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Repair information

4-39

7100-XXX

High voltage power supply (HVPS) removal

1.Remove the RIP board cage. See

“System board cage removal” on page 4-38

.

2.Disconnect all the connectors from the HVPS.

Note: When reinstalling flat cables, ensure that the blue side of the cable is opposite of the pins on the
connectors. Flat cable pins are exposed on only one side (opposite blue side) and must make contact with
the metal pins on the connectors.

3. Remove 11 screws (A) (4 corner screws are gold in color (metal); inner screws are silver (plastic));

remove HVPS.

A

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Summary of Contents for X500N

Page 1: ...P 7100 XXX Table of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark international inc registered in the United States a...

Page 2: ...rmation 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...

Page 3: ...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...

Page 4: ...ain service check 2 46 Banding service check 2 47 Black line service check 2 48 Color misregistration service check 2 49 insufficient fusing service check 2 50 insufficient gloss service check 2 51 Ji...

Page 5: ...sitive parts 4 2 Photodeveloper cartridge 4 3 During transportation storage 4 3 Handling 4 3 MFP removals 4 4 Cleaning roller cover removal 4 4 Transfer belt cleaning roller removal 4 4 Transfer belt...

Page 6: ...al 4 42 Modem speaker removal 4 43 Fuser fan assembly removal 4 43 Modem card removal 4 45 Top removals 4 46 Marker sensor assembly removal 4 46 Waste toner auger removal 4 47 Waste toner agitator rem...

Page 7: ...Table of contents vii 7100 XXX Parts catalog 7 1 How to use this parts catalog 7 1 Index I 1 Part number index I 5...

Page 8: ...viii Service Manual 7100 XXX...

Page 9: ...der bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse I bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprima...

Page 10: ...ot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso h...

Page 11: ...taessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNinG Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i US...

Page 12: ...60825 1 Els productes l ser de classe I no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitu...

Page 13: ...Notices and safety information xiii 7100 XXX...

Page 14: ...xiv Service Manual 7100 XXX...

Page 15: ...echange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certa...

Page 16: ...n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y l...

Page 17: ...pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de d...

Page 18: ...teries according to the manufacturer s instructions and local regulations ACHTUNG Auf Ihrer Systemplatine befindet sich eine Lithiumbatterie Beim Einsetzen eines nicht passenden Batterietyps besteht e...

Page 19: ...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 c...

Page 20: ...xx Service Manual 7100 XXX...

Page 21: ...eliver remarkable quality print images and text The scan and copy functions work with A4 letter and legal ADF only size paper Photographic quality images are possible with scan function The FAX functi...

Page 22: ...lication 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 MFP with standard Ethernet s...

Page 23: ...nd increase the MFP s performance wherever possible Memory configuration Physical specifications and weight WIP The following table contains the dimensions and weights for each MFP model and option Th...

Page 24: ...16 in 400 mm 16 in 400 mm Width Depth Height Weight MFP in in in lb mm mm mm kg X500n X502n 23 4 22 6 29 9 77 595 575 760 42 0 Options 530 Sheet drawer 21 9 22 4 10 9 18 7 556 570 277 8 5 Includes st...

Page 25: ...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 S...

Page 26: ...k card stock letter A4 Up to 4 Up to 3 Envelopes Up to 5 Up to 3 Media type Media size First print time Mono Color Plain paper mode A4 letter 13 seconds 19 seconds Transparency mode A4 letter 23 secon...

Page 27: ...ect to media specifications and MFP operating environment The capacities listed are based on plain paper at 75 g m2 Sources and capacities X500n X502n Input sources Number of standard sources 1 Number...

Page 28: ...2 24 32 lb Plain paper Heavy Card stock Index 163 g m2 90 lb N A Card stock Normal Index 164 210 g m2 91 110 lb N A Card stock Heavy Transparency3 PN 12A5940 PN 12A5941 N A Transparency Labels2 N A La...

Page 29: ...8 5 x 11 7 Optional 250 sheet legal tray 104 8 x 210 to 215 9 x 355 6 4 125 x 8 27 to 8 5 x 14 Envelope sizes Dimensions Dimensions 9 Envelope2 98 4 x 225 4 3 875 x 8 9 X X X COM 10 Envelope 104 8 x 2...

Page 30: ...to host PC Web status monitor Yes Scanner driver TWAIN features Scan mode True color grayscale black white Contrast adjustment Yes Brightness adjustment Yes Color Mono switch Yes Scan to E mail featur...

Page 31: ...tio US 129 155 200 400 EU 122 141 200 400 Advanced copier features Combine multiple copies into one copy 2 into 1 4 into 1 Can be toggled between landscape and portrait Electronic sort Yes Scan once p...

Page 32: ...Halftone error diffusion Error diffusion Speed dial 50 entries name 20 characters number 40 digits Quick dial 20 entries name 20 characters number 40 digits On hook dial Yes Direct Fax number entry Y...

Page 33: ...e 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...

Page 34: ...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 Glos...

Page 35: ...r toner Clean the printer interior using a lint free cloth Do not use solvents or chemical cleaners to clean the printer interior Use only the specified oil or lubricant on printer parts some service...

Page 36: ...nt 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 scr...

Page 37: ...of radiation LCD Liquid crystal display LED Light emitting diode LV Low voltage LVPS Low voltage power supply MFP Multiple function printer NVRAM Nonvolatile random access memory MH Message handling...

Page 38: ...1 18 Service Manual 7100 XXX...

Page 39: ...ovide the user with information on the current status of the printer Ready displays on the first line of the display unless Power Saver is invoked then Power Saver is displayed If a user status messag...

Page 40: ...ay Settings Delete Document Comm Settings Report Settings Admin Settings Date Time Setup User Settings TEL Line Type PBX Selection PBX Access Digit Default Mode Auto Clear Power Saver Display Language...

