FEAR 8 RU d TAE RIPA m 5 EJFARBRTE TIRFES in AY HLW EAE ANGA Safety inf
111. ht Go to step 2 Properly connect cable If cover See Right cover removal on problem persists go to step page 4 13 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 27 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 paper feed clutch See Clutch removal on page 4 27 persists replace faulty paper feed clutch See Clutch removal on page 4 27 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 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 13 Is cable properly connected to 2 registration clutch 2 Disconnect registration clutch from cable Go to step
112. i laser di classe 1 ed 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 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser la stampante sono stati progettati in modo tale che le persone a contatto 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 Notices and safety information ix 7100 XXX Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos l ser de Clase 1 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 I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 795 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante
113. 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 t che 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 non 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 e Durante lo smontaggio la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona elevato Il 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 XV 7100 XXX 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 Wa
114. ine speed and performance Pages minute Media size Standard tray Mono Color Letter Up to 31 Up to 8 A4 Up to 31 Up to 8 Legal Up to 16 Up to 8 Transparencies Up to 3 Up to 2 Thick card stock Up to 3 Up to 2 Labels letter amp Up to 5 Up to 3 A4 Medium thick card Up to 4 Up to 3 stock letter amp A4 Envelopes Up to 5 Up to 3 Print engine time to first print Media type Media size First print time Mono Color Plain paper mode 4 letter 13 seconds 19 seconds Transparency mode 4 letter 23 seconds 29 seconds Label middle thickness stock A4 letter 17 seconds 23 seconds Middle thick stock glossy A4 letter 16 seconds 22 seconds Thick stock A4 letter 23 seconds 29 seconds Envelope 1 mode Commercial 10 International DL 18 seconds 24 seconds Envelope 2 mode Commercial 10 International DL 23 seconds 29 seconds Note 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 measured using a simple text single character page Note Note Warm up time 60 seconds maximum is the time elapsed from when the power is turned on to when the Ready status is reached 1 6 Service Manual 7100 XXX Print engine paper and media specifications Print area The printable area is up to 4 0 mm 0 15
115. ing 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 release from transfer belt onto paper during second transfer process Locations and connectors 5 7 7100 XXX 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 Lo
116. ing level and press to select the new setting Press to exit TX Level This item allows you to adjust the TX level The options are 0 to 15 dBm 15 dBm is the default This setting is automatically set when the MFP is initialized at setup Do not change this setting without second level support supervision If the setting needs to be adjusted use the A and w keys to navigate to the setting level and press to select the new setting Press x to exit Cable Equalizer This setting affect signal attenuation distance and the physical distance the fax can be from a repeater The options available for this setting are 0 km 1 8 km 3 6 km and 7 2 km Do not change this setting If the setting needs to be adjusted use the and w keys to navigate to the setting level and press to select the new setting Press 5 to exit 3 6 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Protocol Definition The two submenu items can be accessed using the A and W keys to navigate to the individual settings When the desired protocol definition setting is displayed press to select the item Training Retries This is the number of attempts made to receive a fax before switching to a different compression setting When Training Retries is selected use the A and w keys to navigate to the desired number of retries and press to select the new setting Press to exit Encoding This allows you
117. int engine SpecifICaBllOnlS iussa ska kziceradbascrexc irea ras 1 6 S an SpecifICallols xa RURUR RO RR aaa eae 1 10 CODY SHECHICAIONS uses sanas em uu RR AX A RERO REGRESAR RR RA RAO RR ER M 1 11 Fax SpeciiCaliOns ERA EE 1 11 Media 9 10 1 reb reddas 1 13 a 1 15 Standard inspection and cleaning procedure cece ewe ahh rr 1 15 SB e aaa ra s edades Ada RA BI db qd bu Mae 1 16 Tools required TOf SOIVICO si ccccc cece cece ed Pde SPREE eG ba RR ERG Ra E E PU Eri Ropa 1 16 AGIOnVITIS x2xakkaskacmsARRAASRRKRGARRRREARARGRAGARAATERGAAAEAATARGSARTTAZAZSAATOSEAESZSAERTEG as 1 17 Diagnostic informalo A oceania send ESTA 2 1 Gall 2 1 Understanding the oparata cn e dU s RR rcp e esa 2 2 Service BITOL COO lt 5 55015 Rd spp Be Cee ed mde EAR 2 3 USB Status INGSSa0CS cesis ang qi equa xad pa REA dad 2 6 User a
118. is the default Light 0 255 127 is the default 3 8 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Printer theory of operation Electrophotographic Process EP process The method that all laser and LED printers use to print is called the electrophotographic process Laser printers use differences in charge to manipulate and move toner from the toner cartridge to the printed page Even though the basic EP Process is the same for every laser and LED printer the specifics for each printer are different We will discuss the Lexmark X500n MFP and its particular method of printing EP Basics The Lexmark X500n is a single laser MFP that uses four toner cartridges Cyan Yellow Magenta and Black to create text and images on media The MFP has one photodeveloper called a photodeveloper cartridge or OPC and a transfer Unit Each color toner is painted to the photodeveloper and to the transfer unit one color or image at a time The photodeveloper and transfer unit must rotate four times to print one page composed of the four images for a color print job During the printing process the printer follows the six basic EP process steps to create its output to the page These six steps are Charge the photodeveloper OPC Expose the photodeveloper OPC Develop toner on the photodeveloper OPC 1st and 2nd transfer of toner to the transfer Unit and then to the media Fuse toner to the media
119. isconnect 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 25 198 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 Check cable continuity from MCN4 pins 1 and 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 25 persists replace faulty cleaning roller clutch See Cleaning roller clutch removal on page 4 25 2 18 Service Manual Paper feed clutch service check 7100 XXX 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 rig
120. ists see Tray empty service check on page 2 29 Paper Change Load Paper Type Size Media size and type mismatch Check the media size Check the media size setting in the cassette Check to make sure the media setting on the printer and drive match the media in the cassette Paper Error Load Tray 1 Paper Type Media type mismatch Load the paper tray with the correct media type Tray 1 2 Missing 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 30 Toner Low C M Y K The toner is low in the cartridge indicated See Toner low empty service check on page 2 31 C M Y K Toner Empty Replace Toner C M Y 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 31 Waste Pack Full 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 31 OPC Exhausted Replace OPC Belt Replace with a new OPC unit See Photodeveloper cartridge removal on page 4 8 OPC Belt Life Replace OPC Belt Replace with a new OPC unit See Photodeveloper cartridge
121. ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan 1116 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNinG Osynlig laserstr lning nar denna del ar ppnad och sparren urkopplad Betrakta ej str len Laser notis Denna skrivare i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren r utformade sa att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass 1 vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven serviceatgard Laser melding Sk
