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Lexmark S 500 SERIES Service Manual

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Lexmark S500 Series All-In-One
Machine Type 4443-301, 4443-302, 4443-303, 4443-30E
Service Manual

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Summary of Contents for Lexmark S 500 SERIES

  • Page 1 Lexmark S500 Series All-In-One Machine Type 4443-301, 4443-302, 4443-303, 4443-30E Service Manual...
  • Page 2 Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. All other trademarks are the property of their respective owners.
  • Page 3 Lexmark S500 Series Service Manual...

  • Page 4: Table Of Contents

    Lexmark S500 Series Table of contents Table of contents ............iv Safety information.
  • Page 5 Lexmark S500 Series Locations and connectors .............

  • Page 6: Safety Information

    Lexmark S500 Series 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.
  • Page 7 Lexmark S500 Series 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.
  • Page 8 Lexmark S500 Series Safety information...

  • Page 9: Preface

    Lexmark S500 Series Preface This manual contains maintenance procedures for service providers. 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. It includes printer specifications, special tools, and acronyms.

  • Page 10: General Information

    Lexmark S500 Series 1. General information The Lexmark™ S500 Series All-In-One (4443-301, 4443-302, 4443-303, 4443-30E) is a letter-quality print, copy, and scan machine. It is a standalone color/mono copier. General information...

  • Page 11: Print Specifications

    Lexmark S500 Series Print specifications Print speed Quick print: 33 ppm mono / 30 ppm color Print functions/features Standalone photo printing: • Color or black (grayscale) photo printing • Photo Menu options pop up at card insert • Print all photos •...

  • Page 12: Scanner Specifications

    Lexmark S500 Series Scanner specifications Scanner type Flatbed CIS Scan modes True Color: • 48 bits internal • 24 bits external Gray Mode: • 16 bits internal • 8 bits external Text/Line Art: 1 bit per pixel Scan method One pass Smart Copy...

  • Page 13: Copy Specifications

    Lexmark S500 Series Copy specifications Copy function Standalone only Standalone copy speed Quick copy: First copy: 8 ppm mono target, 3 ppm color Additional copies: 25 ppm mono, 21 ppm color Standalone copy specifications Mono copy: • Quick: 300 X 600 dpi print, 150 X 150 ppi scan •...

  • Page 14: Media Specifications

    Lexmark S500 Series Media specifications Paper capacities Input tray Plain Up to 100 sheets Envelopes Up to 10 envelopes Banner Up to 20 sheets Heavyweight matte Up to 25 sheets Photo/glossy Up to 25 sheets Transparencies Up to 50 sheets...
  • Page 15 Lexmark S500 Series Media sizes (via driver) continued Automatic sheet feed (continued): • 5 x 7 in. • 13 x 18 cm • Custom size (width 3-8.5 in./height 5.0-17.0 in.) Envelopes: • 6 3/4 (3 5/8 x 6 1/2 in.) •...

  • Page 16: Understanding The Operator Panel

    Lexmark S500 Series Understanding the operator panel Using the operator panel The operator panel buttons allow you to copy, scan, or print documents and photos. The operator panel features: • Power on/off button • Color LCD display with screen saver •...
  • Page 17 Lexmark S500 Series Number Part Button Function Color/Black button Switches to color mode or to black-and-white mode Start button Starts a print, scan, or copy job, depending on which mode is selected. 2-sided/Eco-mode • Activates 2-sided to print on both sides of the paper...

  • Page 18: Maintenance Approach

    Lexmark S500 Series Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error codes, symptom tables, service checks, and diagnostic aids to determine the symptom and repair the failure.
  • Page 19 Lexmark S500 Series 1-10 Service Manual...

  • Page 20: Diagnostic Information

    Lexmark S500 Series 2. Diagnostic information Power-On Self Test (POST) sequence Plug the All-In-One into an electrical outlet, and press the Power button. The All-In-One does a Power-On Self Test (POST) sequence. 1. The Power button light comes on. 2. The following will be displayed on the LCD: Lexmark 3.