Page 41: ...ll Engine CTL Board incorrect data is detected in the NVRAM during data confirmation process at power on 1 POR the machine 2 If problem persists replace the controller board C4 Service Call Engine CTL...

Page 42: ...ction or a shorted or cut cable Erase lamp LED terminal may be cut See Erase lamp service check on page 2 21 F0 Service Call Power Supply Fan Improper fan motor rotation improper fan motor cable conne...

Page 43: ...service check on page 2 25 N3 Service Call HVPS Connection Improper connection between engine controller board and HVPS See HVPS connection service check on page 2 25 N4 Service Call Toner Empty Senso...

Page 44: ...is calibrating Connected to Server The MFP is connected to a server for a push scan job Sending File A scan job is being transmitted Send E mail Notification An e mail is being sent to a user notifyi...

Page 45: ...ering A telephone call is being received These are the normal operating modes Answering The fax is answering an in coming call incoming Call There is an incoming call on the phone line Warming Up The...

Page 46: ...pty Replace Toner C M Y K The specific toner cartridge needs to be replaced in most cases only one of the letters CYMK will appear install the appropriate toner cartridge If problem persists see Toner...

Page 47: ...er is open Close specified cover if open If not open open the cover and close If the problem persists see Cover open service check on page 2 35 TR Belt Life Replace Transfer Belt The transfer belt is...

Page 48: ...E mail memory buffer full Retry the job Break it up if needed Out of Memory Memory depleted Retry the print job Break it up if needed Scan Memory Full Memory for the scan job is full Break the scan jo...

Page 49: ...ans not working or making noise See Service error codes on page 2 3 Find the failing fan and follow the action suggested Print image problems See Print quality symptom table on page 2 13 Photodevelope...

Page 50: ...ding a fax See Modem fax card service check on page 2 43 Lines on outbound fax documents Check the flatbed glass for scratches or marks Words and images on inbound fax documents are stretched out The...

Page 51: ...line service check on page 2 60 Vertical staggering image See Vertical staggering image service check on page 2 61 Banding See Banding service check on page 2 47 White band See White band service che...

Page 52: ...tep 5 5 Is cable properly connected to main motor Go to step 6 Properly connect cable Retest printer If error clears problem solved otherwise go to step 6 6 If waste toner bottle is removed reinsert i...

Page 53: ...present Replace engine controller board See Engine controller board removal on page 4 34 Go step 9 Replace cable that connects ACN1 on LVPS to POCN on engine controller board Remove RIP board cage to...

Page 54: ...oper drive assembly motor Go to step 5 Properly connect cable Retest printer If error clears problem solved otherwise go to step 5 5 If waste toner bottle is removed reinsert it Ensure rear cover asse...

Page 55: ...r steps to remove engine controller board shield Are cables properly connected to engine controller board connectors MCN9 and POCN Go to step 4 Properly connect cables If problem persists go to step 4...

Page 56: ...tch See Clutch removal on page 4 27 Replace cable If problem persists replace faulty transfer roller clutch See Clutch removal on page 4 27 Step Questions actions Yes No 1 Turn printer off and remove...

Page 57: ...d clutch See Clutch removal on page 4 27 Replace cable If problem persists replace faulty paper feed clutch See Clutch removal on page 4 27 Step Questions actions Yes No 1 Turn printer off and remove...

Page 58: ...ngine controller board Check for 5 VDC between MCN7 pin 3 on engine controller board and ground you can touch negative lead of voltmeter to metal frame to obtain ground Is voltage present and correct...

Page 59: ...d Do any LEDs fail to illuminate Replace erase lamp See Erase lamp removal on page 4 20 Retest printer If error clears problem solved otherwise go to step 4 Go to step 4 4 Remove engine controller boa...

Page 60: ...n shorts Is cable okay Replace engine controller board See Engine controller board removal on page 4 34 Replace cable Step Questions actions Yes No 1 Turn printer off and remove engine controller boar...

Page 61: ...art Problem solved Go to step 4 4 Check cable for continuity between engine controller board connector HVCN and HVPS BCN1 connector and for shorted pins Is cable okay Go to step 5 Replace cable 5 Repl...

Page 62: ...ne controller board removal on page 4 34 Step Questions actions Yes No 1 Check for proper input line voltage Is line voltage correct Go to step 2 Provide proper line voltage 2 Remove and reinstall fus...

Page 63: ...ions Yes No 1 Turn printer off and remove engine controller board shield See Engine controller board removal on page 4 34 for steps to remove shield Is cable properly connected to BCN1 on the HVPS and...

Page 64: ...een engine controller board MCN8 cable and toner empty sensor sender TPD cable See Toner sensor sender removal on page 4 24 for steps to gain access to sensor cable MCN8 Toner empty sensor sender pin...

Page 65: ...ler board MCN8 cable and toner empty sensor receiver TTR cable See Toner sensor receiver removal on page 4 42 for steps to gain access to sensor cable MCN8 Toner empty sensor sender pin 2 pin 1 pin 4...

Page 66: ...le Retest printer If error clears problem solved otherwise go to step 2 2 Remove right cover See Right cover removal on page 4 13 Check cable that connects engine controller board connector MCN6 to lo...

Page 67: ...frame to obtain ground Touch positive lead to engine controller board MCN9 pin 12 to ensure 5 VDC is being supplied to paper empty sensor Is 5 VDC present Go to step 5 Go to step 8 5 insert empty pape...

Page 68: ...een LVPS ACN1 and engine controller board POCN Is continuity present Replace LVPS See Low voltage power supply LVPS with cage removal on page 4 40 Go to step 4 4 With paper tray removed take voltage r...

Page 69: ...should slowly decrease until it reads approximately 0 VDC Is toner sensor system working properly Replace engine controller board See Engine controller board removal on page 4 34 Check cable for conti...

