Lexmark 16C0365 - 5500 MFP Service Manual
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Lexmark 16C0365 - 5500 MFP Service Manual

Lexmark 16C0365 - 5500 MFP Service Manual

Service manual
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Download this manual See also: User Manual, Setup Manual
TM
Lexmark
5500 MFP
4036-402
• 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.

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Summary of Contents for Lexmark 16C0365 - 5500 MFP

  • Page 1 Lexmark 5500 MFP 4036-402 • 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.
  • Page 2 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.

  • Page 3: Table Of Contents

    4036-402 Table of contents Safety information ........... . . v Preface .
  • Page 4 4036-402 Removals ..............3-5 Charge-coupled device (CCD) card screws .

  • Page 5: Safety Information

    4036-402 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.
  • Page 6 4036-402 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.
  • Page 7 4036-402 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. •...

  • Page 8: Preface

    4036-402 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the product and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 9: General Information

    Digital copier and full-function fax machine When the scanner is connected to a Lexmark MFP, it performs convenient digital copying. When connected to a telephone line, the scanner performs a full fax function - to send and to receive faxes.

  • Page 10: Maintenance Approach

    4036-402 Maintenance approach This manual is for maintenance engineers. It describes the maintenance areas, installation, disassembly, and the main troubleshooting guides. Read this manual thoroughly to obtain comprehensive knowledge about the scanner before servicing the unit. Service guidelines CAUTION: The combined scanner and automatic document feeder weighs 25.7 kg (56.6 Ib) and requires at least two people to lift it safely.

  • Page 11: Product Specifications

    4036-402 Product specifications The scanner is designed to meet the following product specifications: Scanner type Flatbed scanner with ADF built in ADF capacity 50 sheets 75g/m² (20 lb) Media weight 60 g/m² (16 lb) to 120 g/m² (32 lb) Optical resolution Flatbed: 600 x 600 dpi ADF: 600 x 600 dpi Scan speed...

  • Page 12: Theory Of Operation

    Theory of operation System description The Lexmark X5500 is a duplex scanner option which can synchronously scan both the top and bottom of a document in color. The major system components include a main scanner control card, an automatic document feeder, flatbed, two optical CCD modules (one in ADF, one in flatbed), a user interface with a touch screen panel and a multifunction device controller cage located within the base of the scanner.

  • Page 13: Mechanical Operation

    4036-402 Mechanical operation Flatbed operation When scanning, place the document on the flatbed glass platen, the flatbed optical unit/carrier moves across the underside of the glass, and scans the document. A charge-coupled device (CCD) mounts to the carrier and optically reads the image from the page. The carrier is driven by a 2-phase stepping motor which moves the carriage at 1/600 inch each step.

  • Page 14: Acronyms

    4036-402 Acronyms Auto Document Feeder Charge-Coupled Device CCFL Cold Cathode Fluorescent Lamp Command Data Blocks Digital Multimeter Light Emitting Diode Multifunction Device PCBA Printed Circuit Board Assembly SCSI Small Computer System Interface User Interface Service Manual...

  • Page 15: Diagnostic Information

    4036-402 2. Diagnostic information CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Start This chapter describes two methods to solve the operational problems.

  • Page 16: Error Codes

    4036-402 Error codes MFD controller errors MFD controller errors are errors detected by the MFD (multifunction device) controller card within the MFD cage pertaining to electronic cards. All MFD controller cage errors are posted to the user interface touch screen along with audible beep codes and LED codes. During the Power-On Self Test procedure, errors detected cause a number of audible beeps to be produced three times.
  • Page 17 4036-402 Number LED pattern Error message Action of beeps (on= , off= Error: 24 - Serial port failure Problem with TTY/Serial Port. Replace the MFD controller card. Error: 28 - Problem with the Replace the MFD controller card. Note: Error message not No hard disk drive found.