  • Page 21: Error Code Table

    Lexmark S500 Series Error Code Table Error Name Description Action Code Print Carrier Stall The All-In-One carrier has Technical Support Center: stalled. Clear the carrier jam, and resend the print job. Service: “Carrier service checks” on page 2-12. 0101 Paper Out The All-In-One is out of paper.
  • Page 22 Lexmark S500 Series Error Name Description Action Code 010B Printhead Error The printhead has an error. Technical Support Center: Reinstall the print tanks. If the error is still there, then replace the print tanks. Check the printhead contacts to be sure that they are clean.
  • Page 23 Lexmark S500 Series Error Name Description Action Code 1100 Paper Jam There is paper jammed in the Technical Support Center: All-In-One. Clear the paper jam, and resend the print job. Service: Clear the paper jam, and resend the print job.
  • Page 24 Lexmark S500 Series Error Name Description Action Code 1201 Print Incomplete The print carrier stopped before Technical Support Center: all of the data was used. Clear any carrier jams. Unplug the All-In- One from the wall outlet, wait a few seconds, then plus the All-In-One back in and turn the power on.
  • Page 25 Lexmark S500 Series Error Name Description Action Code 1207 Paper System Error A paper system error control Technical Support Center: failure was detected. Clear the paper path. Unplug the All-In- One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on.
  • Page 26 Lexmark S500 Series Error Name Description Action Code 1212 Watchdog Error Indicates printer system was Technical Support Center: reset by Watchdog timer; Unplug the All-In-One from the wall outlet; Subsystem stall failure. wait a few seconds, then plug the All-In- One back in and turn the power on.
  • Page 27 Lexmark S500 Series Error Name Description Action Code 1217 Printhead Temperature Error There is a problem determining Technical Support Center: temperature. Check and clean the contacts. If the problem persists, then replace the printhead. Service: Check and clean the contacts. If the problem persists, then replace the printhead.
  • Page 28 Lexmark S500 Series Error Name Description Action Code 120A Undefined Error The microprocessor has Technical Support Center: encountered an abort or Unplug the All-In-One from the wall outlet; undefined instruction. wait a few seconds, then plug the All-In- One back in, and turn the power on. If the problem remains, then replace the All-In- One.
  • Page 29 Lexmark S500 Series Error Name Description Action Code 121A Loop Timeout Error Error detected that a while loop Technical Support Center: or similar loop timed out before Unplug the All-In-One from the wall outlet; the event it was waiting on wait a few seconds, then plug the All-In- finished.

  • Page 30: Service Checks

    Lexmark S500 Series Service checks System board service checks Symptom Action Dead machine Check the power supply connector J4, pin 1 for approximately 30 V dc. If voltage is incorrect, replace the power supply. If voltage is correct, check all other connectors on the system board.

  • Page 31: Carrier Service Checks

    Lexmark S500 Series Carrier service checks Symptom Action • The carrier slams • Check the encoder strip for proper installation. against the side • Check the carrier cable connectors J21, J22, and J23 on the system board. If frame. connectors are okay, replace the carrier assembly with belt and cables. See •...

  • Page 32: Diagnostic Aids

    Lexmark S500 Series 3. Diagnostic aids Test mode Test page This test prints the test page. To run a complete test page of black and color patterns, be sure the printhead tanks are in good condition. To enter the test: 1.

  • Page 33: Uninstall/Reinstall Instructions For Windows Users

    1. Unplug the USB cable from the Lexmark S500 Series All-In-One. 2. From your desktop, click Start > Programs > Lexmark S500 Series > Tools > Uninstall Lexmark S500 Series. 3. This message appears: “This program will uninstall the Lexmark S500 Series from your system. Do you wish to continue?”...

  • Page 34: Repair Information

    Lexmark S500 Series 4. Repair information This chapter explains how to make adjustments to the All-In-One and how to remove defective parts. Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below: •...

  • Page 35: Removal Procedures

    Lexmark S500 Series Removal procedures The following procedures are arranged according to the name of the All-In-One part discussed. CAUTION: Unplug the power cord before removing any parts. Releasing plastic latches Many of the parts are held in place with plastic latches. The latches break easily; release them carefully. To remove such parts, press the hook end of the latch away from the part to which it is latched.

  • Page 36: Scanner Assembly Removal

    Lexmark S500 Series Scanner assembly removal 1. Remove the cable cover (A). 2. Disconnect the two cables (B). Repair information...
  • Page 37 Lexmark S500 Series 3. Press on the latch (C), and pull the duplex forward. 4. Remove the duplex. 5. Remove the two screws (D) from the rear of the printer. Service Manual...
  • Page 38 Lexmark S500 Series 6. Disconnect the scanner lid from the scanner assembly. 7. Remove the scanner lid. Repair information...
  • Page 39 Lexmark S500 Series 8. Disconnect the paper support tray from the top of the printer. 9. Remove the paper support tray. Service Manual...
  • Page 40 Lexmark S500 Series 10. Press the clips inward, and lift the scanner away from the midframe. 11. Remove the scanner assembly. Repair information...