122. l 1 7100 XXX wiring diagram and cable harness reference 5 14 low voltage power supply removal 4 40 main drive gear assembly removal 4 27 main motor assembly removal 4 26 maintenance approach 1 15 inspection and cleaning procedure 1 15 required tools 1 16 serial number 1 16 maintenance mode 3 4 density tune 3 8 display info 3 4 engine maintenance 3 6 fax maintenance 3 6 print reports 3 5 scan maintenance 3 6 marker sensor assembly removal 4 46 media guidelines 1 13 envelopes 1 13 glossy 1 14 labels 1 14 paper 1 13 sensing by source 1 14 transparencies 1 13 media input types and weights 1 8 media sizes 1 9 memory configuration 1 3 messages user attendance 2 8 user status 2 6 models 1 1 modem card removal 4 45 modem speaker removal 4 43 alpha numeric keys 3 1 black start 3 1 color start 3 1 copy LEDs 3 1 directory 3 2 fax LEDs 3 1 hook 3 2 image quality 3 2 LCD display 3 1 menu keys 3 1 reduce enlarge 3 2 lighter darker 3 2 re dial 3 2 removal 4 57 scan LEDs 3 1 shift 3 2 2 Index speed dial 3 2 stop cleat 3 1 output capacities 1 9 P packaging and shipping dimensions 1 4 paper and media specifications 1 7 input and output configurations 1 7 print area 1 7 paper exit assembly removal 4 32 paper feed roller removal 4 32 paper guide C assembly removal 4 31 paper guide assembly removal 4 31 paperjam A1 3 24 paper jam 2 3 26 paper jam B re
123. lace the engine controller board See Engine controller board removal on page 4 34 005 Service Call Op Panel See Operator panel service check on page 2 40 006 Service Call Scanner Unit Scanner unit initialization failed Home position not found Possible scanner calibration failure See Flatbed service check on page 2 41 007 Service Call Printer Communication Error Print engine fails to initialize See Engine controller board removal on page 4 34 008 Service Call Fax Card Fax board fails to initialize or fails to respond when a fax is sent See Modem fax card service check on page 2 43 C3 Service Call Engine CTL Board incorrect data is detected in the NVRAM during data confirmation process at power on 1 POR the machine 2 If problem persists replace the controller board C4 Service Call Engine CTL Board 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 C7 Service Call Main Motor Synchronization signal from main motor is not detected See Main motor service check on page 2 14 D4 Service Call LV Power Supply See Low voltage power supply LVPS service check on page 2 23 EO Service Call Developer Motor 1 MK An over current signal is detected due to an abnormal l
124. llendante Messages a e SR d M 2 8 Svom abos E i 2 11 MEP SUmplom DIG sea 22a ees cde a 2 11 Pint quali sSymplomddbl8 2x6 r S 2 13 Primor Service CHECKS ooa qao sedes Edessa eee ERIS pam ES RR 2 14 NAIOP SONICS pP EET 2 14 OF Tamsarvleg eo us qb ue E ERE DRE ME E 2 16 Developer drive assernbly Service CHOCK xr pax m RE Sd 2 16 Transier belt uit SGNVICG da pace a RS MAR aea 2 17 Trapnster toller clutch Sarvicg Ch6CK gre adi a oo cede 2 18 Transfer belt cleaning roller clutch service 2 18 Pape qood Sovico DHODI ss qe qud s diui qd 2 19 Fegistratiom clutch Sovico a RARE SEE d Res 2 19 OPG belt marker sensor svice ChODK ise exc nasce x esq ere Roe mium RA 2 20 Erass lamp RE RE RR ENARRARE EQ RR RR dd ENS 2 21 POWGE Supply Tan CHODI cease dee x r NES Ee RE ig 2 22 Fusa
125. loped and transferred to the transfer unit This process continues until all four planes of color have been transferred to the transfer unit Look at callout 4 in the picture below This is the where the photodeveloper transfers the toner to the transfer unit and the first transfer of the EP Process Note Never touch the surface of the transfer unit with your bare hand The oil from your skin will cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page The transfer unit would need to be replaced Note Don t use solvents or other cleaners to clean the transfer unit surface No matter how careful you are the surface will be compromised causing scratches or a charge differential that will produce a void or light blotch on the printed page The transfer unit would need to be replaced 3 14 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Second transfer Once the last plane of color is transferred to the transfer unit from the photodeveloper media is picked from the paper tray and carried to the transfer roller The transfer unit continues to rotate around and meets the paper at the Transfer Roller area The high voltage power supply sends voltage to the transfer roller to create a positive charge Once the paper passes betwee
126. lways check the media first See Media input types and weights on page 1 8 In addition it is always good practice to check the printer and driver settings to see if the media being used matches the user s settings in the driver It is not uncommon to find a user printing on card stock with the printer programmed to print on a plain paper setting The printer feed and transport components can fail and cause paper jams or other feed and transport problems These components should be examined for damage or wear and replaced if necessary X500n specific information The Lexmark X500n has a simple C shaped paper path see the picture below The tray 1 paper path is shown in red and the optional tray 2 path is shown in blue Tray 2 is not shown Note The tray 1 and tray 2 paper paths merge at the tray 1 paperfeed roll Paper is fed from the rear of the printer and travels upward through the rear cover There is no duplex option or finisher option on this printer There is a 530 sheet drawer available not shown Exit T rollers Fuser Rear 0 cover assy Transfer roll Registration rollers Paper cassette Paper feeding roll Tray 2 path 3 20 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Transport Components In summary as shown in the previous illustration the media is fed from
127. ly 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 11 7100 XXX Assembly 6 Rear 7 12 Service Manual Assembly 6 Rear 7100 XXX 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 13 7100 XXX Assembly 7 Left 7 14 Service Manual 7100 XXX Assembly 7 Left index P N Units Description 7 1 40X4696 1 Board Network RIP US 2 40X4711 1 Card modem US 3 40X4715 1 Cable modem 4 40X3405 1 Power supply high voltage 5 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 6 40X3410 1 Sensor toner present 7 40X4704 1 Power supply 110 V low voltage 8 40X4705 1 Power supply 220 V low voltage 9 40X4719 1 Bracket 110 V power supply 10 40X4720 1 Bracket 220 V power supply 11 40X4689 1 Board engine controller Parts catalog 7 15 71
128. mbly See Developer technical support drive assembly removal on page 4 22 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 overflowing service check on page 2 31 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 48 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 48 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 28 Diagnostic information 2 39 7100 XXX Operator panel service check Step Questions actions Yes No 1 Is the operator panel cable properly Go to step 2 Properly connect the cable connected to the op panel to the op panel 2 Is the op panel cable properly connected to Go to step 3 Properly connect the cable the RIP board connector J PNL1 to J PNL1 3
129. menu Press x to exit this item Fax FW Ver The second item is Fax FW Ver which displays the fax firmware version It cannot be changed in the menu Press to exit this item MCTL FW Ver The third item is MCTL FW Ver which displays the engine controller board firmware version It cannot be changed in the menu Press D to exit this item Press to go back up to the Display info menu 3 4 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Counter The Counter submenu displays various counters maintained by the MFP These are permanent counts While in the Display info menu use the A and w keys to navigate to Counter and press the J key to enter the submenu Counter menu items are accessed by using the and w keys to navigate within the submenu to each item Printer Counter This submenu maintains the base print engine counters Use the and w keys to navigate to each counter within the submenu Press to select the displayed item Press to exit an item Total page Total number of pages printed Total Image Number of images printed Black Image Number of black color planes printed Magenta Number of magenta color planes printed Cyan Number of cyan color planes printed Yellow Number of yellow color planes printed DONAN Scanner Counter This submenu item displays the number of various scans performed by the MFP Use the A and W keys to navigate to eac
