Lexmark X4500 Service Manual
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Lexmark X4500 Service Manual

Lexmark X4500 Service Manual

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Download this manual See also: User Manual, Setup Manual
X4500 Scanner
4036-304
• Table of Contents
• Problem Solving
• 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 X4500

  • Page 1 X4500 Scanner 4036-304 • Table of Contents • Problem Solving • 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

    4036-304 Table of Contents Safety Information ........... . . v Safety Information .
  • Page 4 4036-304 Hard Disk Drive, MFD Controller Card, 1394 Communications Card and Power Distribution Board Removal ........3-19 Main Control Board Removal .

  • Page 5: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts.
  • Page 6 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. • La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
  • Page 7 Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.
  • Page 8 4036-304 viii Service Manual...

  • Page 9: Overview

    4036-304 1. Overview This manual is for maintenance engineers. It describes the maintenance areas, installation, disassembly, and the main troubleshooting guides. Take your time to read this manual thoroughly to obtain comprehensive knowledge about the scanner before servicing the unit. Service Guidelines 1.

  • Page 10: Digital Copier And Full-Function Fax Machine

    4036-304 Digital Copier and Full-function Fax Machine When the scanner is connected to a Lexmark printer, it performs convenient digital copying. When connected to telephone line, the scanner performs a full fax function - to send and to receive faxes.

  • Page 11: Product Specifications

    4036-304 Product Specifications The scanner is designed to meet the following product specifications: Scanner Scanner Type Flatbed Scanner with ADF built in Optical Resolution Flatbed: 300x600 dpi ADF: 300x300 dpi Enhanced Resolution 9600x9600 dpi Scan Speed 10 ppm at 300 dpi color for single page scanning 20 ppm at 300 dpi line-art, duplex for ADF Scan Method Color Charge-Coupled Device (CCD)
  • Page 12 4036-304 Environment: -Operating 10°C to 35°C (50°F to 95°F) 20% to 80% RH (Relative Humidity) -40°C to 65°C (-40°F to 149°F) -Storage 10% to 90% RH (Relative Humidity) Random Vibration: -Unpacked non-op 10-200Hz, 0.005 p.s.d. (G^2/Hz) -Package 5-200Hz, 0.015 p.s.d. -6 dB/oct One hour in 3 major axes -Bump Severity: 25g/6ms, 1000 times in each direction...

  • Page 13: Theory Of Operation

    1394 communications card to communicate with the main scanner board, a MFD controller board to process all jobs performed on the X4500, a hard disk drive containing the operational code for the system and providing memory for processing jobs, and a power distribution board.
  • Page 14 4036-304 Auto Document Feeder Operation When using the Auto Document Feeder (ADF) mechanism, a page is fed into the ADF by a pick roller and through the ADF by a feed roller. A separation pad located opposite to the pick roller is used to properly feed the pages one at a time when placed on the input tray.

  • Page 15: Scanner Mechanism Overview And Locations

    4036-304 Scanner Mechanism Overview and Locations This section contains an overview of the major components of the scanner hardware. External View Overview...

  • Page 16: Internal Components

    4036-304 Internal Components Service Manual...

  • Page 17: Abbreviations

    4036-304 Abbreviations Auto Document Feeder Charge-Couple Device CCFL Cold Cathode Fluorescent Lamp Command Descriptor Blocks Digital Multimeter Light Emitting Diode Multi Function Device PCBA Printed Circuit Board Assembly User Interface Overview...
  • Page 18 4036-304 1-10 Service Manual...

  • Page 19: Problem Solving

    4036-304 2. Problem Solving This chapter describes two methods to solve the operational problems. The first relies on the scanner internal diagnostics to report error codes. The second uses troubleshooting techniques to isolate the problem. In many cases, the internal error codes will help you to locate the source of the problem quickly.
  • Page 20 4036-304 Number Error Error Message LED Pattern Action Number Displayed to UI Beeps Problem with the CPU Replace the MFD controller board. (No Hard Drive Found) Check connections to the hard disk drive and Note: Error code associated cables for message not displayed continuity.
  • Page 21 4036-304 Number Error Error Message LED Pattern Action Number Displayed to UI Beeps Not Enough Memory The memory DIMM was found, but not enough memory is present. Replace the memory DIMM. User Interface failure A problem was detected with the user interface. Check the connection of all cables connecting the UI to the MFD...