  • Page 18: Scanner Errors

    4036-402 Scanner errors Scanner errors are errors detected within the scanner mechanism and auto document feeder assembly. When these errors occur, the user interface touch screen posts 1900 Service Error along with a number of flashes of the flatbed CCD lamp (the flash sequence is repeated ten times). See the following table for an explanation of each error code and the corrective action to resolve the problem.
  • Page 19 4036-402 Number of CCD Error message Description and action lamp flashes Flatbed may be locked. Please Unlock the flatbed. See “Moving the scanner” on check to make sure that the page 5-3 for information about the locking mechanism. flatbed is unlocked and restart the If the flatbed is unlocked and the problem persists, check system.

  • Page 20: Symptoms And Service Checks

    4036-402 Symptoms and service checks The tables in this section provide detailed troubleshooting information. The power does not come on Cause Relevant unit Check * Action Unplugged from outlet None Visual check Insert the ac plug into the outlet. AC power unplugged at LVPS Visual check Insert the ac cable into power...

  • Page 21: Scan Module Does Not Move To The Home Position

    4036-402 Scan module does not move to the home position Cause Relevant unit Check Action Home position sensor— None Visual check Connect the connector. main scanner card connection failure Home position sensor Sensor in the flatbed Visual check Replace the flatbed optical unit. failure optical unit Power supply—main...

  • Page 22: Image Does Not Appear

    4036-402 Image does not appear Cause Relevant unit Check Action ADF cover open ADF cover Visual check Close the ADF cover. Lamp Inverter failure Lamp inverter Visual check Replace the optical unit, lamp, or inverter. Optical unit—main None Visual check Connect the connector.

  • Page 23: Strange Sound Generated (Flatbed)

    4036-402 Strange sound generated (flatbed) Cause Relevant unit Check Action Motor unit failure Motor unit Visual check Replace the flatbed optical unit. Main scanner card Main scanner card Replace the Replace the main scanner card. failure main scanner card. Dirt on rail None Visual check Clean the rail with isopropyl...

  • Page 24: Clearing A Paper Jam

    4036-402 Clearing a paper jam Press the release button on the automatic document feeder and then open the cover. Carefully pull out the jam. If you cannot remove the jam, open the document cover and move the roller lever forward. Then carefully pull out the jam.

  • Page 25: Repair Information

    4036-402 3. Repair information CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Parts replacement Clean the disassembly and assembly location.

  • Page 26: Adjustments

    4036-402 Adjustments Scanner calibration This procedure should be performed whenever a new ADF assembly, internal ADF CCD subassembly, flatbed optical unit, or main scanner card is installed. Use this process to calibrate the grayscale adjustments in the scanner. Carefully follow the steps to perform the calibration.
  • Page 27 4036-402 Place the sheet faceup in the Automatic Document Feeder (ADF). Make sure the sheet is oriented with the leading edge band to the left, as shown. Press Start. Repeat steps 7 and 8. Place the sheet facedown in the ADF. Make sure the sheet is oriented with the leading edge band to the left, as shown.

  • Page 28: Hard Disk Drive Refresh

    This message appears if a refresh fails more than three consecutive times. Code update procedure Occasionally, Lexmark may release new code. This file can be obtained from the Customer Support Center. The code file contains a readme file which contains the code update instructions and other information about the software update.

  • Page 29: Removals

    4036-402 Removals Charge-coupled device (CCD) card screws Screws for the CCD card in the optical unit are as shown. These screws have a red coating indicating they should never be loosened. Flatbed CCD Optical Unit ADF CCD Optical Unit Repair information...

  • Page 30: Adf Assembly

    4036-402 ADF assembly Disconnect the ADF to flatbed cable from the flatbed. Remove the two thumb screws that secure the hinges. Service Manual...
  • Page 31 4036-402 Lift the ADF assembly straight up. CAUTION: Remove the ADF assembly with the cover in the raised position only to ensure the hinges are not energized. Note: After installing a new ADF assembly, perform the “Scanner calibration” on page 3-2.

  • Page 32: Adf Upper Cover

    4036-402 ADF upper cover Open the ADF. Remove the two screws. LIft the upper cover away from the hinge. Service Manual...

  • Page 33: Adf Upper Guide

    4036-402 ADF upper guide Remove the ADF upper cover. See ““ADF upper cover” on page 3-8. Remove the stop guide screw. Rotate the ADF upper guide and pull the upper guide free. Repair information...