130. n the transfer roller and transfer unit the negatively charged toner clings to the paper and the entire image is transferred from the transfer unit This is the 2nd transfer process Look at callout 4 in the picture below This is the where the transfer unit transfers the toner to the media by way of the transfer roller and Step 4b of the EP process Transfer roll Note If the transfer roller has nicks pits or flat spots on it the surface doesn t come into contact with the media and transfer unit properly This will cause voids or lights spots on the page or repeating voids light areas because the toner can t be fully transferred due to the charge difference in the areas of damage Note If the transfer roller does not engage the transfer unit or does not have voltage coming from the high voltage power supply the toner will not fully transfer from the transfer unit the entire page will be very light or blank Any toner that does transfer will be due to a contact transfer instead of a charge transfer Check the transfer roller clutch and the high voltage power supply contacts to the transfer roller Diagnostic aids 3 15 7100 Lexmark confidential until announce edited 1 4 2007 Step 5 Fuse Once the image has been fully transferred to the media the transfer roller helps move the paper into the fuser area The fuser applies heat and pressure to the page to m
131. ner will not stick properly The result would be repeating blotches of voids light print on a page Then the photodeveloper will have to be replaced Note The surface of the photodeveloper is coated with an organic substance that makes it sensitive to light Be sure and cover the photodeveloper when you are working on the printer so you don t burn it If exposed to light for too long it will cause light dark print quality problems and have to be replaced 3 12 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX Step 3 Develop Once the laser exposes the photodeveloper the high voltage power supply sends a charge to the developer roller The first toner cartridge engages the photodeveloper so it is in contact with the surface Because of the charge difference between the toner on the developer roller and the electrostatic image created by the laser the toner will cling to the OPC The toner will only stick where the laser exposed the surface This is the develop process This process is best illustrated by comparing it to using glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Each toner image is developed and transferred to the photodeveloper one color at a time The toner image on the photodeveloper needs to be transferred to the transfer unit before the next color can be developed Look at callout 3 in the picture below This is wh
132. ngine controller Problem solved removal on page 4 36 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 39 from left side of bracket See Low voltage printer to expose power supply bracket power supply LVPS with Using an ohmmeter ensure power switch is cage removal on good Is power switch good page 4 41 for steps to remove power supply bracket 7 Check LVPS ACN1 ACN2 and ACNA for Replace LVPS See Low Properly connect cables proper connection Are cables properly voltage power supply connected to 5 LVPS with cage removal on page 4 41 2 38 Service Manual Toner feed service check 7100 XXX Step Questions actions Yes No 1 Check toner cartridge for damage Checkto 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 22 3 Is developer drive assembly damaged Replace developer drive Contact higher level asse
133. nnector 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 21 7100 XXX 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 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 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 Fan motor and supply fan removal on interlock switch locations on page 5 6 page 4 49 Retest printer If Turn printer on and check for 24VDC error clears problem between engine controller board MCN10 solved otherwise go to step pin 1 and power ground you can touch 3 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
134. nsitive part in its original shipping container a special ESD bag until you are ready to install the part into the MFP Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the MFP Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the MFP cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity 4 2 Service Manual 7100 XXX Photodeveloper cartridge The
135. nter ASCII characters for a Push Scan profile search Fax mode Enter a Fax number Enter ASCII characters for Fax speed dial searches 3 Black Start initiates a black and white scan job in Copy and Scan modes initiates the Fax TX in Fax mode 4 Color Start initiates a color scan in Copy and Scan modes Non functional in Fax mode 5 Stop Clear Cancels copy scan and fax jobs 6 Menu Keys A W Up Down keys These keys are used to scroll through selections A can be used to clear an item can be used to enter a space 3 Return Exits to an upper level of a menu 4 Select This key is used to select and confirm settings or enter a submenu 7 Copy LED Switches the MFP to Copy mode 8 Scan LED Switches the MFP to Scan mode 9 Fax LED Switches the MFP to Fax mode Diagnostic aids 3 1 7100 XXX Lexmark confidential until announce edited 1 4 2007 Number Button Function 10 Reduce Enlarge Copy mode Reduce or enlarge the image data to a copy job Scan mode Select the push scan document size 11 Lighter Darker Copy mode Adjust the copy exposure 5 levels available Scan mode Adjust the push scan density 5 levels available Fax mode Adjust the fax contrast 3 levels 12 Image Quality Copy mode Select the desired copy quality Text Photo Mixed Scan mode Select Push scan resolution Fax mode Select the Fax resolution Standard Fine
136. nter 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 7 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 41 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 43 assembly removal on page 4 43 2 30 Service Manual Toner low empty service check 7100 XXX Step 1 Questions actions Turn printer off and remove engine controller board shield See Engine controller board removal on page 4 34 for steps to remove engine controller board shield Is cable properly
137. o 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 pin 1 Is 0 VDC present board See Engine sensor See Toner controller board removal present sensor removal on page 4 34 on page 4 42 7 Turn printer off Check cable for continuity Replace toner present Replace cable that connects MCN pins 1 2 and to sensor See Toner toner present sensor Also check for shorted present sensor removal pins Is cable okay on page 4 42 8 Touch positive lead to engine controller Replace engine controller Go to step 9 board connector POCN pins 13 15 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 ACN 1 and engine controller board voltage power supply connector POCN Also check for shorted LVPS with cage pins Is cable okay removal on page 4 41 2 32 Service Manual Missing photodeveloper cartridge service check 7100 XXX photodeveloper cartridge contacts B for dirt and damage Are contacts okay Step Questions actions Yes No 1 Check photodeveloper cartridge for proper Go to step 2 install properly installation I
138. oad on developer motor 1 1 Replace black and magenta toner cartridge 2 If error persists see Developer drive assembly service check on page 2 16 E1 Service Call Developer Motor 2 CY 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 16 Diagnostic information 2 3 7100 XXX Error code Action E2 Service Call Main Motor A NOT READY signal rotation error signal is detected because of abnormal main motor rotation See Main motor service check on page 2 14 Service Call Transfer Belt Sensor Unstable transfer belt rotation color matching cannot be secured See Transfer belt unit service check on page 2 17 E5 Service Call Transfer Roller Clutch Improper transfer roller clutch cable connection or a shorted or cut cable See Transfer roller clutch service check on page 2 18 E6 Service Call Transfer Cleaner Solenoid Improper cleaning roller clutch cable connection or a shorted or cut cable See Transfer belt cleaning roller clutch service check on page 2 18 E7 Service Call P feed Clutch Tray 1 Improper paper feed clutch cable connection or a shorted or cut cable See Paper feed clutch service check on page 2 19 E8 Service Call Registration Clutch E9 Service OPC Marker Sensor Im
139. oblems Repair information provides instructions for making printer adjustments and removing and installing FRUs Connector locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples N BY M 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 This type of caution indicates a tipping hazard Preface xix 7100 XXX XX Service Manual 7100 XXX 1 General information The Lexmark X500n and X502n are color laser MFPs that combine print scan copy and fax functions The X500n and X502n are the ideal