  • Page 22: Scanner Errors

    4036-304 Scanner Errors Scanner Errors are errors detected within the scanner mechanism and auto document feeder assembly. These errors appear on the user interface touch screen along with a number of flashes of the flatbed CCD lamp (the flash sequence is repeated 10 times). See the following table for an explanation of each error code and the corrective action to resolve the problem.
  • Page 23 4036-304 Number of CCD Error Message Displayed Action Lamp Flashes to UI None Could not match scanner, The MFD controller cage aborting could not find the rest of the scanner. Make sure the USB- style cable is properly connected between the 1394 communications board and main scanner control board.

  • Page 24: Troubleshooting

    4036-304 Troubleshooting The tables in this section provide detailed troubleshooting information. The Power does not come on Relevant Cause Check * Action Unit Unplugged None Visual check Insert the ac from outlet plug into the outlet. AC power LVPS Visual check Insert the ac unplugged at cable into...
  • Page 25 4036-304 Scan module does not move to lock position Relevant Cause Check Action Unit Home CCD board Tester check Replace the position CCD PCBA. sensor board failure Motor-main None Visual check Connect the control PCBA connector. connection failure Motor failure Carrier motor Visual check Replace the...
  • Page 26 4036-304 Scan module does not move to the home position Relevant Cause Check Action Unit Home None Visual check Connect the position connector. sensor board- main control PCBA connection failure Home Sensor in the Tester check Replace the position flatbed CCD flatbed CCD sensor board assembly...
  • Page 27 4036-304 Scan module does not move to the flatbed position Relevant Cause Check Action Unit Power supply- None Visual check Connect the main scanner connector. board connection failure Power supply Power supply Tester check Replace the fails (+5V, +24V, power supply. GND) Motor-main None...
  • Page 28 4036-304 Image does not appear Relevant Cause Check Action Unit ADF cover ADF cover Visual check Close the ADF open cover. 1394 None Visual check Connect the Communica- connector. tion board- main control board connection failure Lamp Inverter Lamp inverter Visual check Replace the failure...
  • Page 29 4036-304 Large jitter Relevant Cause Check Action Unit 1394 None Visual check Connect the Communica- connector. tion - main control board connection failure Motor-main None Visual check Connect the scanner connector. PCBA connection failure Motor failure Carrier motor Visual check Replace the carrier motor.
  • Page 30 4036-304 Reading position deviation Relevant Cause Check Action Unit Motor-main None Visual check Connect the scanner connector. PCBA connection failure Motor failure Carrier motor Visual check Replace the carrier motor. Home Flatbed CCD Tester or Replace the position optical unit visual check flatbed CCD sensor board-...

  • Page 31: Image Unclear

    4036-304 Image unclear Relevant Cause Check Action Unit Lamp too Lamp Visual check Replace CCD dark optical unit. Dirt on Calibration Visual check Clean the calibration reference flatbed glass reference plate with isopropyl plate alcohol. Dirt on the Mirrors Visual check Clean the mirrors mirrors with...
  • Page 32 4036-304 Strange Sound Generated (flatbed) Relevant Cause Check Action Unit Motor unit Motor unit Visual check Replace the failure carrier motor. Main scanner Main scanner Replace the Replace the card failure card main scanner main scanner card. card. Scanning Scanning Check if Replace the module...
  • Page 33 4036-304 Strange sound generated (ADF) Relevant Cause Check Action Unit Paper setting Operation Is the paper Teach users to failure error correctly set properly in the paper position the chute? paper. Paper failure Operation Is the None error specified paper used? ADF unit Visual check Connect the...
  • Page 34 4036-304 2-16 Service Manual...

  • Page 35: Maintenance

    4036-304 3. Maintenance This chapter describes cleaning methods maintenance parts replacement, and adjustment and lubrication necessary for normal scanner operation. Perform preventative maintenance in the shorter term either every six months or every 60,000 sheets scanning. Cleaning Cover and Glass With soft cloth, wipe the cover and glass.

