Lexmark C 500n User Manual

Download

• Table of contents

• Start diagnostics

• Safety and notices

Lexmark™ C500n

5023-110

• Trademarks

•Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

5023-110

Edition: April 28, 2006

The following paragraph does not apply to any country where such provisions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at 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 reference 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, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

Optra Forms is a trademark of Lexmark International, Inc. PostScript® is a registered trademark of Adobe Systems Incorporated. PCL® is a registered trademark of the Hewlett-Packard Company. All other trademarks are the property of their respective owners.

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.

12G9663

P/N

5023-110

Table of contents

Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Model differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Physical specifications and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Operating clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Packaging and shipping dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Print speed and performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Time to first print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Printer memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Paper and media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Media sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Output capacity by media and source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Printer identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Printer theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Printer paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Printer systems description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Basic principles of color printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Mechanical and electrical structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Printer component systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Basic process of color printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Print system and transfer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Structure of OPC belt (photo developer cartridge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Basic structure of the print system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Details of the print system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Charging process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Exposing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Developing process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

First transfer (drum) process

Belt discharge (erase lamp) process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Belt cleaning process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Details of the transfer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Second transfer (paper) process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Transfer belt cleaning process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

Details of the optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

Details of the paper transportation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Fusing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Fusing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

iii

5023-110

Control system structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35

Electrical system and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35

Control of print process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35

Print sequence diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36

Laser drive control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

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

Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Operator messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Paper jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Accessing jam areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

JAM-A tray, rear (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

JAM-A tray, rear(tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

JAM-B rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

JAM-C rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Printer service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Developer drive assembly service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Transfer belt unit service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Transfer roller clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Transfer belt cleaning roller clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Paper feed clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Registration clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

OPC belt marker sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Erase lamp service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Power supply fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Fuser fan service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

High voltage power supply (HVPS) service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Low voltage power supply (LVPS) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Fuser thermistor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Fuser assembly service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Laser unit assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

HVPS connection service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Toner empty sensor (sender-TPD) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Toner empty sensor (receiver-TTR) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Lower feed unit (secondary paper assembly) service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Tray empty service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Paper tray missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Toner low/empty service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Waste toner bottle service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Missing toner cartridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Missing photodeveloper cartridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Transfer roller missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

Cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

OPC belt (photodeveloper) cartridge drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Missing fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Paper size sensing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

Printer no power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Toner feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Waste toner feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

iv Service Manual

5023-110

Printer paper feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Background service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Back stain service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Banding service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Black line service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Color misregistration service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Insufficient fusing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Insufficient gloss service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Jitter service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Missing image at edge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Mixed color image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Mottle service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Residual image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Ribbing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Toner drop service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Vertical line service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Vertical staggering image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Vertical white band service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

White band service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

White line I service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

White line II service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

White spot / black spot service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

White print service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

Wrinkle / image migration service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Uneven density (right and left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

Spacing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Roller specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Understanding the printer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Maintenance page printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Saving NVRAM settings for hardware replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Saving the engine controller board settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Saving the system (RIP) board settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal and cleaning precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling the printed circuit boards with

MOS ICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

During transportation/storage:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

During replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

During inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Photodeveloper cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

During transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Parts not to be touched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printer removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Precautions to take before maintenance work

CRU/FRU and supplies removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cleaning roller cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Transfer belt cleaning roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Transfer belt unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Transfer roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5023-110

Waste toner bottle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Photodeveloper cartridge removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Secondary paper feed assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Top cover assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Front cover assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Right cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Rear cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Laser unit assembly (printhead) removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Erase lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Right side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Front door interlock switch with bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Waste toner bottle holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Developer drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Toner sensor (sender) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Cleaning roller clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

Main motor assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Clutch removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Main drive gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Waste toner feeder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Rear removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

System board removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Bracket assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

Paper guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Paper guide (C) assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Paper feed roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Paper exit assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Registration assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

Left side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Engine controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

System board cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

High voltage power supply (HVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37

Low voltage power supply (LVPS) with cage removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

HVPS cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Toner present sensor removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Toner sensor (receiver) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

Left tray guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

Top removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Marker sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Waste toner auger removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Waste toner agitator removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Power supply fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Printer

Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Printer circuit board locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Fan/motor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Interlock switch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Clutch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Symbol and part name table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Wiring diagram 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

RIP board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

vi Service Manual

5023-110

Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Low voltage power supply (LVPS) board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

High voltage power supply (HVPS) board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

vii

5023-110

viii Service Manual

Laser notices

The following laser notice labels may be affixed to this printer as shown:

Laser advisory label

5023-110

Laser notices -ix

5023-110

Class 1 Laser statement label

XXXXXXXX2004

4 0 0 2

X X X X

-x Service Manual

5023-110

Laser notice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Laser notices -xi

5023-110

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

-xii Service Manual

5023-110

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laser notices -xiii

5023-110

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal 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 I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

-xiv Service Manual

5023-110

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser notices -xv

5023-110

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

Japanese laser notice

-xvi Service Manual

Chinese laser notice

5023-110

Korean laser notice

Laser notices -xvii

5023-110

-xviii Service Manual

Safety information

• The 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

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 sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTIO N : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

5023-110

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più 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 -xix

5023-110

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und

bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem

Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes

específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.

Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária.

-xx Service Manual

Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components

específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està

destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

5023-110

Safety information -xxi

5023-110

Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to

repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair information provides instructions for making printer adjustments and removing and installing

FRUs.

5. Connector locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to prevent

problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Appendix A contains service tips and information. Appendix B contains representative print samples.

Conventions

Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software.

There are several types of caution statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

-xxii Service Manual

CAUTION

This type of caution indicates a tipping hazard.

5023-110

1. General information

This Lexmark™ C500 color laser printer is the ideal printer for presentations, business graphics, line art, and text. It uses laser diode electrophotographic technology to deliver remarkable quality print images and text. The printer can be used as a shared network or desktop printer.

Maintenance approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. See “Diagnostic information” on page 2-1, for location of each section. You may find that the removals in the Repair information chapter will help you identify parts. After you complete the repair, perform tests as needed to verify the repair.

Tools required for service

The removal and adjustment procedures described in this manual require the following tools and equipment:

• Analog volt ohmmeter (a digital volt ohmmeter 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.

General information 1-1

5023-110

Serial number

Look for serial number information on the right cover and the inside of the front cover of your printer.

XXXXXXXX2004

4 0 0 2 X X X

X X X X

1-2 Service Manual

Acronyms

ASIC Application-Specific Integrated Circuit DPI Dots Per Inch DRAM Dynamic Random Access Memory EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable Unit HV High Voltage HVPS High Voltage Power Supply LAN Local Area Network LASER Light Amplification by Stimulated Emission of

Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LV Low Voltage LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power-On Reset POST Power-On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor VAC Volts alternating current VDC Volts direct current

5023-110

General information 1-3

5023-110

Specifications

Resolution

600 x 600 dpi 2400 image quality

Model differences

C500n C500tn

USB 2.0 X X Parallel Ethernet X X Memory (MB) 64 64

Options available

530-sheet drawer (tray 2) X

Technical specifications

Color Balance Settings

This printer offers color balance control. It is a color correction option that allows you to increase or decrease the amount of toner going to the page for the cyan, magenta, yellow and black color planes. The scale ranges from +10 to -10.

Physical specifications and weight

The following table contains the dimensions and weights for each printer model and option. This does not include packaging but does include the print cartridge that ships with the printer.

Width Depth Height Weight inch inch inch lb mm mm mm kg

Printers

Lexmark C500n

Paper options

530-Sheet drawer 18.1 18.5 7.3 13.3

530-Sheet tray 11.2 14.4 4.5 4.2

Standard tray 10.8 13.0 2.2 2.2

Legal tray 10.8 15.9 2.2 2.5

Comes with standard input tray and starter cartridges.

Weight does not include packaging or pubs.