140. od m ec gite da eR 4 32 Paper exit asselubly s msg ma aid 4 32 Fadgistrauon assambly Termpyal uas mecs seb gd Esa RS dede Eua Greer iu whe gri 4 33 LEU SIOGICHIOVElS 4 34 Engins Doald ar uat cs anon aa nh 4 34 board rom Vahase Dome mare Se ee quu es 4 36 System board cage tice cae FG Sq Fg E EE 4 38 High voltage power supply HVPS 2 24930 md maman mem 4 39 Low voltage power supply LVPS with cage 4 40 PEEL 4 41 Tonor Present Sensor ua eos a ies ud eats d alc 4 41 Toner Senssar Hcelvor uses siren PRAG ERE ER EE 4 42 Lett ay guide assembly removal quiu scm mg nct iR ng rn arg CR S 4 42 Mogcem spsakor KaIDVal auus duas es x PUE RUE AEQ RU a eam als 4 43 Fusar rari xal as ach eee qaaa dd 4 43 Modem cardi eoVal ep pa quee deba tpa qui Soo S dip quocp dea pudiese e
141. oller 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 24 for steps to gain access to sensor cable MCN8 Toner empty sensor sender 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 24 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 26 Service Manual Toner empty sensor receiver TTR service check 7100 XXX Step 1 Questions actions Turn printer off and remove engine 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
142. 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 8 Note Photodeveloper cartridge is a customer order supply Diagnostic information 2 57 7100 XXX Smear service check The entire image appears smudged NL ln J amt NEL I p nme 383335 ptm Problem area Action 1 Photodeveloper cartridge OPC belt and transfer belt This print quality issue is usually accompanied by a paper jam Remove the photodeveloper cartridge and check for a piece of paper on the rear side of the photodeveloper cartridge Remove the piece of paper from the photodeveloper Note This occurs mostly with A5 and B5 size media 2 58 Service Manual Toner drop service check 7100 XXX Registration A toner spot stain on
143. onfiguration Page Press and hold J The configuration page will print out Setting the country code The country code must be reset when the system RIP board is replaced The country code setting determines which communication protocols compression settings and signal strength settings will be used for a given country or region Failure to reset the country code can render the fax functionality unusable To set the country code perform the following steps 1 in Ready mode press to enter the MFP menus 2 Use the A or W keys to scroll to the Administration menu Press to select the Administration menu 4 5 6 Use the or keys to scroll to the Country menu Use the or keys to scroll to the desired country or region Press to select and confirm the country or region Scanner calibration and registration The X5xx scanner is self calibrating Scanner calibration occurs every time the MFP is started in addition calibration is performed before a scan copy or fax action is performed Top edge registration is performed when the MFP is powered on and before every scan copy or fax Right and left edge registrations are performed only when the MFP is started If the scanner fails to calibrate 006 Service Call Scanner Unit will be displayed Should this error display see Flatbed service check on page 2 41 Diagnostic aids 3 3 7100 XXX Lexmark confidential until announce edited 1 4 2007
144. ong table or desk top Inspect all supplies OCR cartridges photodevelopers toner cartridges belts fuser maintenance kits and paper sources cassettes trays feeders duplex drawers finisher mailbox trays for obvious damage and proper installation paper guides not too tight Inspect for correct media usage paper transparencies labels Print demo page e f additional paper sources are installed print a demo page from each of these if possible Failure to print from an additional tray or feeder may imply one or more pins are bent in the mating connector General information 1 15 7100 XXX Serial number Look for serial number information on the right cover and the inside of the front cover of your MFP number Tools required for service The removal and adjustment procedures described in this manual require the following tools and equipment Analog volt ohmmeter A digital volt ohnmmeter may also be used Flat blade screwdrivers Needle nose pliers 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 1 16 Service Manual 7100 XXX Acronyms ADF ASIC BOOTP CCD DDNS DHCP DPI DRAM EP ESD FRU HTTP HV HVPS JBIG LAN LASER LCD LED LV LVPS MFP NVRAM MH MMR MR OEM PABX POR P
145. or 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 MCNO from belt marker sensor Marker engine controller board Check for 5 VDC sensor is part of a bracket between MCNSO pin 1 on engine controller assembly See board and ground you can touch negative assembly removal on s page 4 30 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 MCN9 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 41 touch negative lead of voltmeter to metal Engine controller board frame to obtain ground Is voltage present removal on page 4 34 and correct Diagnostic information 2 17 7100 XXX Transfer roller clutch service check Engine controller boar
146. ormation Xvii 7100 XXX Lithium information CAUTION There is a lithium battery on your system board RISK OF EXPLOSION IF REPLACED BY INCORRECT TYPE The battery is non replaceable Do not replace recharge disassemble or incinerate a lithium battery Discard used batteries according to the manufacturer s instructions and local regulations Lithium Information ACHTUNG Auf Ihrer Systemplatine befindet sich eine Lithiumbatterie Beim Einsetzen eines nicht passenden Batterietyps besteht ein Explosionsrisiko Die Batterie darf nicht ausgetauscht werden Lithiumbatterien d rfen auf keinen Fall ausgetauscht wieder aufgeladen auseinander genommen oder verbrannt werden Befolgen Sie zum Entsorgen verbrauchter Batterien die Anweisungen des Herstellers und die rtlichen Bestimmungen XViil Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX 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 Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer pr
147. ormed Replace toner cartridge 2 Photodeveloper cartridge OPC belt surface is damaged Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 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 7100 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 8 Note 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 5 Diagnostic information 2 49 7100 XXX insufficient fusing servi
148. oval 1 Remove the left secondary paper feed assembly cover Repeat for the right side 2 Loosen the thumbscrew A on the left bracket and remove the bracket Repeat for the right side 3 With help from another person lift the by the recessed handholds and remove the from the secondary paper feed assembly Repair information 4 9 7100 XXX Cover 5 Top cover assembly removal Remove the scanner assembly See Flatbed assembly removal on page 4 49 Remove the upper right rear cover See Upper right rear cover removal on page 4 17 Remove the cleaning roller cover See Cleaning roller cover removal on page 4 4 Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Open the OPC cover Remove the two screws A from the top cover assembly c grim o qe 7 Open the rear cover 8 Remove the upper right rear cover See Upper right rear cover removal on page 4 17 4 10 Service Manual 7100 9 Remove the screw B which secures the top cover to the frame 10 Remove the upper left rear cover See Upper left rear cover removal on page 4 17 11 Remove the screw C which secures the top cover to the MFP frame C 12 Release the tabs on the front of the top cover assembly 13 Lift the top cover assembly and remove Note If you are replacing the top cover assembly remove the scanner arms They will
149. ove the system board See System board removal on page 4 36 Remove the screw A that secures the interlock assembly to the printer engine frame Set the interlock assembly aside 4 44 Service Manual 7100 5 Disconnect the fuser fan cable from the connector B behind the interlock assembly 7 Remove the three screws D that secure the fuser fan assembly to the printer engine frame 8 Lift and remove the fuser fan assembly Repair information 4 45 7100 XXX Modem card removal 1 Remove the rip cage cover 2 Disconnect the 30 pin cable A from the modem card 4 0630 3 Remove the screws that secure the modem to the RIP cage 4 Remove the modem 4 46 Service Manual 7100 XXX Top removals Marker sensor assembly removal Remove all the toner cartridges Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 Remove screw A from the bracket gt 5 Disconnect the cable from the sensor and remove the marker sensor assembly Repair information 4 47 7100 XXX Waste toner auger removal Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 Remove the top cover assembly See cover assembly removal on