  • Page 34: Adf Lower Guide

    4036-402 ADF lower guide Remove the ADF upper guide. See “ADF upper guide” on page 3-9. Remove the paper input tray. See “Paper input tray” on page 3-18. Remove the six screws (A) and (B). Lift the ADF lower guide. 3-10 Service Manual...
  • Page 35 4036-402 Pull the page size sensor cable through the opening in the ADF lower guide. Disconnect the paper present sensor cable. 3-11 Repair information...
  • Page 36 4036-402 Remove the ground screw and washer. Lift off the ADF lower guide. 3-12 Service Manual...

  • Page 37: Adf Drive Motor

    4036-402 ADF drive motor Remove the ADF lower guide. See “ADF lower guide” on page 3-10. Disconnect the cable to the ADF drive motor. Remove the ground screw and disconnect the ground cable. 3-13 Repair information...
  • Page 38 4036-402 Remove the three screws (A) securing the ADF drive motor. Remove the motor. 3-14 Service Manual...

  • Page 39: Adf Controller Card

    4036-402 ADF controller card Remove the ADF assembly. See “ADF assembly” on page 3-6. Place the ADF unit upside down. Remove the two screws (A) to the controller card access cover. Remove the cover. 3-15 Repair information...
  • Page 40 4036-402 Disconnect the four cables from the controller card. Remove the two screws (A) holding the controller card. Remove the card. 3-16 Service Manual...

  • Page 41: Adf Hinge

    4036-402 ADF hinge Remove the ADF assembly and place it upside down. See “ADF assembly” on page 3-6. Remove the four screws (A) holding the hinge plate. Lift the hinge. 3-17 Repair information...

  • Page 42: Paper Input Tray

    4036-402 Paper input tray Fold the supports flat against the paper input tray bottom. Remove the screw. 3-18 Service Manual...
  • Page 43 4036-402 Carefully bend the cover back to access the page size sensor cable. Disconnect the page size sensor cable. Lift to remove the paper input tray. 3-19 Repair information...

  • Page 44: Internal Adf Ccd Subassembly

    4036-402 Internal ADF CCD subassembly Warning: Screws for the CCD card in the optical unit are as shown in “Charge-coupled device (CCD) card screws” on page 3-5. These screws have a red coating indicating they should never be loosened. Remove the ADF drive motor. See “ADF drive motor”...
  • Page 45 4036-402 Turn the ADF upright. Remove the four screws. Disconnect the cables from the: • ADF lamp shutter motor cable • ADF controller to ADF sensor card cable from the sensor card • ADF paper size sensor 3-21 Repair information...
  • Page 46 4036-402 Remove the ground screw and disconnect the ground screw cable. Disconnect the ADF CCD optical card subassembly cable and release the cable from the restraining clip. 3-22 Service Manual...
  • Page 47 4036-402 Lift the internal ADF CCD subassembly. Note: After installing a new internal ADF CCD subassembly, perform the “Scanner calibration” on page 3-2. 3-23 Repair information...

  • Page 48: Adf Pick Pad

    4036-402 ADF pick pad Press the ADF release button and open the upper cover. Squeeze the ends of the pick pad. 3-24 Service Manual...
  • Page 49 4036-402 Remove the pick pad. 3-25 Repair information...

  • Page 50: Adf Pick Roller

    4036-402 ADF pick roller Press the ADF release and open the upper cover. Release the clip holding the pick roller. 3-26 Service Manual...

  • Page 51: Adf Paper Present Sensor

    4036-402 Remove the pick roller. ADF paper present sensor Remove the lower ADF guide. See “ADF lower guide” on page 3-10. Press the tabs together to remove the sensor. 3-27 Repair information...

  • Page 52: Adf Cover Open Sensor

    4036-402 ADF cover open sensor Remove the ADF lower guide. See “ADF lower guide” on page 3-10. Disconnect the cover open sensor cable from the sensor card. Remove the cable from the cable clips. 3-28 Service Manual...
  • Page 53 4036-402 Remove the screw that secures the sensor. Lift the sensor from the bracket. 3-29 Repair information...

