Lexmark™ C500n 5023-110 • 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 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.
5023-110 Table of contents Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5023-110 Control system structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35 Electrical system and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35 Control of print process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35 Print sequence diagram . . . . . . . . . . . . . . . . .
023-110 Printer paper feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Background service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Back stain service check . . . . . . . . . . . . . . . . . . . .
5023-110 Waste toner bottle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Photodeveloper cartridge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Secondary paper feed assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5023-110 Laser notices The following laser notice labels may be affixed to this printer as shown: Laser advisory label Laser notices -ix
5023-110 Class 1 Laser statement label XXXXXXXX2004 04 XX20 XXX XXX XXX XX2 004 XXX -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.
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.
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.
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.
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.
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.
5023-110 Chinese laser notice Korean laser notice Laser notices -xvii
5023-110 -xviii Service Manual
5023-110 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.
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.
5023-110 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.
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 2. 3. 4. 5. 6. 7. repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
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.
5023-110 Serial number Look for serial number information on the right cover and the inside of the front cover of your printer.
5023-110 Acronyms ASIC DPI DRAM EP ESD FRU HV HVPS LAN LASER LCD LED LV LVPS NVRAM OEM POR POST PQET RIP VAC VDC Application-Specific Integrated Circuit Dots Per Inch Dynamic Random Access Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage High Voltage Power Supply Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Low Voltage Power Supply Nonvolatile Random Access Memory Original Eq
5023-110 Specifications Resolution 600 x 600 dpi 2400 image quality Model differences C500n C500tn X X USB 2.0 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.
5023-110 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 Printers1 C500n Width Depth Height Weight in in in lb mm mm mm kg 22.6 20.9 22.4 77 574 530 570 35.0 Options 530-Sheet drawer Legal tray 1 21.7 22.2 10.4 18.
5023-110 Duty cycle Maximum duty cycle-35,000 pages (one month's usage) Printer memory Memory configuration Standard DRAM Optional SDRAM Max DRAM 64MB N/A 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.
5023-110 Media input types and weights Source Type Standard tray Legal tray 530-Sheet tray Printer menu Item Paper type Paper1,2 (grain long) Card stock Xerographic or bond paper 60-74 g/m2 (16-19 lb) 60-74 g/m2 (16-19 lb) Plain paper Light Xerographic or bond paper 75-120 g/m2 (20-32 lb) 75-120 g/m2 (20-32 lb) Plain paper Normal 100% Cotton 75-120 g/m2 (24-32 lb) 75-120 g/m2 (24-32 lb) Plain paper Heavy Index 163 g/m2 (90 lb) N/A Card stock Normal Index 164- 210 g/m2 (91-110 lb
5023-110 Media sizes Optional legal tray mm in. A4 210 x 297 8.27 x 11.7 A5 148 x 210 5.83 x 8.27 X JIS B53 182 x 257 7.17 x 10.1 X X Letter 216 x 279.4 8.5 x 11 X X X X Legal 216 x 356 8.5 x 14 Executive 184.2 x 266.7 7.25 x 10.5 X Folio 216 x 330 8.5 x 13 X Statement 139.7 x 215.9 5.5 x 8.5 X Universal1 Standard 250-sheet letter tray 104.8x210 to 215.9x297 4.125x8.27 to 8.5x11.7 Optional 250-sheet legal tray 104.8x210 to 215.9x355.6 4.125x8.27 to 8.
5023-110 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.
5023-110 Sensing by source Input Paper size Paper out Tray present Integrated 250-sheet X X X Optional 530-sheet X X X Connectivity Cables Personal computers • For USB attachment, a USB cable (P/N 12A2405) is recommended and must be ordered separately. Operating systems This printer is compatible with applications running under the following operating systems for either local or network connections: Apple Macintosh • Mac OS 8.6, 9.
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.
5023-110 Power and electrical specifications Printing states C500n Off 0W 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 6A 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.
5023-110 Printer identification Operator panel/cover Top cover assembly Rear cover assembly Paper stopper Release lever Release lever Front cover Right cover Paper tray Front view Left cover Power switch AC input inlet 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.
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: 6.3 Paper Exit Roller Top Cover Assy Fuser Exit Sensor Rear Cover Assy Fuser Unit 6.2 Transfer Roller Assy Registration Roller Registration Sensor Paper Feed Roller 6.
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.
5023-110 Printer component systems 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.
5023-110 Print system and transfer system This illustration shows the basic structure of the print system having the OPC belt as a main function, and the transfer system including the transfer belt. A color print is accomplished by actuating each process in the print system and the transfer system.
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.
5023-110 Basic structure of the print system The print system process consists of the following: 1. The OPC belt is biased to the -CBV(V) by power supply CBV. 2. The OPC belt is then evenly charged to the negative high voltage by the OPC charging system. The charging system consists of a charging brush that is biased by power supply CHV and a discharge roller that is biased by power supply DCV. 3. The developer roller in the toner cartridge is biased to -DBV(V) by power supply DBV. 4.
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).
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.
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. b. c. d.
5023-110 Developing process In the developing process, an electrostatic latent image attracts printer toner and becomes visible on the OPC belt. There are four toner cartridges. See “Printer theory of operation” on page 1-14 for toner cartridges location. The toner cartridges are located in the printer from top to bottom in the order of black, yellow, magenta, and cyan. 1. Toner adheres to the developer roller.
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.
5023-110 4. The toner image is then transferred to paper. 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.
23-110 The residual toner is collected in a waste toner container located by the waste toner feeder.
5023-110 Details of the transfer system Second transfer (paper) process In the second transfer process, the toner image on the transfer belt is transferred to paper. See “Printer theory of operation” on page 1-14 for second transfer roller location. The transfer roller, normally separated from the transfer belt, is positively biased by the power supply THV. The transfer roller contacts the transfer belt as paper passes between the transfer roller and the transfer belt.
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.
5023-110 Details of the optical system In the optical system process, the printer utilizes a semiconductor laser diode as a light source. This laser diode is controlled by fast switching which matches the transmitted image data (video signal). The generated laser light scans the OPC belt through a polygon mirror and lens. The electrostatic latent images are formed on the OPC belt. The Optical printhead unit consists of following parts: No.
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.
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.
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.
5023-110 Control system structure Electrical system and function The engine board controls most of the main electrical parts in this printer. No. Control process Function 1 Print process control Controls print process from paper feed through paper exit. 2 Laser output control Automatically controls laser output to the default. 3 Fuser temperature control Controls fuser heater, allowing heated roller to reach default temperature. 4 Toner sensing control Controls sensing of toner empty status.
5023-110 Print sequence diagram 1-36 Service Manual
5023-110 Laser drive control circuit The laser drive control circuit (LDC) consists of a video signal input circuit, laser drive circuit, laser diode, output sensing circuit, and output control circuit. See the illustration. 1. When the video signal is received, the laser drive control circuit switches the laser diode switch on and radiates according to the video signal. 2. The radiated laser beam senses the photo detector (PD). The detected signal is returned to the output control circuit. 3.
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