150. p 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 13 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 9 Does error clear 4 Replace engine controller board See Problem solved Contact higher level Engine controller board removal on support page 4 34 Does error clear 2 28 Service Manual Tray empty service check 7100 XXX 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 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
151. pecifications Printing states X5xxn Off ow Average power while operating Continuous printing 670 W Power consumption standby Power saver on 35 W Power saver off 200 W Maximum current while operating 115 Volts 11A 230 Volts 6A Average current while operating 115 Volts 6 0 A 230 Volts 3 0 A 1 4 Service Manual 7100 XXX Environment Environment Specifications Operating Air temperature product operating 10 to 32 5 C 50 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 F 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 C 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 General information 1 5 7100 XXX Print engine specifications Print engine resolution 600 x 600 dpi 1200 x 600 dpi Color balance settings This MFP 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 all four color planes The scale ranges from 10 to 10 Emulations Raster Graphics CMYK bi tone JBIG Compressed Print eng
152. 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 20 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 cover touch meter Erase lamp removal on positive lead to left LED connection and page 4 20 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 shield See Go to step 5 Properly connect cable Engine controller board removal on Retest printer If error page 4 34 for steps to remove engine clears problem solved controller board shield Is cable properly otherwise go to step 5 connected to engine controller board connector MCN8 5 Disconnect cable from erase lamp and Replace engine controller Replace cable Retest engine controller board 8 Check for board See Engine printer Go to step 6 continuity between cable pin that controller board removal corresponds to MCN8 pin 11 and erase on page 4 34 Go to step 6 lamp cable co
153. proper registration clutch cable connection or a shorted or cut cable See Registration clutch service check on page 2 19 Marker sensor is not properly detecting mark on OPC belt See OPC belt marker sensor service check on page 2 20 EL Service Call Erase Lamp 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 21 FO Service Call Power Supply Fan Improper fan motor rotation improper fan motor cable connection or a shorted or cut cable See Power supply fan service check on page 2 22 F4 Service Call Fuser Fan Improper fan motor rotation improper fan motor cable connection or a shorted or cut cable See Fuser fan service check on page 2 22 F5 Service Call HV Power Supply Unit 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 23 F6 Service Call LV Power Supply Unit Data communication error between LVPS and the engine controller board See Low voltage power supply LVPS service check on page 2 23 HO Service Call Fuser Unit Temperature signal from thermistor is not detected See Fuser thermistor service check on page 2 24 H1 Service Call Fuser Unit Circuitry that controls the fuser temperature has failed See Fuser assembly service check on page
154. r Parts catalog 7 5 7100 XXX Assembly 3 Scanner unit 7 6 Service Manual Assembly 3 Scanner Unit 7100 XXX index P N Units Description 3 1 40X4702 1 Assembly pick roll 2 40X4703 1 Pad ADF separator 3 40X4701 1 Assembly ADF 4 40X4709 1 Cover ADF mechanism 5 40X4708 1 Tray ADF input 6 40X4714 1 Cable ADF 7 40X4713 1 Guide Cable 8 40X4700 1 Assembly flatbed 9 40X4693 1 Panel operator X 500 9 40X4695 1 Panel operator X 502 10 40X4721 1 X 500 Bezel operator panel 10 40X4722 1 X 502 Bezel operator panel Parts catalog 7 7 7100 XXX Front Assembly 4 P NDA ANN i d ay Jk 4 7 8 Service Manual Assembly 4 Front 7100 XXX 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 temperature thermistor 4 40X3401 Right tray guide 5 40X3416 Lamp erase Parts catalog 7 9 7100 XXX Assembly 5 Right 7 10 Service Manual Assembly 5 Right 7100 XXX 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 40X4718 1 Packet parts 6 40X3390 1 Clutch paper feed 7 40 3397 1 Drive assemb
155. r Tull SOIVICO COOR 53 saeua rad iu ada qq du Mad aed 2 22 High voltage power supply HVPS service check 020 e cece ee eee eee eee 2 23 Low voltage power supply LVPS service 2 23 Fusar herm SOIvicg ChOCK oo que sqq ex 2 24 Fuso assombly Sorvico CHECK zu si m MAIS id Re 2 24 Laser unit assembly SOWICECHOCK ah gracie pec e voi m need ames 2 25 PVE connection Service sus auri RA RS RE cee ae 2 25 Toner empty sensor sender TPD service 2 26 Toner empty sensor receiver TTR service 2 27 Lower feed unit secondary paper assembly service 2 28 Tray empty Service CHECK eeu Rama E dae a E d MS RI REGE 2 29 Paper tray missio Service asas adeo x ew x duds 2 30 Toner Service CHECK sump PEG ERA 2 31 Table of contents iii 7100 XXX Waste toner bolle Serica CHECK mu ese epa ba medicare a ba a RR S a d ds 2 31 Missing tener Barind5e Service CHebK so aree
156. r board and toner sensor sender board See Toner empty sensor sender TPD service check on page 2 26 N5 Service Call Toner Empty Rcv Improper connection between engine controller board and toner sensor receiver board See Toner empty sensor receiver TTR service check on page 2 27 N6 Service Call LFU Connection Improper connection between engine controller board and lower paper feed unit See Lower feed unit secondary paper assembly service check on page 2 28 P6 Service Call Pfeed Clutch Tray 2 Data communication error between engine controller board and LFU paper feed clutch See Lower feed unit secondary paper assembly service check on page 2 28 Diagnostic information 2 5 7100 XXX User status messages Message Description Action Tray 1 2 Missing 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 30 Toner Low C M Y K The toner is low in the cartridge indicated See Toner low empty service check on page 2 31 Sleep The MFP is idle Please Wait The MFP is warming up READY The MFP is ready to perform a task PC Printing The MFP is printing Calibrating The MFP is calibrating Connected to Server The MFP is connected to a server for a push scan job Sending File A scan job is being transmitted S
157. r 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 6 Ensure transfer roller 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 40 One color missing 4 Toner cartridge Replace faulty toner cartridge 2 66 Service Manual 7100 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 6 Replace faulty fuser assembly Note Fuser assembly is a customer order supply Diagnostic information 2 67 7100 XXX Uneven density right and left Optical density is different between right and left side of printed image Action
158. riginal 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 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 XVi Service Manual Lexmark confidential until announce edited 1 4 2007 Informaci de Seguretat espec fics El fabricant no es fa responsable de les q estions de seguretat si s utilitzen peces de recanvi no autoritzades destinada a ning que no ho sigui 7100 XXX La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est 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
159. riter ongin Sensor IDOSUDEHS acack en acd Rcs Rie ric EO 5 4 MFP circuit board logdllOlS 225resseesetaacEkeeXaccweerdu wee er a age 5 5 Farvmoter anc interno SWC aac qnaa qu ad sae a sad SEN E eua durae ae M a c RR 5 6 E oro aa DES oues p siga aas E MESE EE ER EPA CERES ERA GE 5 7 Symbal and partriame Table asco deren Rx exce E REA 5 8 Engine controller board wiring diagrami assess mas Quei rx a GUI RE E Ra ERG E RUE 5 9 RIP DIS GERE RN E EK ENS ME RM REF DE 5 15 RIP cai Val adds x oues EA SERE 5 15 Erdira DOBLE uos s So avg X opo Bara gras iv S e oa acne edo iR Er 5 16 Low voltage power supply LVPS boards ausreicht m rm ee eee een ow 5 16 High voltage power supply HVPS board Sea RR 5 17 Modem Card voltages arid Signals 2 4 3 epa E RTEQamS E PEG EA PERS S 5 18 Prevenimve malhtenale6 RU EGER ER E d MEER BOR RU RR Rd 6 1 Vi Service Manual 7100 PANS catalog oa css aue dd dis 7 1 Howto use this parts catalog dads
160. riveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse 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 niva under vanlig bruk vedlikehold som utfgres av brukeren eller foreskrevne serviceoperasjoner Notices and safety information X 7100 XXX Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte laser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un laser de classe IIIb 8b d arseni r de gal li nominalment de 5 mil liwats i funciona a 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 prescrit