18.9 16.5 15.2 66.0 480 420 385 29.0

460 470 185 6.0

285 365 115 1.9

275 330 55 1.0

275 405 55 1.1

1-4 Service Manual

Operating clearances

Printer sides C500n C500n with 530-sheet tray

Left side 8 in (203 mm) 8 in (203 mm) Right side 20 in (508 mm) 20 in (508 mm) Front 28 in (711 mm) 28 in (711 mm) Rear 10 in (254 mm) 10 in (254 mm) Top 23 in (584 mm) 29 in (736 mm)

Packaging and shipping dimensions

Width Depth Height Weight

Printers

C500n 22.6 20.9 22.4 77

Options 530-Sheet drawer 21.7 22.2 10.4 18.8

Legal tray 13.2 19.0 5.7 5.5

in in in lb mm mm mm kg

574 530 570 35.0

550 564 265 8.5

335 483 144 2.5

Includes start-up kit (supplies)

5023-110

Print speed and performance

Pages/minute)

Media size Standard tray

Letter 31 8 A4 31 8 Legal 16 8 Transparencies 3 2 Thick card stock 3 2 Labels (letter &

A4) Medium thick card

stock (letter & A4) Envelopes 5 3

Time to first print

Time from standby mode 13 seconds 19 seconds Time from power saver mode 45 seconds 45 seconds

Note: Time to first page (TTFP) is the time from the moment when the host sends the print signal until the moment the trailing edge of the first page leaves the exit feed rollers. TTFP is measured using a simple text (single character) page.

Note: Warm up time, 45 seconds maximum, is the time elapsed from when the power is turned on to when the ready status is reached.

Processor

ARM-9, 200 MHz

General information 1-5

5023-110

Duty cycle

Maximum duty cycle-35,000 pages (one month's usage)

Printer memory

Memory configuration

Standard DRAM 64MB Optional SDRAM N/A Max DRAM 64MB

Paper and media specifications

Print area

The printable area is up to 4.0 mm (0.158 in.) from the top and bottom of the media, and up to 3.0 mm (0.118 in.) from the left and right edges. Any information placed outside this specified printable area will not print. Note: For envelopes, the printable area is up to 4.0 mm (0.158 in.) of the left and right edges, and 3.0 mm(0.118 in.) of the top and bottom edges.

Input and output configurations

The following table shows the standard number of input sources and output destinations, as well as the estimated capacity of each. Capacity may vary and is subject to media specifications and printer operating environment. The capacities listed are based on plain paper at 75 g/m

Sources and capacities C500n

Input sources Number of standard sources 1 Number of optional input drawers 1 Maximum number of input sources Maximum input capacity 780

Standard input Primary tray capacity 250 Total standard capacity 250 Optional input Optional legal tray capacity 250 Optional tray 1capacity 250 Optional tray 2 capacity 530

Number of standard destinations 1 Output capacities Standard output bin capacity (top) Media up to 20 lb paper 250

Optional input drawer is a 530-sheet capacity drawer. Only one optional drawer may be installed at any time.

The printer supports top output (face down) as standard. No additional output options are available.

Note: All capacities are based on use of 20 lb paper.

Input capacities

Output destinations

1-6 Service Manual

Media input types and weights

5023-110

Source Type Standard tray

530-Sheet tray Printer menu Item

Legal tray

Paper

type

1,2

Paper (grain long)

Card stock Index 163 g/m

Index 164- 210 g/m

Transparency

Labels

Envelopes 75-90

Punched, embossed, water-marked, perforated, punched, inkjet paper or plastic-coated media should not be used.

Only occasional use of paper labels in an office environment is supported.

Only PN 12A5940 and 12A5941 should be used.

Xerographic or bond paper

100% Cotton 75-120

60-74

g/m (16-19 lb)

75-120

g/m

g/m (24-32 lb)

(90 lb)

(91-110 lb) PN 12A5940

PN 12A5941

g/m (20-24lb)

(20-32 lb)

60-74

g/m (16-19 lb)

75-120 g/m2 (20-32 lb)

75-120

g/m (24-32 lb)

Plain paper Light

Plain paper Normal

Plain paper Heavy

N/A Card stock Normal

N/A Card stock Heavy

N/A Transparency

N/A Label N/A Envelope Normal

There is no automatic paper type sensing. These settings should be manually set in the operation panel.