Page 70: ...Touch positive lead to engine controller board connector MCN2 pin 2 to ensure 5 VDC is being supplied to toner present sensor Is 5 VDC present Go to step 5 Go to step 8 5 Check voltage level on MCN2 p...

Page 71: ...perly 2 Check printer contacts A and photodeveloper cartridge contacts B for dirt and damage Are contacts okay Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 Note ph...

Page 72: ...as slipped off frame put it back on If you cannot see it remove HVPS cage see HVPS cage removal on page 4 41 and put it back in place If B is damaged replace registration assembly See Registration ass...

Page 73: ...tween pins 1 and 3 Are switches good Go to step 3 Replace switch in question See Front door interlock switch with bracket on page 4 21 for front interlock switch see Power supply fan removal on page 4...

Page 74: ...aged Replace main motor assembly See Main motor assembly removal on page 4 26 Replace main drive assembly See Main drive gear assembly removal on page 4 27 Step Questions actions Yes No 1 Check photod...

Page 75: ...paper tray into printer Using table below check for proper paper size sensor action by taking voltage readings between ground and engine controller board MCN7 pins 4 6 8 and 10 Is paper size sensor w...

Page 76: ...4 Replace RIP board See System board removal on page 4 36 Does problem persist Replace engine controller board See Engine controller board removal on page 4 34 Problem solved 5 Turn printer off and ch...

Page 77: ...ransfer belt unit cleaning roller properly installed Go to step 2 Properly install cleaning roller 2 Check cleaning roller clutch gear located inside printer for damage Is cleaning roller clutch damag...

Page 78: ...o to step 2 Properly connect the cable at both ends 2 Try a different USB cable Does this fix the issue Issue fixed Go to step 3 3 Connect a different device to the USB cable Did the host PC see the d...

Page 79: ...removal on page 4 49 Replace the system board See System board removal on page 4 36 Step Questions actions Yes No 1 Check to see if the flatbed is locked Is it locked Unlock the flatbed Go to step 2 2...

Page 80: ...ay that would keep it from contacting the paper sensor actuator Is the paper damaged Bad media Go to step 6 6 Is there dirt in the sensors or is the paper present actuator stuck Clean the sensors or r...

Page 81: ...m board at J FAX 1 and the modem card Go to step 3 Properly connect the modem card cable to the modem card and system board 3 Check the modem card cable for continuity Is there continuity Go to step 4...

Page 82: ...and replace if necessary See Registration assembly removal on page 4 33 Check transfer roller for damage and replace if necessary See Transfer roller removal on page 4 6 5 Transfer belt unit Ensure tr...

Page 83: ...ts Ensure primary and secondary contact points are free from contamination and toner debris Check toner cartridge developer roller bias pole If contaminated clean it If damaged or deformed replace ton...

Page 84: ...user assembly Fuser roller and back up roller are stained Fusing offset error occurred Replace fuser assembly See Fuser assembly removal on page 4 6 Note Fuser assembly is a customer ordered supply 2...

Page 85: ...due to uneven rotational speed caused by a shock which occurs when the seam of the OPC belt passes over the cleaning blade Replace photodeveloper cartridge See Photodeveloper cartridge removal on page...

Page 86: ...is deformed Replace toner cartridge 2 Photodeveloper OPC cartridge OPC belt surface is damaged Replace photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 3 Debris Foreign parti...

Page 87: ...er and transfer belt cleaning roller are properly installed 2 Toner cartridge Developer cartridge OPC belt fails to maintain regular and proper rotation due to impact caused when toner cartridge conta...

Page 88: ...r and remove shipping pieces if still installed Close release lever 2 Driver media settings Driver media setting is wrong Ensure proper media setting is selected for specific media in use 3 Non recomm...

Page 89: ...area Action 1 Driver media settings Driver media setting is wrong Ensure proper media setting is selected for specific media in use 2 Fuser Fuser roller is deteriorated Fuser temperature is not prope...

Page 90: ...oval on page 4 8 Note Photodeveloper cartridge is a customer order supply 2 Main motor assembly Irregular rotation of main motor assembly Main motor assembly gear unit failure Variation of OPC belt ru...

Page 91: ...rea Action 1 Toner cartridge Too small a toner mass amount and charging amount in the development process Replace toner cartridge 2 Photodeveloper cartridge OPC belt is deformed and wavy Replace photo...

Page 92: ...ithout a lot of resistance Compare toner cartridge in question with one of the other known working cartridges Replace toner cartridge if defective 2 Transfer roller clutch Replace transfer roller clut...

Page 93: ...s not fixed in place Open rear cover assembly and close properly 2 Transfer roller Transfer roller is not properly installed Remove and reinstall transfer roller See Transfer roller removal on page 4...

Page 94: ...oller Cleaning roller is not installed properly Remove and reinstall Ensure left side of cleaning roller is making good contact with HVPS contact If error continues to occur after reinstallation repla...

Page 95: ...e the toner cartridge horizontally several times to level the toner 3 Toner cartridge Toner in the toner cartridge is not level and collects on one side Shake the toner cartridge horizontally several...

Page 96: ...r cartridge OPC belt and transfer belt This print quality issue is usually accompanied by a paper jam Remove the photodeveloper cartridge and check for a piece of paper on the rear side of the photode...

Page 97: ...lected by waste toner feeder Check to ensure that waste toner feeder is not compacted If so replace waste toner feeder See Waste toner feeder removal on page 4 28 Check for waste toner in printer If f...

Page 98: ...parts located around photodeveloper cartridge and transfer belt unit which consequently contact toner image on transfer belt unit Remove and clean photodeveloper cartridge transfer belt unit and adja...

Page 99: ...ggers in vertical direction Problem area Action 1 Printer vibration Check for printer vibrations or shock to printer 2 Laser unit assembly printhead Optical unit failure caused by vibration from scann...