  • Page 54: User Interface

    4036-402 User interface Remove the ADF assembly. See “ADF assembly” on page 3-6. Place the flatbed on its back. Remove the three screws to loosen the user interface from the flatbed. Place the flatbed upright and slide the user interface off. 3-30 Service Manual...
  • Page 55 4036-402 Disconnect the cables. Remove the user interface. 3-31 Repair information...

  • Page 56: Upper Housing

    4036-402 Upper housing Remove the user interface. See “User interface” on page 3-30. Remove the 3 screws on the front of the housing. Remove the five screws from the back of the housing. 3-32 Service Manual...
  • Page 57 4036-402 Pull forward and upward to unlatch the housing. Lift the housing off. 3-33 Repair information...

  • Page 58: Flatbed Lamp Assembly

    4036-402 Flatbed lamp assembly Warning: Do not touch the lamp or you may damage the scanner. Remove the upper housing. See “Upper housing” on page 3-32. Remove the two screws. Remove the flatbed CCD optical unit cover. 3-34 Service Manual...
  • Page 59 4036-402 Unlatch the lamp assembly from the flatbed CCD optical unit and remove the lamp assembly toward the rear of the flatbed. Disconnect the lamp cable from the inverter. Remove the lamp assembly from the wire hooks (A and B). 3-35 Repair information...

  • Page 60: Flatbed Ccd Optical Unit

    4036-402 Flatbed CCD optical unit Warning: Do not loosen the red coated screws in the CCD optical unit. Remove the upper housing. See “Upper housing” on page 3-32. Remove the screw. Slide the shaft out. 3-36 Service Manual...
  • Page 61 4036-402 Lift the belt from the hook. Disconnect the ribbon cable from the CCD. Remove the flatbed CCD optical unit. 3-37 Repair information...

  • Page 62: Multifunction Device (Mfd) Controller Card Cage

    4036-402 Installation note When you reinstall the belt, be sure to route the belt through the belt gears, as shown. Note: After installing a new optical unit, perform the “Scanner calibration” on page 3-2. Multifunction device (MFD) controller card cage CAUTION: Controller cage edges are sharp.
  • Page 63 4036-402 Slide the card cage to expose the user interface cables. Turn the unit around and lift the card cage to disconnect the user interface cables. 3-39 Repair information...
  • Page 64 4036-402 Remove the ground screw. Disconnect the two cables from the main scanner card. Remove the MFD controller cage. 3-40 Service Manual...

  • Page 65: Hard Disk Drive, Mfd Controller Card, Power Distribution Card, Memory Dimm, And Cooling Fan

    4036-402 Hard disk drive, MFD controller card, power distribution card, memory DIMM, and cooling fan Remove the MFD controller card cage. See “Multifunction device (MFD) controller card cage” on page 3-38. With the MFD controller card cage positioned upside down near the edge of a table, remove the two screws (A) from the backside and the three screws (B) from the bottom.

  • Page 66: Main Scanner Card

    4036-402 Remove the component you want from within the MFD card cage. Main scanner card Remove the MFD controller card cage. “Multifunction device (MFD) controller card cage” on page 3-38. Remove the five cables connected to the main scanner card. 3-42 Service Manual...
  • Page 67 4036-402 Remove the seven screws that secure the shield and the main scanner card. Remove the main scanner card. Note: After installing a new main scanner card, perform the “Scanner calibration” on page 3-2. 3-43 Repair information...
  • Page 68 4036-402 3-44 Service Manual...

  • Page 69: Connector Locations

    4036-402 4. Connector locations Locations Paper path and sensors Connector locations...

  • Page 70: Internal View

    4036-402 Internal view Service Manual...

  • Page 71: Connectors

    4036-402 Connectors The pin assignments shown are voltages and grounds which can be tested in the field. Use a multimeter grounded to the scanner MFD controller cage when measuring the voltage for the main scanner card. Main scanner card Main scanner card Pin no.

  • Page 72: Low Voltage Power Supply

    4036-402 Low voltage power supply The following diagram and chart represents the power supply output connector. Low voltage power supply Pin no. Wire color Assignment Black Ground Black Ground Black Ground Black Ground Black Ground Black Ground White +24V dc +5V dc Yellow +12V dc...