Paper

weight

General information 1-7

5023-110

Media sizes

Media sizes Dimensions Input Output

Standard 250-sheet tray 1

Optional legal tray

Optional 530-sheet tray 2

Standard 250-sheet bin

mm in. A4 210 x 297 8.27 x 11.7 X X X X A5 148 x 210 5.83 x 8.27 X X

JIS B5 Letter 216 x 279.4 8.5 x 11 X X X X Legal 216 x 356 8.5 x 14 X X Executive 184.2 x 266.7 7.25 x 10.5 X X X X Folio 216 x 330 8.5 x 13 X X Statement 139.7 x 215.9 5.5 x 8.5 X X Universal

Standard 250-sheet letter tray 104.8x210 to

Optional 250-sheet legal tray 104.8x210 to

Envelope sizes Dimensions Dimensions 9 Envelope

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 B5 Envelope

Select Universal when using a non-standard size sheet of print material. The printer formats the page for the maximum size 8.5 X 14

in.(215.9 X 355.6 mm). Set the actual size from your software application.

Supported through the driver.

B5 may be supported in optional tray 1, but size sensing must be turned off.

182 x 257 7.17 x 10.1 X X X

XX X

4.125x8.27 to 8.5x11.7

215.9x297

4.125x8.27 to 8.5x14

215.9x355.6

98.4x225.4 3.875 x 8.9 X X X

162 x 229 6.38 x 9.01 X X X

176 x 250 6.93 x 9.84 X X X

Output capacity by media and source

Source Media Capacity Orientation

Standard output bin (top)¹ Supports all sizes listed in the "Media

sizes" table

250 sheets (20 lb paper) 50 Transparencies

Collated Face down

Media guidelines

Paper designed for use with xerographic copiers should provide satisfactory print quality and feed reliability. Other media types may be suitable. We recommend that users test any particular brand for suitability to their applications. Refer to the printer User's Reference for additional media specifications.

1-8 Service Manual

Paper

• Rough, highly textured, limp, or pre-curled papers will result in lower print quality and more frequent

paper feed failures.

• Colored papers must be able to withstand 338°F (170°C) fusing temperature.

• Preprinted forms and letterheads should be selected using guidelines in the printer User's Reference.

The chemical process used in preprinting may render some papers unsuitable for use with the printer.

• Unsuitable papers include punched, embossed, water-marked, perforated media, any kind of inkjet

paper or plastic-coated paper.

• Recycled paper less than 75 g/m

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.

(20 lb) may cause unacceptable results.

• If envelope wrinkling occurs, refer to the User's Reference for correct loading and stacking of

envelopes.

• All envelopes should be new, unused, and without damage.

• Envelopes with excessive curl or twist exceeding 6.0 mm, those stuck together, those with bent corners

or nicked edges, or those that interlock should not be used.

• Minimum weight: 90 g/m

(24 lb).

• 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

5023-110

• Under high humidity conditions (over 60%), the envelopes may seal during printing.

• For best results, print on new 90 g/m

Transparencies

(24 lb) sulfite or 25% cotton-bond envelope.

• Use letter (12A5940) or A4-size (12A5941) sheets only.

• Transparencies are only supported in tray 1 (standard or legal trays).

Labels

• Labels should be selected using guidelines found in the User's Reference, Complete Printer

Reference, or the Card stock & Label Guide (located at www.lexmark.com), and tested for acceptability.

• Vinyl labels are not supported.

• Labels are only supported in tray 1 (standard or legal trays).

Glossy Paper

• Use letter (12A5950) or A4-size (12A5951) sheets only.

• Glossy paper is only supported from tray 1 (standard or legal trays).

General information 1-9

5023-110

Sensing by source

Input Paper size Paper out Tray present

Integrated 250-sheet Optional 530-sheet

XXX XXX

Connectivity

Cables

Personal computers

• For USB attachment, a USB cable (P/N 12A2405) is recommended and must be ordered separately.

Operating systems

This printer is compatible with applications running under the following operating systems for either local or network connections:

Apple Macintosh

• Mac OS 8.6, 9.x, OS X

Download the latest Lexmark printer PPD files or printer drivers from the Lexmark Web Site.

Microsoft Windows

• Microsoft Windows 98 2nd Edition

• Microsoft Windows Me

• Microsoft Windows NT 4.00

• Microsoft Windows NT 4.00 Server

• Microsoft Windows 2000 Professional

• Microsoft Windows 2000 Server

• Microsoft Windows 2000 Advanced Server

• Microsoft Windows XP Home

• Microsoft Windows XP Professional

• Microsoft Windows Server 2003

Download the latest printer drivers from the Lexmark Web Site.