  • Page 41: Wick Removal

    Lexmark S500 Series Wick removal 1. Press the clips inward, and lift the scanner away from the midframe. 2. Dislodge the wick from the housing with a prying tool. Service Manual...
  • Page 42 Lexmark S500 Series 3. Remove the wick from the housing. Note: When re-installing the wick, slide it in the housing. Make sure that it is properly positioned under the tabs (A). Repair information...

  • Page 43: Midframe Removal

    Lexmark S500 Series Midframe removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the four screws (A) from the midframe. 3. Disconnect the INA card cable (B). 4-10 Service Manual...
  • Page 44 Lexmark S500 Series 4. Disconnect the midframe from the printer base, and lift. 5. Remove the midframe. 4-11 Repair information...

  • Page 45: Ina Card Removal

    Lexmark S500 Series INA card removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the screw (A) from the midframe. 4. Lift the INA card shield, and disconnect the cable (B) from the INA card.
  • Page 46 Lexmark S500 Series 6. Remove the INA card. 4-13 Repair information...

  • Page 47: Exit Tray Removal

    Lexmark S500 Series Exit tray removal 1. Remove the operator panel. See “Operator panel removal” on page 4-18. 2. Press down in the middle of the exit tray to disconnect it from the front of the printer. 3. Remove the exit tray.

  • Page 48: Operator Panel Insert Removal

    Lexmark S500 Series Operator panel insert removal 1. Disconnect the operator panel insert from the operator panel. 2. Remove the operator panel insert. 4-15 Repair information...

  • Page 49: Operator Panel Overlay Removal

    Lexmark S500 Series Operator panel overlay removal 1. Remove the operator panel insert. See “Operator panel insert removal” on page 4-15. 2. Lift the operator panel overlay away from the operator panel. 3. Remove the operator panel overlay. 4-16 Service Manual...

  • Page 50: Logo Plate Removal

    Lexmark S500 Series Logo plate removal 1. Use a knife blade to pry the logo plate away from the front of the printer. 2. Remove the logo plate. 4-17 Repair information...

  • Page 51: Operator Panel Removal

    Lexmark S500 Series Operator panel removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Disconnect the cable (A). 4. Lift the operator panel, and remove.

  • Page 52: Rfid Card Removal

    Lexmark S500 Series RFID card removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See“Midframe removal” on page 4-10. 3. Remove the two screws (A), and disconnect the cable (B). 4. Remove the RFID card.

  • Page 53: Print Engine Removal

    Lexmark S500 Series Print engine removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the RFID card. See “RFID card removal” on page 4-19.
  • Page 54 Lexmark S500 Series 6. Lift the print engine, and remove. 4-21 Repair information...

  • Page 55: Paper Feed Assembly Removal

    Lexmark S500 Series Paper feed assembly removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the RFID card. See “RFID card removal” on page 4-19.
  • Page 56 Lexmark S500 Series 7. Unroute the cables from the rear of the printer. 8. Remove the five screws (C) from the paper feed assembly. 9. Disconnect the spring (D). 4-23 Repair information...
  • Page 57 Lexmark S500 Series 10. Remove the cable (E) from the media sensor assembly bracket. 11. Remove the two screws (F) from the media sensor assembly. 4-24 Service Manual...
  • Page 58 Lexmark S500 Series 12. Lift the media sensor assembly slightly to remove the paper feed assembly. 13. Remove the paper feed assembly. 4-25 Repair information...

  • Page 59: System Board Removal

    Lexmark S500 Series System board removal CAUTION: POTENTIAL INJURY This device contains a lithium battery. There is a danger of explosion if a lithium battery is incorrectly replaced. Replace it only with the same or equivalent type of lithium battery.
  • Page 60 Lexmark S500 Series 6. Disconnect all cables, and remove the two screws (B) from the system board. 7. Remove the system board. 4-27 Repair information...