161. rror codes 2 3 symptom tables 2 11 user attendance messages 2 8 user status messages 2 6 E emulations 1 6 engine controller board removal 4 34 wiring diagram 5 9 engine controller board connections 5 10 environment 1 5 erase lamp removal 4 20 error codes service 2 3 user attendance messages 2 8 user status messages 2 6 ESD sensitive parts 4 2 fax specifications 1 11 document sizes supported 1 12 miscellaneous 1 12 phone network connectivity 1 11 7100 XXX scan resolutions 1 12 flatbed assembly removal 4 49 front cover assembly removal 4 12 front door interlock switch removal 4 21 fuser aseembly removal 4 6 fuser fan assembly removal 4 43 H handling ESD sensitive parts 4 2 high voltage power supply removal 4 39 HVPS cage removal 4 41 J jam messages JAM A tray rear tray 1 3 24 JAM A tray rear tray 2 3 26 JAM B rear 3 27 JAM C rear 3 29 L Laser unit assembly removal 4 18 left front cover removal 4 15 left rear cover removal 4 16 left tray guide assembly removal 4 42 Lithium Information i xvili Lithium Warning i xviii locations 5 1 circuit boards 5 5 connections engine card 5 10 modem card 5 18 engine controller board 5 16 fans and motors 5 6 high voltage supply board 5 17 low voltage power supply board 5 16 printer front and rear view 5 1 RIP board 5 15 scanner 5 3 sensors printer engine 5 4 solenoids and clutches 5 7 wiring diagram engine controller board 5 9 Index
162. rtungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine gef hrliche 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 Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones 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 da os 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 o
163. s cartridge installed properly 2 Check printer contacts A and Replace photodeveloper Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Note photodeveloper cartridge is a customer ordered supply If problem persists replace HVPS See High voltage power supply HVPS removal on page 4 40 cartridge See Photodeveloper cartridge removal on page 4 8 Diagnostic information 2 33 7100 XXX Transfer roller missing service check Step 1 Questions actions Turn 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 5 cage removal on page 4 42 and put it back in place If B is damaged replace registration assembly See Registration assembly removal on page 4 33 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 40 2 34 Service Manual Cover open service check 7100 XXX 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 13 actuator Check all interlock swit
164. ssembly Remove the two screws A from the laser unit assembly cover The photograph below is looking through the opening in the top cover assembly 4 18 Service Manual 7100 7 Remove four screws B from the laser unit assembly 8 Remove the laser unit assembly from the MFP 9 Disconnect the connector from the laser unit assembly Repair information 4 19 7100 XXX Erase lamp removal Remove all the toner cartridges Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 Remove the two screws A peso Toros 5 Disconnect the erase lamp cable B 6 Remove the erase lamp 4 20 Service Manual 7100 Right side removals Front door interlock switch with bracket 1 Remove the top cover assembly See cover assembly removal on page 4 10 2 Remove the right cover See Right cover removal on page 4 13 3 Disconnect the interlock switch cable A from the interlock switch 4 Remove the screw B and disengage the locking clip on the back of the bracket 5 Remove the switch with the bracket Repair information 4 21 7100 XXX Waste toner bottle holder removal 1 Remove the right cover See Right cover removal on page 4 13 2 Disconnect the waste toner bottle holder connector A 3 Remove three screws B from the waste toner bot
165. 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 Upper right 4 continuity and shorted pins Is cable okay rear cover removal on page 4 17 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 BCN1 on the HVPS and the engine controller board HVCN connector 2 Turn printer off and remove items to expose Replace HVPS See High Replace cable Retest voltage power supply HVPS removal on page 4 40 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 25 7100 XXX Toner empty sensor sender TPD service check Step 1 Questions actions Turn printer off and remove engine contr
166. step 7 present actuator stuck remove debis from the actuators 7 Are the sensor actuators on the ADF Replace the ADF Go to step 8 mechanism cover damaged mechanism cover 8 Is the ADF connector properly connected to Go to step 9 Properly connect the cable J ADF1 on the system board to the system board 9 inspect the connections on the ADF relay Go to step 10 Secure all the connections card in the ADF Are all the connections properly connected 10 Check the ADF cable for continuity Is there Go to step 11 Replace the ADF cable continuity 11 Check for signals or voltages from J ADF Replace the ADF unit See Replace the system board The voltage will only be present on pin 1 when a copy job is run Pin one on connector J ADF1 should measure Are there signals or voltages present ADF unit removal on page 4 54 See System board removal on page 4 36 2 42 Service Manual Modem fax card service check 7100 XXX Step Questions actions Yes No 1 Is the phone line properly connected to the Go to step 2 Properly connect the phone modem card and the wall jack line to the modem card and wall jack 2 Is the modem card cable properly Go to step 3 Properly connect the connected to the system board at J FAX 1 modem card cable to the and the modem card modem card and system board 3 Check the modem card cable for continuity Go to step 4 Replace the modem card
167. steps to remove engine problem solved otherwise controller board shield Disconnect MCN5 go to step 8 from engine controller board Check for continuity and shorted pins on cable that connects 5 to main motor Is cable okay 2 14 Service Manual 7100 XXX Step Questions actions Yes No 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 board cage removal on Are voltages present page 4 39 Go to step 9 9 Reassemble and retest printer Does error Problem solved Contact next level of clear support Diagnostic information 2 15 7100 XXX CPU fan service check Step Questions actions Yes No 1 Open the RIP cage cover Is the CPU fan No issue to fix Go to step 2 spinning 2 Is the CPU fan cable properly connected to Connect the cable to J Replace the RIP board See 1 on the RIP board Fant System board removal on page 4 36 Developer drive assembly service check Step Questions actions Yes No 1 Are there any unusual noises heard around Replace toner cartridge Go to step 4 d
168. su uso normal el mantenimiento realizado 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 em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe nao sao considerados perigosos internamente a impressora cont m um produto laser da Classe 3b designado laser de arseneto de pot ssio de 5 milliwatts operando 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 a radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse 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 1116 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 norma
169. t 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 7100 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 replace toner cartridge 3 Photodeveloper cartridge Photodeveloper cartridge has reached life or is failing Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Note Photodeveloper cartridge is
170. tage power supply Provides power to control the MFP LVPS High voltage power supply Provides power necessary for the printing HVPS process Locations and connectors 5 5 7100 XXX Fan motor and interlock switch locations switch Paper exit interlock switch Main motor Front interlock switch Developer motor Scanner motor Name Code Function Main motor MM Drives OPC belt and paper transport system Developer motors DM Drives toner cartridge and developing system Scanner motor SCM 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 Front interlock switch DSW1 mbly DSW2 Safety interlock switches that break power when covers are opened Top interlock switch DSW3 5 6 Service Manual Clutch locations 7100 XXX Cleaning roller clutch 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 Transports paper by coupling registration roller to main gear unit RECL as synchronized with rotation of transfer belt Cleaning roller clutch Drives the transfer belt cleaner brush by coupling clean