The Windows software applications, which operate in the operating systems listed above, are best suited to run with the drivers supplied with this printer. The drivers for Windows take advantage of your printer functions and increase the printer performance wherever possible.

The software applications that operate with most Apple LaserWriter printers will generally operate with this printer.

Network Connections

Internal Network Connections

The Lexmark C500n printer comes standard with Ethernet 10/100BaseTX built into the controller board.

1-10 Service Manual

5023-110

Internal Print Servers

The standard Ethernet connection and optional N2100 Series print servers support the following protocols:

• TCP/IP—The TCP/IP standard set of application services are supported including DHCP, BOOTP,

WINS, SNMP (mib-2, host resources MIB, printer MIB, enterprise MIB, SNMP traps), HTTP, LPR/LPD, FTP, IPP1,SLP, DDNS

• AppleTalk

This printer with standard Ethernet supports an Embedded Web Server. The current status of the operator panel is viewable using the resident web pages.

Standard Interfaces

This printer ships with the following interfaces:

• Ethernet 10/100 Base TX

• USB 2.0 supporting full speed (12Mb /s) data transfer.

Note: The ethernet and USB interfaces may be used simultaneously.

The USB interface supports:

• Windows 98 SE

• Windows Me

• Windows NT

• Windows 2000 Professional

• Windows XP Operating Systems

• Windows Server 2003 Operating Systems

• Apple Mac OS 9.x, 10.1, 10.2, 10.3, 10.4

General information 1-11

5023-110

Power and electrical specifications

Printing states C500n

Off 0 W

Average power while printing

Continuous printing 670 W

Power consumption, standby

Power saver on 35 W Power saver off 200 W

Maximum current while printing

115 Volts 11 A 230 Volts 6 A

Average current while printing

115 Volts 6.5 A 230 Volts 3.0 A

Environment

Environment Specifications

Operating Air temperature - product operating 10 to 32.5°C (50 to 90.5°F) Air temperature - product power off 5 to 35°C (41 to 95°F) Air relative humidity 15 to 80% Altitude 0 - 2,500 m (0 - 8,200 ft.)

Ship / Storage Temperature-printer and supplies 0 to 35°C (32 to 95°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).

1-12 Service Manual

Printer identification

Operato panel/cover

5023-110

Top cover

assembly

Rear cover assembly

Paper stopper

Front cover

Release lever

Right cover

Paper tray

Front view

AC input inlet

Left cover

Power switch

Back view

General information 1-13

5023-110

Printer theory of operation

The following diagram shows the major parts of the printer and paper path.

1-14 Service Manual

5023-110

Printer paper path

The following illustration shows the paper path and the associated paper jam messages for jams at specific points in the paper path. The printer depicted in the illustration has a duplex unit and secondary paper feed assembly installed:

Fuser Exit Sensor

Rear Cover Assy

Fuser Unit

Transfer Roller Assy

Registration Roller

Registration Sensor

Paper Feed Roller

Paper Exit Roller

6.3

Assy

6.2

6.1

Top Cover

Paper Cassette

General information 1-15

5023-110

Printer systems description

See the illustration “Printer component systems” on page 1-17, for more information.

Basic principles of color printing

Color printing is made through the subtractive process of combining the three primary colors: yellow, magenta, and cyan.

Mechanical and electrical structures

This color laser printer consists of five engineering systems: print, transfer, optical, paper transport, and control system.

Print system

The print system consists of six functional parts located around the optical photoconductor (OPC) belt and forms a toner image on the OPC belt: charge, expose, develop, first transfer, discharge, and clean.

Transfer system

The transfer system consists of three functional parts that transfers the toner image formed on the transfer belt to paper: transfer belt unit, second transfer, and cleaning roller.

Optical system

The optical system consists of two functional parts that forms an electrostatic latent image on the OPC belt using a laser light: optical unit and scanner motor (SCM).

Paper transport system

The paper transport system consists of five functional parts that picks up paper from the paper tray, separates the transported paper from the transfer belt, and exits it from the printer after fusing the toner image on the paper: paper tray, transport, fuser, and paper exit.

Control system

The control system consists of four control parts and runs the printer by processing the interface signals transmitted from the computer and the other printer systems such as the print, transfer, optical, and transport system: sequence control, laser control, fusing temperature control, and interface control.