  • Page 61: Carrier Assembly Removal

    Lexmark S500 Series Carrier assembly removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the operator panel. See “Operator panel removal” on page 4-18.
  • Page 62 Lexmark S500 Series 8. Disconnect the clip (D) from the left side of the carrier assembly. 9. Disconnect the hose (E) from the purge pump. 4-29 Repair information...
  • Page 63 Lexmark S500 Series 10. Lift the purge pump, and remove. Note: Be sure to pay attention to the position of the encoder dial when reinstalling the purge pump. 11. Disconnect the belt (F). 12. Remove the carrier shaft through the right side of the carrier assembly frame.
  • Page 64 Lexmark S500 Series 13. Press on the clip (G), and remove the carrier cables. 14. Remove the clip from the carrier cables. 4-31 Repair information...
  • Page 65 Lexmark S500 Series 15. Remove the carrier assembly. 4-32 Service Manual...

  • Page 66: Encoder Dial Sensor Removal

    Lexmark S500 Series Encoder dial sensor removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the RFID card. See “RFID card removal” on page 4-19.

  • Page 67: Media Sensor Removal

    Lexmark S500 Series Media sensor removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the two screws (A). 4. Disconnect the cable (B). 4-34...
  • Page 68 Lexmark S500 Series 5. Remove the media sensor. 4-35 Repair information...

  • Page 69: Printer Base Removal

    Lexmark S500 Series Printer base removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-3. 2. Remove the midframe. See “Midframe removal” on page 4-10. 3. Remove the operator panel. See “Operator panel removal” on page 4-18.

  • Page 70: Locations And Connectors

    Lexmark S500 Series 5. Locations and connectors Locations Front view Number Part Function Paper guide adjustment lever Adjusts the paper guides Paper support Loads paper Paper guides Keeps paper straight when feeding Memory card slots Inserts a memory card PictBridge and USB port...

  • Page 71: Rear View

    Lexmark S500 Series Rear view Number Part Function Top cover Accesses the scanner glass Scanner glass Scans and copies photos and documents USB port Connects the printer to a computer using a USB cable Power supply with port Connects the printer to a power source...

  • Page 72: System Board

    Lexmark S500 Series System board Lithium battery CR2032 J2 J3 Locations and connectors...

  • Page 73: System Board Connections

    Lexmark S500 Series System board connections Connector Description Cable color Pin number Value Paper feed motor Red, green Transport carrier motor Red, black 1 & 2 30 V Purge pump motor Red, yellow 1 & 2 30 V Power supply Blue, black 1 &...

  • Page 74: Ina Card

    Lexmark S500 Series INA card INA card connections Connector Description Pin number Value Locations and connectors...

  • Page 75: Rfid Card

    Lexmark S500 Series RFID card (under shield) RFID card connections Connector Description Pin number Value Service Manual...

  • Page 76: Preventive Maintenance

    Lexmark S500 Series 6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help prevent problems and maintain optimum performance. Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease to lubricate the following: •...
  • Page 77 Lexmark S500 Series Service Manual...

  • Page 78: Parts Catalog

    Lexmark S500 Series 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Asm- Units/ Units/ Description Index mach • Asm-index: Identifies the assembly and the item in the diagram. For example, 2-1 indicates assembly 2 and item number 1.

  • Page 79: Assembly 1: Covers

    Lexmark S500 Series Assembly 1: Covers Service Manual...
  • Page 80 Lexmark S500 Series Assembly 1: Covers Asm- Units/ Units/ Description Index mach Paper 505 support tray ADF scanner assembly lid Scanner module assembly INA wireless card Midframe cover Cable cover Light pipe Control panel insert (clear) Control panel overlay Operator panel assembly...

  • Page 81: Assembly 2: Electronics

    Lexmark S500 Series Assembly 2: Electronics Service Manual...
  • Page 82 Lexmark S500 Series Assembly 2: Electronics Asm- Units/ Units/ Description Index mach Encoder with spring Carrier assembly with belts and cables Wick (40X6350) RFID card assembly Print engine assembly System board Duplex Printer base cover assembly Paper tray Parts catalog...
  • Page 83 Lexmark S500 Series Service Manual...

  • Page 84: Index

    Lexmark S500 Series Index Acronyms Tools required Diagnostic aids Test mode Diagnostic information POST 2-11 Service checks 2-12 Carrier 2-11 CIS module assembly 2-11 System board Troubleshooting tables Error code table General information Copy specifications Media specifications Print specifications Scanner specifications...
  • Page 85 Lexmark S500 Series Service Manual...

This manual is also suitable for:

4443-3024443-3014443-30e4443-303

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