  • Page 36: Maintenance Tools

    4036-304 Maintenance Tools The following table describes the tools necessary for the maintenance of this scanner. Name Description Flathead screwdriver Idler pulley module screw Phillips screwdriver (magnetic) Nominal No.2 M3, M4 Nut driver 6 mm Digital voltmeter With 0.01 V range Chip Puller Puller for main scanner board chip Removals...
  • Page 37 4036-304 CCD Board Screws Screws for the CCD board 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 Maintenance...

  • Page 38: Adf Snap-In Pad Module Removal And Mounting

    4036-304 ADF Snap-in Pad Module Removal and Mounting After scanning approximately 100,000 pages through the ADF, the ADF pad module may be worn and you may experience problems with document feeding. In this case, replace the ADF pad module. To remove the ADF snap-in pad module: 1.

  • Page 39: Document Cover Removal

    4036-304 Document Cover Removal Lift the document cover to remove the studs from the hinge holes. The studs are loosely attached to the hinge holes to accommodate the depth of the original. ADF Cover Removal Remove the two ADF cover screws and lift the ADF cover. Maintenance...

  • Page 40: Adf Optical Ccd Unit Removal

    4036-304 ADF Optical CCD Unit Removal Warning: Do not loosen any screws with red coating. 1. Remove the ADF cover. Go to “ADF Cover Removal” on page 3-5. Remove the two screws from the ADF optical CCD unit as shown, and pull out the unit. 2.

  • Page 41: Adf Unit (Upper And Lower Unit) Removal

    4036-304 4. Disconnect the two CCD connectors. 5. Remove the ADF optical CCD unit. ADF Unit (Upper and Lower Unit) Removal 1. Remove the ADF optical CCD unit. Go to “ADF Optical CCD Unit Removal” on page 3-6. 2. Remove the screws located at the four corners of the ADF unit. Maintenance...
  • Page 42 4036-304 3. Disconnect 15PIN ADF motor/sensor cable from ADF motor/sensor card. 4. Lift the ADF unit and remove it. Service Manual...

  • Page 43: User Interface Removal

    4036-304 Note: The upper and lower units of the ADF unit can now be separated. User Interface Removal 1. Remove the document output tray and document cover. 2. Place the scanner on its back. 3. Remove the three screws to loosen the user interface from the scanner. Maintenance...
  • Page 44 4036-304 4. Place the scanner right side up and slide the user interface forward. 5. Disconnect the cables. 3-10 Service Manual...
  • Page 45 4036-304 6. Remove the right side touch screen support bracket to disconnect the ground wire. 7. Remove the user interface gently. 3-11 Maintenance...

  • Page 46: Upper Housing Removal

    4036-304 Upper Housing Removal 1. Remove the ADF unit. Go to “ADF Unit (Upper and Lower Unit) Removal” on page 3-7. 2. Remove the user interface. Go to “User Interface Removal” on page 3-9. 3. Remove the four rubber pads with a flat screwdriver. 4.
  • Page 47 4036-304 5. Remove the four screws on the left side of the housing. 6. Remove the five screws form the front of the housing. 7. Remove the upper housing. 3-13 Maintenance...

  • Page 48: Flatbed Ccd Optical Unit Removal

    4036-304 Flatbed CCD Optical Unit Removal Warning: Do not loosen any screws with red coating. 1. Remove the upper housing. Go to “Upper Housing Removal” on page 3-12. 2. Press the pulley on the carriage belt pulley assembly toward the center of the unit and remove the carriage belt from the pulley.
  • Page 49 4036-304 3. Remove the sliding rod and the flat cable. (See following figures.) Warning: Be very careful when handling the flatbed optical CCD. The lamp is exposed and can be easily broken. Do not touch. 4. Take out the flatbed optical CCD. 5.