Page 100: ...n of printed image Problem area Action 1 Toner cartridge Replace faulty toner cartridge 2 Photodeveloper cartridge Replace faulty photodeveloper cartridge See Photodeveloper cartridge removal on page...

Page 101: ...er roller bias pole is not making proper contact with high voltage spring contact Remove and reinstall transfer roller Ensure spring contact on left side looking from front of printer is not damaged R...

Page 102: ...er of specific toner cartridge is dirty Remove foreign particle adhering to specific toner cartridge developer roller Developer roller surface is damaged Replace problem toner cartridge Problem area A...

Page 103: ...n cloth If problem persists replace photodeveloper cartridge 2 Transfer belt unit There are foreign particles adhering to transfer belt unit Remove transfer belt unit see Transfer belt unit removal on...

Page 104: ...Ensure there are no foreign particles stuck at the opening of the optical unit 2 Transfer roller Transfer roller is not properly installed Remove transfer roller and reinstall See Transfer roller rem...

Page 105: ...Non recommended paper Paper being used is not recommended for printer Replace paper with recommended paper 2 Rear cover assembly Open rear cover assembly and reclose ensuring that both sides properly...

Page 106: ...ve transfer roller and reinstall See Transfer roller removal on page 4 6 Ensure transfer roller bias pole is touching spring contact on left side as viewed from front of printer of roller 3 Laser unit...

Page 107: ...Developer roller 18 345 35 Transfer belt drive roller part of transfer belt unit 30 128 95 Transfer belt cleaning roller 26 182 67 OPC belt charge brush part of photodeveloper charging system 11 256 4...

Page 108: ...2 70 Service Manual 7100 XXX...

Page 109: ...Enter copy quantity Scan mode Enter ASCII characters for a Push Scan profile search Fax mode Enter a Fax number Enter ASCII characters for Fax speed dial searches 3 Black Start initiates a black and...

Page 110: ...y Text Photo Mixed Scan mode Select Push scan resolution Fax mode Select the Fax resolution Standard Fine Photo 13 Shift Press to access the other 10 speed dial settings 14 Speed Dial One touch dial S...

Page 111: ...em RIP board is replaced The country code setting determines which communication protocols compression settings and signal strength settings will be used for a given country or region Failure to reset...

Page 112: ...this menu Model Name Model Name is the default menu item in the Display info submenu This item displays the MFP model name The options are X500 and X502 This item cannot be changed Press to exit this...

Page 113: ...within the submenu Press to select the displayed item Press to exit an item 1 Total Page Total number of pages scanned 2 Total Image Total number of images 3 Black Page Total number of black and white...

Page 114: ...ssed using the and keys to navigate to the individual settings When the desired modem setting is displayed press to select the item RX Level This item allows you to adjust the RX level The options are...

Page 115: ...the new setting Press to exit Encoding This allows you set the fax compression setting The options are JBIG MMR MR and MH This can also be changed in the user menus When Encoding is selected use the a...

Page 116: ...he default Density Notch 4 0 255 127 is the default Density Notch 5 0 255 127 is the default Scan The SCAN settings submenu items can be accessed using the and keys to navigate to the individual setti...

Page 117: ...4 1st and 2nd transfer of toner to the transfer Unit and then to the media 5 Fuse toner to the media 6 Clean Erase the photodeveloper and transfer Unit in summary the printer RIP board receives the co...

Page 118: ...3 10 Service Manual 7100 XXX Lexmark confidential until announce edited 1 4 2007 Summary of the EP process on the X500 This graphic illustrates the steps of the EP process on the X500...

Page 119: ...callout 1 in the picture below This is the location of the charge roller inside the photodeveloper The charge roller is the main component in step 1 of the EP process Note If the surface of the charge...

Page 120: ...he EP process Note The laser beam passes through a glass lens as it exits the laser unit If this lens gets contaminated with toner or other debris it will cause vertical streaking of white lightness o...

Page 121: ...toner image is developed and transferred to the photodeveloper one color at a time The toner image on the photodeveloper needs to be transferred to the transfer unit before the next color can be devel...

Page 122: ...to the transfer unit This process continues until all four planes of color have been transferred to the transfer unit Look at callout 4 in the picture below This is the where the photodeveloper transf...

Page 123: ...cture below This is the where the transfer unit transfers the toner to the media by way of the transfer roller and Step 4b of the EP process Note If the transfer roller has nicks pits or flat spots on...

Page 124: ...nently on the page Note If the fuser rollers are damaged they can cause toner to be pulled off the page or cause paper jams Note Toner that rubs off a printed page can be a sign of a malfunctioning fu...

Page 125: ...nsfer unit from the photodeveloper a cleaning blade scrapes the remaining toner from the surface of the photodeveloper while an erase lamp discharges the remaining voltage This is the clean erase proc...

Page 126: ...so the toner will want to stick to the cleaning brush instead of the transfer unit surface The waste toner is kicked into a containment area and moved by an auger system into the waste toner bottle Th...

Page 127: ...Diagnostic aids 3 19 Lexmark confidential until announce edited 1 4 2007 7100 XXX Printer Components The following graphic illustrates all the EP and paper transport processes in the X500...

Page 128: ...atches the user s settings in the driver It is not uncommon to find a user printing on card stock with the printer programmed to print on a plain paper setting The printer feed and transport component...

Page 129: ...ion rollers can properly time the media entry to the EP process The registration rollers help ensure that the image is properly spaced and aligned on the media The registration rollers push the media...

Page 130: ...unce edited 1 4 2007 Paper jam messages The following illustration lists paper jam messages indicating where the paper jam occurred CAUTION When clearing paper jams inside of the printer may be hot Al...

Page 131: ...nd possible jam areas Use the following table to locate instructions for a particular jam however to resolve any message you must clear all media from the media path Jam message Go to page Paper Jam A...