1-16 Service Manual

Printer component systems

5023-110

General information 1-17

5023-110

Basic process of color printing

1. This printer has a toner cartridge for each color — yellow, magenta, cyan, and black.

2. The toner image is developed with primary colors and then transferred to the transfer belt for color combination.

3. The toner image formed on the transfer belt is transferred to paper.

4. The toner is fused to the paper by the thermal fuser unit. During the fusing process, the primary colors mix, yielding the desired color.

1-18 Service Manual

Print system and transfer system

This illustration shows the basic structure of the print system having the OPC belt as a main function, and the transfer system including the transfer belt. A color print is accomplished by actuating each process in the print system and the transfer system.

5023-110

General information 1-19

5023-110

Structure of OPC belt (photo developer cartridge)

The OPC belt consists of a surface layer having an optical photoconductor (OPC) of organic material, the inner layer consists of an insulator material (PET), and the aluminum deposit layer in between. The OPC belt is a main part of the print system.

1-20 Service Manual

Basic structure of the print system

The print system process consists of the following:

1. The OPC belt is biased to the -CBV(V) by power supply CBV.

2. The OPC belt is then evenly charged to the negative high voltage by the OPC charging system. The charging system consists of a charging brush that is biased by power supply CHV and a discharge roller that is biased by power supply DCV.

3. The developer roller in the toner cartridge is biased to

-DBV(V) by power supply DBV.

4. Frame potential of transfer drum is GND.

5023-110

General information 1-21

5023-110

5. Variation of the OPC belt potential: a. The OPC belt is biased to -CBV(V).

b. The OPC belt surface is evenly charged to -Vo(V) during the charging process. c. During the exposing process, the optical unit emits a laser beam that strikes the OPC belt surface

forming an electrostatic image. The electrostatic image is at -VR(V) potential.

d. The negatively charged toner is moved to the OPC belt in the development process due to the

difference between

-VR(V) and -DBV(V). A visible image is the result.

e. The negatively charged toner on the OPC belt is moved to the transfer belt because the potential

GND of the transfer belt is greater than -VR(V) of the OPC belt.

f. The OPC belt is discharged by the erase lamp radiating on the OPC belt.

-CBV

OPC belt

OPC belt surface

-CBV

-V0 Charge brush

-CBV

-CHV (-BRV)

-V0

Charging 1

-VR

Discharge roller

OPC charging system

DCV

Latent image

-V0

Laser diode exposing

-V0

TEST

-V0

Developer roller

-V0

KYMC

Developing

Toner image

-V0

TEST

-V0

-DBV

-V0

Transfer belt

(M)toner

-V0

TEST

-CBV

Erase lamp

Blade 6

1-22 Service Manual

5023-110

Details of the print system

Charging process

In the charging process, the OPC belt is evenly charged by the charger. See “Printer theory of operation” on page 1-14 for charger unit location.

The charger unit consists of a charging brush and a discharge roller.

1. The charge brush charges the OPC belt surface to

-Vo(V) potential. The charge on the surface of the OPC belt is then smoothed to an even -Vo(V) by the discharge roller.

2. The charger unit controls the grid to a constant voltage of ZD(V) for even charging.

3. Before charging, the OPC belt surface is -CBV(V). The charger unit evenly charges the OPC belt surface to -Vo(V) by generating a negative charge.

General information 1-23

5023-110

Exposing process

In the exposing process, the OPC belt surface is exposed to the laser light which forms an electrostatic latent image.

The luminous source of the laser is a semiconductor laser. See “Printer theory of operation” on page 1-14 for optical unit location.

The laser light scans the OPC belt, forming an electrostatic latent image.

1. The OPC belt surface is charged to -Vo(V) potential. a. The laser scans the OPC belt in a rectangular pattern during forward movement of the OPC belt.

b. High speed switching of the laser matches the transmitted image data. c. The charge of the areas radiated by the laser light is discharged, creating a -VR(V) potential. d. An electrostatic latent image is formed (invisible) on the OPC belt.

1-24 Service Manual

Developing process

In the developing process, an electrostatic latent image attracts printer toner and becomes visible on the OPC belt.

There are four toner cartridges. See “Printer theory of operation” on page 1-14 for toner cartridges location. The toner cartridges are located in the printer from top to bottom in the order of black, yellow, magenta, and cyan.

