Lexmark X502n Service Manual - Page 3

Table of contents

iii

7100-XXX

Table of contents

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

General information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Models

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

MFP Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

General device technical specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Print engine specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Scan specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Copy specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Fax specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Media guidelines

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Maintenance approach

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Standard inspection and cleaning procedure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Serial number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Tools required for service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Acronyms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Diagnostic information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Understanding the operator panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Service error codes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

User status messages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

User attendance messages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Symptom tables

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

MFP symptom table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Print quality symptom table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Printer service checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Main motor service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

CPU fan service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Developer drive assembly service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Transfer belt unit service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Transfer roller clutch service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Transfer belt cleaning roller clutch service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Paper feed clutch service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Registration clutch service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

OPC belt marker sensor service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Erase lamp service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Power supply fan service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Fuser fan service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

High voltage power supply (HVPS) service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Low voltage power supply (LVPS) service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Fuser thermistor service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Fuser assembly service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Laser unit assembly service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

HVPS connection service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Toner empty sensor (sender-TPD) service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Toner empty sensor (receiver-TTR) service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Lower feed unit (secondary paper assembly) service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Tray empty service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Paper tray missing service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Toner low/empty service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Lexmark X502n Service Manual - Page 3

Table of contents, Notices and safety information .. ix, Preface .xix, General information - cpu fan