Page 132: ...aper Jam A1 rear tray 1 A PAPER JAM A1 message indicates the media is jammed in tray 1 To clear a jam from the standard tray Tray 1 1 Pull the tray out Remove the tray completely For a misfeed of the...

Page 133: ...the tray area locate the jam on the bottom surface of the tray housing You may have to reach far under the printer to locate the jam as shown in the following illustration Pull the jam straight out 2...

Page 134: ...For a misfeed of the media the single piece of media is laying on top of the stack Pull it straight out For media jammed behind the tray area locate the jam on the bottom surface of the support unit...

Page 135: ...PER JAM B message indicates the media is jammed behind the rear door To clear this type of jam do the following 1 Push the rear door release latch 2 Gently lower the rear door CAUTION When clearing pa...

Page 136: ...so you do not tear it Note If there is no media present in the fuser area and print jobs appear smudged see Smear service check on page 2 58 5 Close the rear door 6 Check registration sensor and its a...

Page 137: ...med media and pull it up and out Note Gently pull the media out so you do not tear it Whenever possible pull the media towards the bottom of the printer to avoid contamination of the fuser 4 Close the...

Page 138: ...ADF paper jams An ADF JAM Open ADF Cover and Clear Jam message indicates a jam in the ADF WARNING Do not clear any ADF jams until the release lever on the ADF pick roller assembly is opened WARNING D...

Page 139: ...7 7100 XXX To clear an ADF paper jam follow these steps 1 Open the ADF top cover 2 Lift the green separator roll release lever to the up position Do not remove the separator roll 3 Pull the paper from...

Page 140: ...3 32 Service Manual 7100 XXX Lexmark confidential until announce edited 1 4 2007 4 Lower the separator roller release lever until it locks in place 5 Close the ADF cover and test the ADF...

Page 141: ...ation is complete confirm the ground wire is reconnected to the earth mark After part replacement ensure the wiring harness is not caught or damaged Do not attempt to cut or extend the wiring harness...

Page 142: ...ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the MFP cover or on a met...

Page 143: ...ation storage Use the specified carton whenever moving or storing the photodeveloper cartridge Handling The OPC belt in the photodeveloper cartridge exhibits the greatest light fatigue after being exp...

Page 144: ...procedure will specify when the part must be removed Cleaning roller cover removal 1 Raise the scanner unit 2 Open the top cover 3 Depress the tabs and remove the cleaning roller cover Transfer belt...

Page 145: ...2 Rotate the two captive screws A counterclockwise until they are loose Warning Take great care when removing the transfer belt unit to prevent scratching the transfer belt Do not touch or hit the be...

Page 146: ...roller removal 1 Open the rear cover assembly 2 Rotate the transfer roller to release lift and remove Fuser assembly removal 1 Push the rear cover assembly latch and lower the rear cover assembly 2 Tu...

Page 147: ...way from the MFP Waste toner bottle removal 1 Open the front cover 2 Remove the waste toner bottle Warning Ensure that the waste toner bottle is secured and not allowed to tip over during repair proce...

Page 148: ...idge on page 4 3 when removing the photodeveloper cartridge 1 Raise the scanner assembly 2 Open the top cover assembly 3 Depress the release levers A 4 Lift and remove the photodeveloper cartridge 5 L...

Page 149: ...secondary paper feed assembly cover Repeat for the right side 2 Loosen the thumbscrew A on the left bracket and remove the bracket Repeat for the right side 3 With help from another person lift the M...

Page 150: ...right rear cover removal on page 4 17 3 Remove the cleaning roller cover See Cleaning roller cover removal on page 4 4 4 Remove the photodeveloper cartridge See Photodeveloper cartridge removal on pag...

Page 151: ...ear cover removal on page 4 17 11 Remove the screw C which secures the top cover to the MFP frame 12 Release the tabs on the front of the top cover assembly 13 Lift the top cover assembly and remove N...

Page 152: ...moval 1 Open the front cover assembly 2 Remove the 8 screws A from the inner front cover 3 Disengage the support strap from the MFP 4 Release the tabs on the front cover 5 Remove the front cover from...

Page 153: ...pin 8 Remove the front inner cover from the MFP Right cover removal 1 Remove the waste toner bottle See Waste toner bottle removal on page 4 7 2 Remove the top cover assembly See Top cover assembly re...

Page 154: ...ect the rear cover assembly connector A 5 Remove the support pin B disconnecting the support cable from the MFP 6 Remove two screws C from the rear cover assembly 7 Slide the right side of the rear co...

Page 155: ...on 4 15 7100 XXX Left front cover removal 1 Remove the top cover assembly See Top cover assembly removal on page 4 10 2 Remove two screws A from the bottom of the left front cover 3 Remove the left co...

Page 156: ...4 16 Service Manual 7100 XXX Left rear cover removal 1 Remove the screw A that secures the left rear cover to frame 2 Slide the left rear cover back and remove it from the printer A...

Page 157: ...14 2 Remove the screw A that secures the upper right rear cover to the frame 3 Remove the upper right rear cover Upper left rear cover removal 1 Remove the left rear cover See Rear cover assembly remo...

Page 158: ...idges 3 Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 4 Open the top cover assembly 5 Remove the two screws A from the laser unit assembly cover The photograph b...

Page 159: ...Repair information 4 19 7100 XXX 7 Remove four screws B from the laser unit assembly 8 Remove the laser unit assembly from the MFP 9 Disconnect the connector from the laser unit assembly B B...

Page 160: ...er cartridges 2 Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 3 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 4 Remove the two screws...

Page 161: ...cover assembly See Top cover assembly removal on page 4 10 2 Remove the right cover See Right cover removal on page 4 13 3 Disconnect the interlock switch cable A from the interlock switch 4 Remove t...

Page 162: ...waste toner bottle holder The bottom screw is longer than the other screws 4 Remove the waste toner bottle holder from the MFP Developer drive assembly removal 1 Remove the main motor assembly See Mai...