  • Page 50: Carriage Motor Assembly Removal

    4036-304 Carriage Motor Assembly Removal 1. Remove the upper housing unit. Go to “Upper Housing Removal” on page 3-12. 2. Press the pulley on the carriage belt pulley assembly toward the center of the unit and remove the carriage belt from the pulley. 3.
  • Page 51 4036-304 4. Lower MFD controller cage and disconnect the three connectors and ground wire. 3-17 Maintenance...
  • Page 52 4036-304 5. Swing the MFD controller cage assembly to the right and disconnect the two cables. Use a screwdriver on the lower cable connector to unlatch the connector. 6. Remove the MFD controller cage. Note: When reinstalling the USB-style cable to the main control board, connect the cable to the upper connector.

  • Page 53: Hard Disk Drive, Mfd Controller Card, 1394 Communications Card And Power Distribution Board Removal

    4036-304 Hard Disk Drive, MFD Controller Card, 1394 Communications Card and Power Distribution Board Removal 1. Remove the MFD controller cage. Go to “MFD Controller Cage Removal” on page 3-16. 2. With the MFD controller cage positioned upside down near an edge of a table, remove the two screws from the back side and three screws from the bottom.
  • Page 54 4036-304 4. Remove the component you want from within the MFD cage. 3-20 Service Manual...

  • Page 55: Main Control Board Removal

    4036-304 Main Control Board Removal 1. Remove the MFD controller cage. Go to “MFD Controller Cage Removal” on page 3-16. 2. Remove the screws securing the main control board. 3. Disconnect the cables and remove the board. 3-21 Maintenance...
  • Page 56 4036-304 Note: When replacing the main scanner control board with a new one, remove the EPROM from the old board (with a chip puller) and install it in the new board. This EPROM contains settings unique to the scanner. 3-22 Service Manual...

  • Page 57: Connector Locations

    1234-XXX 4. Connector Locations 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 board. Main Scanner Board ADF Video Circuit J7: Pin No.

  • Page 58: Mfd Controller Cage

    1234-XXX MFD Controller Cage All components within the MFD controller cage are self diagnosed. Any errors are reported as MFD controller cage errors. Low Voltage Power Supply The following diagram and chart represents the power supply output connector. Pin No. Wire Color Assignment Black...

  • Page 59: Parts Catalog

    4036-304 5. Parts Catalog Parts Catalog...
  • Page 60 4036-304 Assembly 1: Upper Scanner Service Manual...
  • Page 61 4036-304 Assembly 1: Upper Scanner Asm- Part Units Description Index Number 56P0170 Tray, Document Input 56P0024 Cover, Scanner Document 56P0032 Cover, Upper with Glass 56P0020 User Interface, Complete 56P0030 Assembly, Lower ADF 56P0023 Tray, Document Output 56P0025 Assembly, ADF Optical Unit 56P0029 Assembly, Upper ADF 56P0079...
  • Page 62 4036-304 Assembly 2: Lower Scanner Service Manual...
  • Page 63 4036-304 Assembly 2: Lower Scanner Asm- Part Units Description Index Number 56P0036 Cable, ADF CCD (6PIN + 14PIN) 56P0035 Cable, ADF Motor/Sensor (15PIN) 56P0033 Pulley Assembly, Carriage Belt 56P0031 Assembly, Flatbed CCD Optical Unit 56P0308 Card Assembly, Flatbed CCD Lamp Invertor 56P0037 Belt, Carriage 56P0042...
  • Page 64 4036-304 Assembly 2 (cont.): Lower Scanner Service Manual...
  • Page 65 4036-304 Assembly 2 (cont.): Lower Scanner Asm- Part Units Description Index Number 12G9063 Fan, CPU Cooling 56P9910 Card Assembly, 128MB DIMM 56P0558 Cable, RJ11 with Toriod 56P0559 Cable, RJ45 with Toriod Parts Catalog...
  • Page 66 4036-304 Service Manual...

  • Page 67: Index

    4036-304 Index Abbreviations Safety Information Cleaning Theory of Operation ADF Unit Mechanical Operation Cover and Glass System Description Touch Screen Troubleshooting Connector Locations Unit Error Codes Part Numbers MFD Controller Scanner 11D0328 11D0329 11D0330 Maintenance 11D0331 Maintenance Tools 11D0332 11D0333 11D0334 11D0335 Overview...
  • Page 68 4036-304 56P0079 56P0170 56P0192 56P0308 56P0558 56P0559 56P9910 99A0471 Service Manual...

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