  • Page 73: Preventive Maintenance

    4036-402 5. Preventive maintenance This chapter describes cleaning methods and procedures for transporting the scanner. Perform preventative maintenance either every six months or every 60,000 sheets scanning. Cleaning Cover and glass With soft cloth, wipe the cover and glass. If the dirt is heavy, use a neutral cleanser or alcohol. Wipe the glass carefully so no cleanser remains on the surface.
  • Page 74 4036-402 ADF unit Press the release button and lift the upper cover. Clean the pick pad, pick roller, and feed rollers with a lint-free cloth and isopropyl alcohol. Service Manual...

  • Page 75: Moving The Scanner

    4036-402 Moving the scanner CAUTION: The combined scanner and automatic document feeder weighs 25.7 kg (56.6 Ib) and requires at least two people to lift it safely. Anytime you move or lift the scanner, make sure you have enough people to help you. If you need to transport the scanner, follow these instructions to relock the scanner: Warning: Failure to lock the scan mechanism before moving the scanner can cause internal damage.
  • Page 76 4036-402 Service Manual...

  • Page 77: Parts Catalog

    4036-402 6. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority 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 description.

  • Page 78: Assembly 1: Upper Scanner

    4036-402 Assembly 1: Upper Scanner Service Manual...
  • Page 79 4036-402 Assembly 1: Upper scanner Asm- Part Units Description index number 1—1 56P2048 Cover, ADF upper 56P2045 Guide, ADF upper 56P2049 Kit, ADF pick roller and pad 56P2047 Guide, ADF lower 56P2059 Strip, MYLAR, paper entry 56P2046 Tray, paper input 56P2060 Sensor, ADF paper present 56P2063...

  • Page 80: Assembly 2: Lower Scanner

    4036-402 Assembly 2: Lower scanner Service Manual...
  • Page 81 4036-402 Assembly 2: Lower scanner Asm- Part Units Description index number 2—1 56P2053 Lamp assembly, flatbed 56P2055 Unit assembly, flatbed CCD/optical 56P2054 Card assembly, flatbed lamp inverter 56P2057 Card assembly, main scanner 12G6918 Power supply, universal, external 56P1473 Cable, 1394, 16.5 inch 11D0328 Power cord, U.S., Canada, LAD (LV), and APG (LV) 11D0330...

  • Page 82: Assembly 3: Miscellaneous

    4036-402 Assembly 3: Miscellaneous Asm- Part Units Description index number 3—1 7372358 Field replacement kit (packaging) 56P2169 Scanner calibration sheet Service Manual...

  • Page 83: Index

    4036-402 Index acronyms description ADF assembly, removal drive motor, ADF ADF CCD cable parts ADF cover release removal 3-13 adjustment hard disk drive refresh scanner calibration error codes automatic document feeder (ADF) CCD lamp flashes cleaning MFD controller operation features beeps, MDF controller error codes field replacement kit flashes, lamp...
  • Page 84 4036-402 locations ADF cover release packaging ADF motor pad, ADF pick, removal 3-24 belt paper input tray cooling fan parts catalog feed rollers removal 3-18 hard disk drive paper jam, clearing 2-10 home position sensor paper length sensor main scanner control card paper present sensor, ADF MDF controller card location...
  • Page 85 4036-402 MFD controller card 3-41 MFD controller card cage 3-38 upper cover, ADF paper input tray 3-18 upper guide, ADF power distribution card 3-41 parts catalog upper housing 3-32 removal user interface 3-30 upper housing parts catalog removal 3-32 safety information user interface scanner lamp flashes...
  • Page 86 4036-402 Service Manual...

  • Page 87: Part Number Index

    4036-402 Part number index Description Page 11D0328 Power cord, U.S., Canada, LAD (LV), and APG (LV) ........6-5 11D0330 Power cord, Argentina .
  • Page 88 4036-402 56P2115 Hinge, ADF assembly, left ............6-3 56P2116 Card assembly, ADF controller .

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