Page 163: ...Repair information 4 23 7100 XXX 4 Disconnect the developer driver assembly cables B 5 Remove the four screws C from the developer drive assembly 6 Remove the developer drive assembly from the MFP B C...

Page 164: ...ve the developer drive assembly See Developer drive assembly removal on page 4 22 2 Remove two screws A from the toner sensor Note The bottom screw is longer than the top screw 3 Pull the toner sensor...

Page 165: ...removal on page 4 4 2 Remove the right cover See Right cover removal on page 4 13 3 Using a flat tipped tool pry and remove the cleaning roller clutch gear from the inside of the MFP 4 Disconnect the...

Page 166: ...ssembly removal 1 Remove the right cover See Right cover removal on page 4 13 2 Disconnect the main motor assembly cable A from the main motor 3 Remove 4 screws B from the main motor assembly 4 Remove...

Page 167: ...cleaning roller clutch See Toner sensor sender removal on page 4 24 2 Remove the main motor assembly See Main motor assembly removal on page 4 26 Note If you are removing the main drive gear assembly...

Page 168: ...ssembly from the MFP Note When reinserting the main drive gear assembly ensure that the bottom right corner is installed before the lower right frame Waste toner feeder removal 1 Remove the main drive...

Page 169: ...r information 4 29 7100 XXX 3 Remove screw B from the waste toner feeder pipe 4 Remove the waste toner feeder pipe from the waste toner bottle holder 5 Pull and remove the waste toner feeder from the...

Page 170: ...sembly removal 1 Remove the erase lamp See Erase lamp removal on page 4 20 2 Remove two screws A 3 Disconnect connector B from the transfer belt marker sensor 4 Disconnect connector C from the toner d...

Page 171: ...mbly B from the MFP Paper guide C assembly removal 1 Remove the paper guide assembly See Paper guide assembly removal on page 4 31 2 Remove the transfer belt unit See Transfer belt unit removal on pag...

Page 172: ...00 XXX Paper feed roller removal 1 Remove the paper guide C assembly See Paper guide C assembly removal on page 4 31 2 Slide the paper feed roller off the shaft to remove Paper exit assembly removal 1...

Page 173: ...ect the cable B 3 Remove two screws C Registration assembly removal 1 Remove the transfer roller See Transfer roller removal on page 4 6 2 Remove three metal screws A and three plastic screws B 3 Lift...

Page 174: ...oller board save the onboard settings See Printing the maintenance and configuration pages on page 3 3 1 Remove the left front cover See Left front cover removal on page 4 15 2 Remove the system board...

Page 175: ...ews B from the engine controller board remove the engine controller board Note When reinstalling flat cables ensure that the blue side of the cable is opposite of the pins on the connectors Flat cable...

Page 176: ...3 3 1 Disconnect any attached USB or network cables 2 Remove the left rear cover See Left rear cover removal on page 4 16 3 Remove the screw A securing the system board cover 4 Remove the system boar...

Page 177: ...7100 XXX 5 Remove the screw B securing the two ground wires 6 Disconnect all the cables from the system board 7 Remove two screws C securing the system board to the system board cage 8 Slide the syste...

Page 178: ...ard shield 3 Remove the engine card shield 4 Disconnect all the cables from the engine card 5 Disconnect the modem speaker cable from the RIP card 6 Remove the three screws B which secure the card cag...

Page 179: ...ectors from the HVPS Note When reinstalling flat cables ensure that the blue side of the cable is opposite of the pins on the connectors Flat cable pins are exposed on only one side opposite blue side...

Page 180: ...moval on page 4 38 3 Remove the grounding terminal screw A 4 Disconnect the power supply bracket connector B 5 Remove three screws C that attach the power supply bracket remove the power supply bracke...

Page 181: ...removal on page 4 39 2 Remove the LVPS with cage See Low voltage power supply LVPS with cage removal on page 4 40 3 Remove three screws A remove the HVPS cage Toner present sensor removal 1 Remove the...

Page 182: ...e 2 screws A remove the toner sensor receiver 3 Disconnect the toner sensor cable from the connector B on the toner sensor receiver Note The bottom screw is longer than the top screw Left tray guide a...

Page 183: ...interlock assembly by prying the speaker retaining tabs back and sliding the speaker out of the interlock assembly Fuser fan assembly removal 1 Remove the left rear cover See Left rear cover removal...

Page 184: ...the connector B behind the interlock assembly 6 Remove the top screw C that secures the system board cage to the printer frame 7 Remove the three screws D that secure the fuser fan assembly to the pr...

Page 185: ...information 4 45 7100 XXX Modem card removal 1 Remove the rip cage cover 2 Disconnect the 30 pin cable A from the modem card 3 Remove the screws B that secure the modem to the RIP cage 4 Remove the mo...

Page 186: ...oner cartridges 2 Remove the photodeveloper cartridge See Photodeveloper cartridge removal on page 4 8 3 Remove the transfer belt unit See Transfer belt unit removal on page 4 5 4 Remove screw A from...

Page 187: ...cover assembly See Top cover assembly removal on page 4 10 4 Remove the transfer belt cleaning roller See Transfer belt cleaning roller removal on page 4 4 5 Remove two screws A from the waste toner a...

Page 188: ...sembly removal on page 4 10 2 Disconnect the modem speaker cable from the system board and carefully route the cable through the engine board cage 3 Remove screw A from the power supply fan 4 While ho...

Page 189: ...page 4 16 2 Remove the RIP System board cover See System board removal on page 4 36 3 Open the MFP rear cover 4 Remove the screws A securing the upper left and right covers 5 Remove the ADF unit See...

Page 190: ...100 XXX 7 Route all the cables through the RIP cage and around the fuser fan 8 Remove the ribbon cable guide from the ribbon cable and flatbed unit 9 Remove the four screws C that attach the flatbed t...