1. Toner adheres to the developer roller. The developer roller makes contact with the surface of the OPC belt which begins the developing

process.

5023-110

2. The developer roller has been biased to -DBV(V) potential.

The first illustration shows the relationship between the toner, the

-Vo(V) at the non-exposed area of the OPC belt and the -VR(V) at the exposed area of the OPC belt.

Dev. roller

(-CBV)+(-DBV)

Toner

(-CBV)

OPC belt

DBV

CBV

General information 1-25

5023-110

3. Developing is processed by toner adhering to the OPC belt due to the attraction between the toner and the -VR(V) charge at the exposed area of OPC belt. The toner image becomes visible on the OPC belt.

Note: No developing takes place on the non-exposed area because the potential of toner and that of the non-exposed area of the OPC belt is an identical pole and therefore, repels.

First transfer (drum) process

The first transfer process consists of toner images on the OPC belt being transferred to the transfer belt. The transfer belt is composed of a special rubber. See “Printer theory of operation” on page 1-14 for transfer belt location.

1. After the development process, the OPC belt rotates making contact and synchronizing with the transfer belt and the aluminum drum.

Transfer belt

Aluminum drum tube

Film (transfer belt)

2. The OPC belt has been biased to -CBV(V) potential. The potential of the transfer belt and drum is nearly GND.

3. Toner on the OPC belt is moved to the transfer belt. This occurs because of the difference of potential between the OPC belt and the transfer belt. Toner that has been developed, in each color, is moved from the OPC belt to the transfer belt and the two color toner image is overlapped on the transfer belt.

1-26 Service Manual

4. The toner image is then transferred to paper.

5023-110

Belt discharge (erase lamp) process

Electrical belt cleaning is accomplished by an erase lamp radiating on the OPC belt. Radiation discharges the residual charge -VR(V) remaining on the belt after the first transfer process. Electrical cleaning occurs after each toner color transfer. The erase lamp is a luminous source consisting of 24 light emitting diodes. After the electrical belt cleaning, the OPC belt is cleaned with a mechanical blade.

OPC belt

OPC belt cleaning (blade)

First transfer

OPC belt discharging (erase lamp)

Belt cleaning process

In the belt cleaning process, residual toner adhering to the OPC belt surface is mechanically removed by a blade edge.

General information 1-27

5023-110

The residual toner is collected in a waste toner container located by the waste toner feeder.

OPC belt

OPC belt cleaning (blade)

First transfer

OPC belt discharging (erase lamp)

1-28 Service Manual

Details of the transfer system

Second transfer (paper) process

In the second transfer process, the toner image on the transfer belt is transferred to paper. See “Printer theory of operation” on page 1-14 for second transfer roller location.

The transfer roller, normally separated from the transfer belt, is positively biased by the power supply THV. The transfer roller contacts the transfer belt as paper passes between the transfer roller and the transfer belt. The positive bias of the transfer roller causes the toner to release from the transfer belt and adhere to the paper.

5023-110

General information 1-29

5023-110

Transfer belt cleaning process

The residual toner on the surface of the transfer belt is removed after the paper transfer process. See “Printer theory of operation” on page 1-14 for transfer belt cleaner unit location.

The belt cleaner brush is a semiconductor-type fur brush. The cleaning roller is charged by voltage FCBV. The resistance of the cleaning brush against the cleaning roller charges the brush. The brush in turn contacts the surface of the rotating transfer belt. The negatively charged toner adheres to the positively charged (FCBV) brush, which cleans the transfer belt. The cleaning brush does not contact the transfer belt during the imaging process.

Waste toner, adhering to the surface of the cleaning roller, is removed by the cleaning blade, routed by the waste toner feeder to the waste toner container where it is deposited.

1-30 Service Manual

Details of the optical system

In the optical system process, the printer utilizes a semiconductor laser diode as a light source. This laser diode is controlled by fast switching which matches the transmitted image data (video signal).

The generated laser light scans the OPC belt through a polygon mirror and lens. The electrostatic latent images are formed on the OPC belt.