171. tation 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 motor assembly removal on page 4 26 3 Developer drive assembly Replace faulty developer drive assembly See Developer drive assembly removal on page 4 22 2 52 Service Manual 7100 XXX 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 8 Note Photodeveloper cartridge is a customer order supply Diagnostic information 2 53 7100 XXX 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 toner cartridge if defective 2 Transfer roller clutch Replace transfer roller clutch See Clutch removal on page 4 27 3 Transfer belt unit cleaning roller clutch Replace transfer belt unit cleaning roller clutch See Cleaning roller clutch removal
172. tep 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 6 Does voltage power supply error clear LVPS with cage removal on page 4 41 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 24 Service Manual Laser unit assembly service check 7100 XXX HVPS See High voltage power supply HVPS removal on page 4 40 for steps Check for continuity and pin shorts of cable that connects engine controller board HVCN and HVPS BCN1 Is cable okay Also ensure that there is no damage to the connectors on both boards 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
173. ter over the RIP card Power switch Turns the printer on and off Upper left cover Covers the fuser fan USB connection Connects the MFP to the host by USB Network connection Connects the printer to an 10 100 1000 base T network AC input inlet Connects the power cord that supplies AC power to the printer 5 2 Service Manual Scanner locations 7100 XXX Callout Description Paperpath Sensor ADF pick roll assembly ADF separator assembly Cover closed sensor Paper present sensor ADF paper tray Flatbed cover ADF Assembly Flatbed assembly NI ODO a AJOJN Operator panel Locations and connectors 5 3 7100 XXX Electronic components Printer engine sensor locations OPC 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 F
174. terlock 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 MCN7 pin 3 on engine controller removal on page 4 47 Tr problem persists replace board 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 of voltmeter to metal frame to obtain ground Controller board removal Is voltage present and correct i ca lata 6 Turn printer off Disconnect cable that Replace LVPS See Low Replace cable connects LVPS ACN 1 to engine controller voltage power supply board POCN and check for continuity LVPS with cage shorted pins or any other cable damage 5 removal on page 4 41 cable okay 2 20 Service Manual Erase lamp service check 7100 XXX 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
175. terlock switch 7 11 Paper guide assembly 7 13 Assembly marker sensor OPC includes bracket 7 17 Part number index 1 5 7100 XXX 40X3441 40X3442 40X3443 40X4686 40X4687 40X4688 40X4689 40X4690 40X4691 40X4692 40X4693 40X4694 40X4695 40X4696 40X4698 40X4699 40X4700 40X4701 40X4702 40X4702 40X4703 40X4704 40X4705 40X4706 40X4708 40X4710 40X4711 40X4713 40X4714 40X4715 40X4716 40X4717 40X4717 40X4717 40X4718 40X4719 40X4720 40X4721 40X4722 7372640 Cover laser unit assembly lens 7 9 Parts packet harness 7 19 Parts packet harness 7 19 Cover assembly top 7 5 Cover front left sree ee ee 7 5 Cover rearlafts ese ee ec decere 7 5 Board engine controller 7 15 Fan power supply includes top cover and rear cover assembly interlock switches 7 17 Assembly fuser fan 7 47
176. the Service error codes on page 2 3 and take the appropriate action Diagnostic information 2 1 7100 XXX Understanding the operator panel Using the MFP menus Copy Settings Paper Select Sort Density Quality Reduce Enlarge Scan Settings Document Size Multi Page in A Document Limitless Scan Color Compress Ratio Resolution Density Limitation of size of mail 2 2 Service Manual Machine Settings Speaker Volume Paper Settings Job Timeout Auto Continue Toner Saver Mode Supplies info Scanner Carriage Fax Settings TX Settings RX Settings Tray Settings Delete Document Comm Settings Report Settings Network Settings Ethernet IP Configuration Fax Directory Quick Dial Entry Speed Dial Entry Reports Print Configuration Page Activity Report Memory List Quick Dial List Speed Dial List Scan Directory Scan Transmission Log Demo Page Maintenance Page Admin Settings Date Time Setup User Settings TEL Line Type PBX Selection PBX Access Digit Default Mode Auto Clear Power Saver Display Language Country Code Setting Default Admin Menu Lock 7100 XXX Service error codes Error code Action 001 Service Call System Board CPU 002 Service Call System Board Flash 003 Service Call System Board DRAM 004 Service Call System Board RTC 009 Service Call System Board Replace the RIP board See System board removal on page 4 36 Or rep
177. the X500 Lexmark confidential until announce edited 1 4 2007 This graphic illustrates the steps of the EP process on the X500 Charging Print system Exposing KIC MY 6 OPC belt cleaning Developing My 5 Belt discharge Transfer system belt First transfer transfer belt K Transfer belt Second transfer paper 8 Transfer belt cleaning Transport system 10 Paper exit 3 10 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX X500 EP steps in detail Step 1 Charge During the charge step voltage is sent from the high voltage power supply to the charge roller inside the photodeveloper The charge roller is part of the photodeveloper unit The charge roller puts a uniform negative charge over the entire surface of the photodeveloper to prepare it for the laser beam This is the charge process Look at callout 1 in the picture below This is the location of the charge roller inside the photodeveloper The charge roller is the main component in step 1 of the EP process Note If the surface of the charge roller is damaged such as a nick or pit it will cause the charge to be uneven on the photodeveloper This will cause a repeating mark on the printed page Check the service manu
178. the paper tray into the printer by a feed roller which carries the media to the registration rollers The media trips the registration sensor At this point the media pauses so the registration rollers can properly time the media entry to the EP process The registration rollers help ensure that the image is properly spaced and aligned on the media The registration rollers push the media to the transfer roller where the image is transferred to the page The transfer roller moves the media to the fuser The fuser applies heat and pressure to the page The heat and pressure permanently bond the image to the media The fuser rollers push the media toward the exit bin and past the fuser exit sensor The exit rollers guide the paper into the output bin Diagnostic aids 3 21 7100 Lexmark confidential until announce edited 1 4 2007 Paper jam messages The following illustration lists paper jam messages indicating where the paper jam occurred CAUTION N When clearing paper jams inside of the printer may be hot Allow printer to cool before touching any internal components 3 22 Service Manual Lexmark confidential until announce edited 1 4 2007 7100 XXX 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
179. tle holder The bottom screw is longer than the other Screws 4 Remove the waste toner bottle holder from the MFP Developer drive assembly removal 1 Remove the main motor assembly See Main motor assembly removal on page 4 26 2 Remove the waste toner bottle holder See Waste toner bottle holder removal on page 4 22 3 Remove four clips and the developer drive gears A from the inside of the MFP 4 22 Service Manual 7100 4 Disconnect the developer driver assembly cables B 5 Remove the four screws C from the developer drive assembly 6 Remove the developer drive assembly from the MFP Repair information 4 23 7100 XXX Toner sensor sender removal 1 Remove the developer drive assembly See Developer drive assembly removal on page 4 22 2 Remove two screws A from the toner sensor Note The bottom screw is longer than the top screw 3 Pull the toner sensor away from the MFP disconnect the cable and remove the sensor 4 24 Service Manual 7100 Cleaning roller clutch removal 1 Remove the transfer belt cleaning roller See Transfer belt cleaning roller removal on page 4 4 2 Remove the right cover See Right cover removal on page 4 13 3 Using a flat tipped tool pry and remove the cleaning roller clutch gear from the inside of the MFP 4 Disconnect the cleaning roller clutch cable A 5 Remove three screws B from the cleaning roller clutch 6