Page 191: ...Repair information 4 51 7100 XXX 10 Tilt the scanner assembly vertically carefully pulling the white slides off of the flatbed 11 Lift the flatbed assembly off of the printer engine base...

Page 192: ...the screw A securing the scanner armlock to the printer top cover 3 Tilt the top of the scanner arm to the center of the MFP and remove the armlock B Note Save the armlock for the new scanner arm 4 C...

Page 193: ...The spring will go on the new arm ADF unit removal 1 Remove the upper left rear cover See Upper left rear cover removal on page 4 17 2 Remove the left rear cover See Left rear cover removal on page 4...

Page 194: ...00 XXX 6 Remove the ADF cable cover from the rear of the flatbed unit 7 Route the ADF cable and ADF ground wire through the RIP cage and flatbed unit 8 Lift the flatbed cover to a vertical position an...

Page 195: ...ed unit Note Remove the ADF paper tray from the old ADF unit It will be used on the new ADF unit ADF mechanism cover removal 1 Open the ADF top cover and remove the ADF separator roll and ADF separato...

Page 196: ...the ADF front cover 5 Remove the screw B which secures the ADF separator roll lock to the ADF 6 Remove the ADF separator roll lock 7 Remove the two screws C which secures the ADF mechanism cover to th...

Page 197: ...Repair information 4 57 7100 XXX Operator panel removal 1 Remove the operator panel bezel by prying it off the operator panel cover 2 Remove the two screws A...

Page 198: ...ing a flat blade screwdriver carefully pry the operator panel away from the scanner assembly in four places B 4 Lift up the operator panel and disconnect the operator panel cable C from the operator p...

Page 199: ...Locations and connectors 5 1 7100 XXX 5 Locations and connectors Printer front and rear views...

Page 200: ...unit Right cover Covers the right side of the printer where the motors and drives are located Front cover Printer front enclosure that opens allowing toner cartridge or waste toner bottle replacement...

Page 201: ...X Scanner locations Callout Description 1 Paperpath Sensor 2 ADF pick roll assembly 3 ADF separator assembly 4 Cover closed sensor 5 Paper present sensor 6 ADF paper tray 7 Flatbed cover ADF Assembly...

Page 202: ...osition of OPC belt Toner empty sensor TPD TTR Detects if any toner cartridge is empty Waste toner sensor WTS LED TR Detects when waste toner bottle is full Temperature sensor for fuser unit TH Thermi...

Page 203: ...d Controls flatbed and ADF functionality Host connectivity Controls flatbed and ADF functionality Operator panel indication Modem Fax board Controls fax transmission and reception Erase lamp Discharge...

Page 204: ...anner motor SCM Drives laser beam scanning in optical unit Power supply fan PSFAN Exhausts heat from power supply unit and interface controller Exit fan EXFAN Exhausts heat from fusing unit Laser fan...

Page 205: ...t as synchronized with rotation of transfer belt Cleaning roller clutch FBCL Drives the transfer belt cleaner brush by coupling cleaning clutch to main gear unit at the time of transfer belt cleaning...

Page 206: ...Erase lamp PEU Upper paper empty sensor FBCL Cleaning roller solenoid PFUL Exit paper full sensor FBSOL Cleaning cam clutch PSU Upper paper size sensor FCS Cleaning roller sensor PT1 Paper feed sensor...

Page 207: ...Locations and connectors 5 9 7100 XXX Engine controller board wiring diagram...

Page 208: ...I 16 24V 1D 6 DBV KY PWM N 17 24V 1D 7 THVPWM N 18 24V 1D 8 DBV MC PWM N 19 PGND 9 THVRON 20 PGND 10 CBVPWM N 21 PGND 11 BRVERR LCN 24 Pin Connects to LSU assembly Pin Voltage Signal Pin Voltage Signa...

Page 209: ...3 Pin Toner present sensor Pin Voltage Signal Pin Voltage Signal 1 Toner OK N 3 SGND 2 5V S MCN10 3Pin Power supply fan Pin Voltage Signal Pin Voltage Signal 1 CTFANON P 3 CTFANERR 2 PGND MCN7 12 Pin...

Page 210: ...7 24V 1DF3 17 SGND 8 RECLON N 18 9 24V 1DF3 19 10 PKCLU10N N 20 MCN5 26 Pin Dev motors 1 2 main motor Pin Voltage Signal Pin Voltage Signal 1 DM1 OUT 14 MMGAin 2 24V 1D B COM 15 MMREV N 3 DM1 OUT 16...

Page 211: ...12 Pin Toner Sensor TTR TDP Pin Voltage Signal Pin Voltage Signal 1 LEDON P 7 NC SGND 2 TLES K P 8 TLES C P 3 TLESCHK 9 TLESSCN N 4 TLES Y P 10 SGND 5 SGND 11 ELON N 6 TLES M P 12 24V F2 LVCN 14 Pin L...

Page 212: ...ge Signal 1 5V CNT 16 SGND 2 PSGNT CNT 17 5V 1 3 5V CNT 18 SGND 4 PSGNT CNT 19 PGND 5 5V CNT 20 PGND 6 PSGNT CNT 21 24V 1D 7 3 3V 2 22 PGND 8 PSGND 23 24V 1D 9 3 3V 2 24 PGND 10 PSGND 25 24V 11 3 3V 2...

Page 213: ...connectors 5 15 7100 XXX RIP board RIP card voltages Connector Pin Voltage Signal J PNL1 Pin 1 5V J ADF 1 Pin 5 2 5V J FB1 Pin1 5V J CCD Pin 8 12V J CCD Pin 10 5V J CCD Pin12 3 3 J CCD Pin 16 3 3V J...