Page 3 highlights

Section	Page
Table of contents	3
Notices and safety information	9
Laser notice	9
Laser	9
Avis relatif à l’utilisation de laser	9
Avvertenze sui prodotti laser	9
Avisos sobre el láser	10
Declaração sobre Laser	10
Laserinformatie	10
Lasermeddelelse	10
Laserilmoitus	11
Huomautus laserlaitteesta	11
Laser-notis	11
Laser-melding	11
Avís sobre el Làser	12
Consignes de sécurité	15
Norme di sicurezza	15
Sicherheitshinweise	16
Pautas de Seguridad	16
Informações de Segurança	16
Informació de Seguretat	17
1. General information	21
Models	21
MFP Specifications	22
General device technical specifications	22
Print engine specifications	26
Scan specifications	30
Copy specifications	31
Fax specifications	31
Media guidelines	33
Maintenance approach	35
Standard inspection and cleaning procedure	35
Serial number	36
Tools required for service	36
Acronyms	37
2. Diagnostic information	39
Start	39
Understanding the operator panel	40
Service error codes	41
User status messages	44
User attendance messages	46
Symptom tables	49
MFP symptom table	49
Print quality symptom table	51
Printer service checks	52
Main motor service check	52
CPU fan service check	54
Developer drive assembly service check	54
Transfer belt unit service check	55
Transfer roller clutch service check	56
Transfer belt cleaning roller clutch service check	56
Paper feed clutch service check	57
Registration clutch service check	57
OPC belt marker sensor service check	58
Erase lamp service check	59
Power supply fan service check	60
Fuser fan service check	60
High voltage power supply (HVPS) service check	61
Low voltage power supply (LVPS) service check	61
Fuser thermistor service check	62
Fuser assembly service check	62
Laser unit assembly service check	63
HVPS connection service check	63
Toner empty sensor (sender-TPD) service check	64
Toner empty sensor (receiver-TTR) service check	65
Lower feed unit (secondary paper assembly) service check	66
Tray empty service check	67
Paper tray missing service check	68
Toner low/empty service check	69
Waste toner bottle service check	69
Missing toner cartridge service check	70
Missing photodeveloper cartridge service check	71
Transfer roller missing service check	72
Cover open service check	73
OPC belt (photodeveloper) cartridge drive service check	74
Missing fuser service check	74
Paper size sensing service check	75
Printer no power service check	76
Toner feed service check	77
Waste toner feed service check	77
Operator panel service check	78
USB service check	78
Network service check	78
Scanner / Copy / Fax service checks	79
Black page copy service check	79
Flatbed service check	79
ADF streak service check	79
ADF paper feed service check	80
Modem / fax card service check	81
Paper feed service checks	82
Printer paper feed service check	82
Print quality service checks	83
Background service check	83
Back stain service check	84
Banding service check	85
Black line service check	86
Color misregistration service check	87
insufficient fusing service check	88
insufficient gloss service check	89
Jitter service check	90
Missing image at edge service check	91
Mixed color image service check	92
Mottle service check	93
Residual image service check	94
Ribbing service check	95
Smear service check	96
Toner drop service check	97
Vertical line service check	98
Vertical staggering image service check	99
Vertical white band service check	100
White band service check	101
White line I service check	102
White line II service check	102
White spot / black spot service check	103
White print service check	104
Wrinkle / image migration service check	105
Uneven density (right and left)	106
Spacing table	107
Roller specifications	107
3. Diagnostic aids	109
Understanding the MFP operator panel	109
Retrieving, printing and restoring the MFP settings	111
Printing the maintenance and configuration pages	111
Setting the country code	111
Scanner calibration and registration	111
Maintenance mode	112
Display info	112
Print Reports	113
Engine maintenance	114
Scan Maintenance	114
Fax Maintenance	114
Density Tune Up	116
Printer theory of operation	117
Electrophotographic Process (EP process)	117
EP Basics	117
Summary of the EP process on the X500	118
X500 EP steps in detail	119
Printer Components	127
Paper path components	128
X500n specific information	128
Paper jam messages	130
Accessing jam areas	131
Paper Jam A1, rear (tray 1)	132
Paper Jam A2, rear (tray 2)	134
Paper Jam B rear	135
Paper Jam C rear	137
ADF paper jams	138
4. Repair information	141
Removal and cleaning precautions	141
Handling ESD-sensitive parts	142
Photodeveloper cartridge	143
During transportation/storage	143
Handling	143
MFP removals	144
Cleaning roller cover removal	144
Transfer belt cleaning roller removal	144
Transfer belt unit removal	145
Transfer roller removal	146
Fuser assembly removal	146
Waste toner bottle removal	147
Photodeveloper cartridge removal	148
Secondary paper feed assembly removal	149
Cover removals	150
Top cover assembly removal	150
Front cover assembly removal	152
Right cover removal	153
Rear cover assembly removal	154
Left front cover removal	155
Left rear cover removal	156
Upper right rear cover removal	157
Upper left rear cover removal	157
Laser unit assembly (printhead) removal	158
Erase lamp removal	160
Right side removals	161
Front door interlock switch with bracket	161
Waste toner bottle holder removal	162
Developer drive assembly removal	162
Toner sensor (sender) removal	164
Cleaning roller clutch removal	165
Main motor assembly removal	166
Clutch removal	167
Main drive gear assembly removal	167
Waste toner feeder removal	168
Rear removals	170
Bracket assembly removal	170
Paper guide assembly removal	171
Paper guide C assembly removal	171
Paper feed roller removal	172
Paper exit assembly removal	172
Registration assembly removal	173
Left side removals	174
Engine controller board removal	174
System board removal	176
System board cage removal	178
High voltage power supply (HVPS) removal	179
Low voltage power supply (LVPS) with cage removal	180
HVPS cage removal	181
Toner present sensor removal	181
Toner sensor (receiver) removal	182
Left tray guide assembly removal	182
Modem speaker removal	183
Fuser fan assembly removal	183
Modem card removal	185
Top removals	186
Marker sensor assembly removal	186
Waste toner auger removal	187
Waste toner agitator removal	187
Power supply fan removal	188
Scanner assembly removals	189
Flatbed assembly removal	189
Scanner arm removal	192
ADF unit removal	193
ADF mechanism cover removal	195
Operator panel removal	197
5. Locations and connectors	199
Printer front and rear views	199
Scanner locations	201
Electronic components	202
Printer engine sensor locations	202
MFP circuit board locations	203
Fan/motor and interlock switch locations	204
Clutch locations	205
Symbol and part name table	206
Engine controller board wiring diagram	207
RIP board	213
RIP card voltages	213
Engine controller board	214
Low voltage power supply (LVPS) board	214
High voltage power supply (HVPS) board	215
Modem Card voltages and signals	216
6. Preventive maintenance	217
7. Parts catalog	219
How to use this parts catalog	219
Assembly 1: Base printer	220
Assembly 2: Covers	222
Assembly 3: Scanner unit	224
Assembly 4: Front	226
Assembly 5: Right	228
Assembly 6: Rear	230
Assembly 7: Left	232
Assembly 8: Top	234
Assembly 9: Miscellaneous/Options	236
Index	239