180. two captive screws A counterclockwise until they are 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 the transfer belt unit toward rear of the MFP lift and remove Repair information 4 5 7100 XXX Transfer roller removal 1 Open the rear cover assembly 2 Rotate the transfer roller to release lift and remove Fuser assembly removal 1 Push the rear cover assembly latch and lower the rear cover assembly 2 Turn two green fuser release levers A 4 6 Service Manual 7100 XXX 3 Lift the fuser straight up and away from the MFP Waste toner bottle removal 1 Open the front cover 2 Remove the waste toner bottle Warning Ensure that the 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 Repair information 4 7 7100 XXX Photodeveloper cartridge removal Warning Follow precautionary procedures see Photodeveloper cartridge on page 4 3 when removing the photodeveloper cartridge Raise the scanner assembly Open the top cover assembly Depress the release levers A Lift and remove the photodeveloper cartridge 5 Lay the photodeveloper cartridge as shown in a clean area 4 8 Service Manual 7100 XXX Secondary paper feed assembly rem
181. ty 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 3 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 User attendance 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 User attendance 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 11 Locate your symptom and take the appropriate action If a service error code appears while you are working on the printer go to
182. ua gra ease 4 45 Hus TEC eX 4 46 Marker sensor assembly removal caes ps ages 4 46 Waste Toner BUGS E RISE Kis RN NES RAN 4 47 Waste toner aditelor TEITtOVal mra EARS ers Fa PR eG e E dps 4 47 Power supply TS WRT AA Rc gi e aac S aam cul cc i e el 4 48 ocannghassaaibbyemavale 33 252x193 EU aU 4 49 Flatbed assembly ermoval oe aad xri ES daa RS oe au arido 4 49 SCQHTar SINLFONIOVG puede pps qaod Chee addis pues i 4 52 ADIFABIECTOTOVSIS ub eos ed eR dea ari 4 53 AOF meschamsm Cover retilgval 225 22 2 qup e e OST PES CMS mess 4 55 Operator panel removal SN TES 4 57 Locations and connectors tense 5 1 Printer rom and rear VIOWE RR RR GEM RENE 5 1 SCAM CHIONS 5 3 Elactonic ColmppoUerila s s ees PAM REG E PRESE 5 4 Pl
183. und 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 f After part replacement ensure the wiring harness is not caught or damaged Do not attempt to cut or 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 MFP stops running Always unplug connectors by holding the connector housing Remember to install the ground wire or ground plate to ensure a positive conduction Install the screw with a toothed washer in the correct position at reassembly Never lift the MFP from the scanner assembly Confirm the direction of all parts and screw lengths during removal replacement 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 Utilize the proper cleaning procedures solvents during maintenance Repair information 4 1 7100 XXX Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing logic cards Keep the ESD se
184. user 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 PAR 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 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 5 4 Service Manual 7100 circuit board locations Erase lamp HVPS System RIP board Modem fax board LVPS Engine controller board Name Function Engine controller board Controls the following MFP processes Fuser temperature control Laser output control Toner empty sensing control Error processing control interface control System RIP Board Controls flatbed and ADF functionality Host connectivity Controls flatbed and ADF functionality Operator panel indication Modem Fax board Controls fax transmission and reception Erase lamp Discharges OPC belt located in the photodeveloper cartridge Low vol
185. wer paper feeding unit TPD Toner empty sensor TTR LVPS Power supply unit TRCM Transfer cam clutch 5 8 Service Manual Engine controller board wiring diagram Toner empty sensor TPD sender receiver Transfer unit sensor Toner density sensor Registration sensor fes Tray empty sensor Power supply fan Vr lt controller LFU Erase lamp 57 Paper size sensor 0 0 0 Room temp sensor sneak lo Ed 0 en 0 E 0 o 9009000 MCN9 0000000 9900000 MCN6 0000000 1 control board O MCN8 MCN7 Lint 1 1 Ld 1 ia FUCN ene 000000000000000 1 ACN1 Low voltage power suppy MCN5 HVCN So Z S Front door Top door Rear door Development motors Main motor iie 7100 XXX BRV CLV OCV High voltage power supply Registration clutch Transfer roller clutch Cleaning roller solenoid FBCL WTS LED Paper feed clutch DM1 rotation detection Waste toner sensor receiver Toner present sensor Fuser exit
186. wo separate parts the sender and the receiver The sender portion of the toner sensor is located on the right side of the MFP See Toner sensor sender removal on page 4 24 for removal 1 Remove the HVPS cage See HVPS cage removal on page 4 41 2 Remove 2 screws A remove the toner sensor receiver 3 Disconnect the toner sensor cable from the connector B on the toner sensor receiver Note The bottom screw is longer than the top screw 0 qs Left tray guide assembly removal 1 Remove the marker sensor See Marker sensor assembly removal on page 4 46 2 Remove the HVPS cage See HVPS cage removal on page 4 41 3 Reroute cable A to allow sufficient cable length for removing the left tray guide assembly from the frame 4 Remove two B screws that secure the left tray guide assembly to the MFP frame Repair information 4 43 7100 XXX 5 Slide the left tray guide assembly out in front of the MFP Modem speaker removal Remove the left rear cover Remove the top cover Disconnect the modem speaker cable from the system RIP board Remove the old speaker from the interlock assembly by prying the speaker retaining tabs back and sliding the speaker out of the interlock assembly Fuser fan assembly removal Remove the left rear cover See Left rear cover removal on page 4 16 Remove the top cover See Top cover assembly removal on page 4 10 Rem
187. xit unit 4 14 paper feed roller 4 32 paper guide C assembly 4 31 paper guide assembly 4 31 photodeveloper cartridge 4 8 power supply fan 4 48 rear 4 30 rear cover assembly 4 14 registration assembly 4 33 right cover 4 13 right side 4 21 scannerarm 4 52 second paper feed assembly 4 9 sensor assembly 4 46 system board 4 36 system board cage 4 38 toner present sensor 4 41 toner sensor receiver 4 42 toner sensor sender 4 24 top 4 46 top cover assembly 4 10 transfer belt cleaning roller 4 4 transfer belt unit 4 5 transfer roller 4 6 upper left rear cover 4 17 upper right rear cover 4 17 waste toner agitator 4 47 waste toner agitator removal 4 47 waste toner auger 4 47 waste toner bottle 4 7 waste toner bottle holder 4 22 waste toner feeder 4 28 repair information 4 1 required tools 1 16 right cover removal 4 13 7100 XXX roller spacing 2 69 5 safety information i xv scan specifications 1 10 scanner arm removal 4 52 Scanner calibration and registration 3 3 secondary paper feed assembly removal 4 9 sensing by source 1 14 serial number 1 16 service checks ADF paperfeed 2 42 ADF streak 2 41 black page 2 41 cover open 2 35 developer drive assembly 2 16 erase lamp 2 21 flatbed 2 41 fuser assembly 2 24 fuser fan 2 22 fuser thermistor 2 24 high voltage power supply 2 23 HVPS connection 2 25 laser unitassembly 2 25 lower feed unit paper tray 2 2 28 lower voltage power supply 2 23 main motor 2 14 missing fuser
188. y one side opposite blue side and must make contact with the metal pins on the connectors 3 Remove 11 screws A 4 corner screws are gold in color metal inner screws are silver plastic remove HVPS 4 40 Service Manual 7100 Low voltage power supply LVPS with cage removal 1 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 2 Remove the RIP board cage See System board cage removal on page 4 38 3 Remove the grounding terminal screw A 4 Disconnect the power supply bracket connector B 5 Remove three screws C that attach the power supply bracket remove the power supply bracket N sg B SS B A C 6 Remove the screw D and disconnect all the connectors from the LVPS 7 Remove three metal screws E and 3 plastic screws that attach the LVPS with the cage remove the LVPS with the cage Repair information 4 41 7100 XXX HVPS cage removal 1 Remove the HVPS See High voltage power supply HVPS removal on page 4 39 2 Remove the LVPS with cage See Low voltage power supply LVPS with cage removal on page 4 40 3 Remove three screws A remove the HVPS cage Toner present sensor removal 1 Remove the HVPS cage See HVPS cage removal on page 4 41 2 Remove two screws A remove the toner present sensor 4 42 Service Manual 7100 Toner sensor receiver removal Note The toner sensor is comprised of t

Lexmark X500n-X502n MFP 7100 Service Manual

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