Page 214: ...rvice Manual 7100 XXX Engine controller board Low voltage power supply LVPS board MCN9 1 MCN8 1 MCN7 MCN6 MCN5 MCN4 HVCN 1 1 1 1 MCN10 1 1 1 PACN FBCN MCN3 MCN2 MCN1 1 1 1 1 LCN FUCN 1 POCN LVCN 1 1 1...

Page 215: ...Locations and connectors 5 17 7100 XXX High voltage power supply HVPS board...

Page 216: ...gnal 1 3 3 V 2 3 3V 3 Signal 4 Signal 5 Signal 6 Signal 7 Signal 8 Signal 9 Signal 10 Signal 11 Signal 12 Signal 13 Signal 14 Signal 15 Signal 16 Signal 17 SCS3 18 Signal 19 SRD 20 IRQN 21 SWR 22 Sign...

Page 217: ...maintenance 6 1 7100 XXX 6 Preventive maintenance There is no preventive maintenance performed by a service technician for this printer Maintenance parts for the X5xx series MFPs are installed by the...

Page 218: ...6 2 Service Manual 7100 XXX...

Page 219: ...ajority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by descr...

Page 220: ...7 2 Service Manual 7100 XXX Assembly 1 Base printer...

Page 221: ...r Guatemala Honduras Mexico Nicaragua Panama Peru Venezuela 8 40X0301 1 Power cord HV Argentina 8 40X1767 1 Power cord HV Brazil 8 40X0273 1 Power cord HV Chile 8 40X0286 1 Power cord HV UK Ireland 8...

Page 222: ...7 4 Service Manual 7100 XXX Assembly 2 Covers...

Page 223: ...4 40X4699 1 Cover top right 5 40X4692 1 Rear cover assembly includes 40X3428 and 40X3430 6 40X3428 1 Assembly paper exit contains fuser exit sensor and flag 7 40X4718 1 Packet parts 8 40X3430 1 Assem...

Page 224: ...7 6 Service Manual 7100 XXX Assembly 3 Scanner unit...

Page 225: ...Pad ADF separator 3 40X4701 1 Assembly ADF 4 40X4709 1 Cover ADF mechanism 5 40X4708 1 Tray ADF input 6 40X4714 1 Cable ADF 7 40X4713 1 Guide Cable 8 40X4700 1 Assembly flatbed 9 40X4693 1 Panel oper...

Page 226: ...7 8 Service Manual 7100 XXX Assembly 4 Front...

Page 227: ...its Description 3 1 40X3441 1 Cover laser unit assembly lens 2 40X3400 1 Laser unit assembly printhead 3 40X3431 1 Left tray guide assembly with cable includes paper size sensor and temperature thermi...

Page 228: ...7 10 Service Manual 7100 XXX Assembly 5 Right...

Page 229: ...utch cleaning roller 5 40X4718 1 Packet parts 6 40X3390 1 Clutch paper feed 7 40X3397 1 Drive assembly developer 8 40X3389 1 Motor assembly main 9 40X3398 1 Assembly waste toner holder 10 40X3396 1 Wa...

Page 230: ...7 12 Service Manual 7100 XXX Assembly 6 Rear...

Page 231: ...1 40X3429 1 Assembly bracket includes marker sensor transfer belt unit toner density sensor 2 40X3433 1 Paper guide assembly 3 40X3413 1 Paper guide C assembly with cable includes registration sensor...

Page 232: ...7 14 Service Manual 7100 XXX Assembly 7 Left...

Page 233: ...gh voltage 5 40X3399 1 Sensor toner receiver TTR This is a two piece sensor system Ordering of this part number includes both the right and left side 6 40X3410 1 Sensor toner present 7 40X4704 1 Power...

Page 234: ...7 16 Service Manual 7100 XXX Assembly 8 Top...

Page 235: ...X3402 1 Auger waste toner 2 40X3403 1 Agitator waste toner 3 40X3434 1 Assembly marker sensor OPC includes bracket 4 40X4691 1 Assembly fuser fan 5 40X4690 1 Fan power supply includes top cover interl...

Page 236: ...7 18 Service Manual 7100 XXX Assembly 9 Miscellaneous Options...

Page 237: ...ndex P N Units Description 9 1 40X3421 1 Assembly secondary paper feed NS 40X4717 1 Parts packet harness NS 40X3442 1 Cable 120V fuser NS 40X3443 1 Cable 240V fuser NS 40X4718 1 Parts packet screw NS...

Page 238: ...7 20 Service Manual 7100 XXX...

Page 239: ...fications 1 11 document sizes supported 1 12 miscellaneous 1 12 phone network connectivity 1 11 scan resolutions 1 12 flatbed assembly removal 4 49 front cover assembly removal 4 12 front door interlo...

Page 240: ...shift 3 2 speed dial 3 2 stop cleat 3 1 output capacities 1 9 P packaging and shipping dimensions 1 4 paper and media specifications 1 7 input and output configurations 1 7 print area 1 7 paper exit a...

Page 241: ...agitator removal 4 47 waste toner auger 4 47 waste toner bottle 4 7 waste toner bottle holder 4 22 waste toner feeder 4 28 repair information 4 1 required tools 1 16 right cover removal 4 13 roller s...

Page 242: ...untry code 3 3 spacing table 2 69 specifications 1 2 supported operating systems 1 2 symptom tables MFP 2 11 print quality 2 13 system board removal 4 36 system board cage removal 4 38 T theory of ope...

Page 243: ...embly main drive 7 11 40X3396 Waste toner feeder 7 11 40X3397 Drive assembly developer 7 11 40X3398 Assembly waste toner holder 7 11 40X3399 Sensor toner receiver TTR This is a two piece sensor system...

Page 244: ...ht 7 5 40X4700 Assembly flatbed 7 7 40X4701 Assembly ADF 7 7 40X4702 Assembly ADF separator roll 7 3 40X4702 Assembly pick roll 7 7 40X4703 Pad ADF separator 7 3 7 7 40X4704 Power supply 110 V low vol...

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