5023-110

The Optical printhead unit consists of following parts:

No. Description

PD: photo detector

Polygon mirror: hexahedral mirror that reflects the laser beam

Cylinder lens: laser beam condenser

Laser unit: laser diode light emitting source

LDC: laser diode control circuit

BTD mirror: beam timing detector mirror to guide the laser beam to PD

Scanner motor: rotates the polygon mirror

F-lens: laser beam focus lens

Mirror: laser beam path reflecting mirror

General information 1-31

5023-110

Details of the paper transportation system

In the paper transportation process, paper is automatically fed by the pick-up roller and transported to the registration roller. The registration roller synchronizes with the transfer belt. The registration roller transports the paper to the transfer roller. During the transfer process, the transfer roller forwards the paper to the fuser rollers. During the fusing process, the fuser rollers transport the fused paper to the exit roller and the exit roller pushes the final paper out of the rear cover assembly.

The paper transportation system consists of the following parts:

No. Part Function

Paper tray Accommodates paper to be automatically fed through the printer.

Pick-up roller Feeds paper one by one, preventing multi-feed.

Registration roller Transports and synchronizes paper with the transfer belt.

Transfer roller Works in conjunction with the transfer belt to transfer the image to paper and

to transport the paper to the fuser.

Fuser unit Utilizes a heat roller to fuse the toner image to the paper.

Paper exit roller Exits the fused paper from the printer.

1-32 Service Manual

5023-110

Fusing unit

The fusing unit utilizes a thermal fusing system that contains a heated fusing roller and a belt-like backup roller. The heated roller contains an inner heating element. The backup roller contains three pressure members located behind the belt. Paper carrying a toner image passes between the rollers where heat and pressure are applied to the paper to fuse the toner to the paper.

The fusing unit consists of the following components:

No. Part Function

Fusing roller Used for fusing, containing a heater.

Back-up roller Pressure roller.

Fusing heater Heating device heated by a halogen lamp.

Thermistor Sensor that detects the temperature of the fuser roller’s surface.

Thermal fuse Protective device that prevents the fuser roller from being excessively

heated.

General information 1-33

5023-110

Fusing process

1. When the paper reaches the fuser, the toner image is transferred on the paper, but not yet fused to the paper.

2. The transported paper passes between the heated roller and the back-up roller. The heated roller’s temperature is approximately 338°F (170°C).

3. When the paper with toner image passes between the heated roller and the backup roller, the heat from the heated roller in combination with the pressure between the two rollers, melts the toner, fusing it to the paper.

4. The fused paper then separates from the rollers and is transported out of the printer into the output bin or is routed back into the printer for printing on the other side of the duplex print.

1-34 Service Manual

Control system structure

Electrical system and function

The engine board controls most of the main electrical parts in this printer.

No. Control process Function

1 Print process control Controls print process from paper feed through paper exit.

2 Laser output control Automatically controls laser output to the default.

3 Fuser temperature control Controls fuser heater, allowing heated roller to reach default

temperature.

4 Toner sensing control Controls sensing of toner empty status.

5023-110

5 Interface control (video signal) Processes the input and output signal with external controller

6 Operator panel indicator Displays printer operation status.

7 Error control Controls safe stop procedures when errors occur.

computer.

Control of print process

Control block diagram

No. Control process Function

1 Sequence control Controls print sequence of printer.

2 Temperature control Controls temperature of fuser unit.

3 Consumables’ life control Controls toner empty status for each toner cartridge and life of periodic

4 Operator panel control Controls operator panel indication and operator signals.

5 Error processing control Senses errors occurring as well as stop procedures.

6 Interface control Controls receipt and transmission of interface signals from external

replacement parts.

controller.

7 Laser control Controls laser scanning and laser power.

Note: A micro CPU mounted on the engine board controls the print processes.

General information 1-35

5023-110

Print sequence diagram

1-36 Service Manual

Laser drive control circuit

The laser drive control circuit (LDC) consists of a video signal input circuit, laser drive circuit, laser diode, output sensing circuit, and output control circuit. See the illustration.

1. When the video signal is received, the laser drive control circuit switches the laser diode switch on and radiates according to the video signal.

2. The radiated laser beam senses the photo detector (PD). The detected signal is returned to the output control circuit.

3. The output control circuit controls the radiated output to a constant, by comparing the laser output default with the feedback value transmitted from the output sensing circuit.

4. The laser beam, scanned by the scanner motor, is sensed by the beam detector (PD), and then outputs the beam detecting timing (BDT) signal.

5023-110

General information 1-37

5023-110

1-38 Service Manual

Lexmark C 500n User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual