Lexmark 7500-432 Manuals

Manuals and User Guides for Lexmark 7500-432. We have 1 Lexmark 7500-432 manual available for free PDF download: Service Manual

Lexmark 7500-432 Service Manual

Lexmark 7500-432 Service Manual (851 pages)

Brand: Lexmark | Category: All in One Printer | Size: 14.62 MB

Table of Contents

Table of Contents
3
Notices

15
- Laser Notice
  15
- Lithium Warning
  19
- Safety Information
  19
Preface

22
- Change History
  22
- Conventions
  22
General Information

25
- Models
  25
- Printer Technology
  25
- Maximum Resolution
  25
- Processor
  25
- Memory
  25
- Standard Connectivity
  25
- Optional Connectivity
  25
- Operating Systems-Printer Driver
  26
- Emulation
  26
- Fonts
  26
- Paper Capacity
  26
- Paper Handling
  27
- Media Types
  27
- Media Weights
  27
- Size and Weight-Without Finisher
  27
- Duty Cycle
  27
- Printer Overview
  28
  - Basic Model
    28
  - Configured Model
    29
- Printer Theory
  30
  - Driving Force Transmission Path
    30
  - Media Transport
    32
  - Functions of Main Components
    34
  - Media Tray Assembly
    34
  - Media Tray Assembly
    35
  - Multi-Purpose Feeder (MPF)
    37
  - Detecting Media Size
    38
  - Registration
    39
  - Transfer Roll Assembly
    39
  - Printhead Assembly
    40
  - Fuser
    42
  - Exit
    43
  - Drive
    45
  - Electrical Components and Controller
    46
- Control
  48
  - Media Size Control
    48
  - Printhead Control
    49
  - Fuser Control
    49
  - Xerographic Process During a Print Cycle
    50
- Safety System Diagram
  57
- Document Scanning
  58
  - Document Scanning at Platen
    58
  - Document Scanning at ADF
    59
- Image Data Flow
  65
- Drive Torque Transfer Scheme
  66
  - ADF Feed Motor Assembly
    66
- Previous
  66
  - ADF Registration Motor
    67
  - Names and Functions of Components
    69
    
    Scanner Unit Assembly
    69
    
    Adf
    70
  - Control
    74
    
    Document Size Detection at Scanner Unit Assembly
    74
- Next
  74
  - ADF Document Size Detection
    76
  - Document Scanning Steps
    79
  - Tandem Tray Theory
    80
    
    Driving Force Transmission Path
    81
    
    Media Transport
    82
    
    Media Tray Assembly
    84
    
    Main Components
    87
  - Duplex
    89
    
    Duplex Drive Motor
    89
    
    Media Transport
    90
  - Exit 2
    93
    
    Exit 2 Drive Motor
    93
    
    Media Transport
    94
  - Tools Required for Service
    97
  - Acronyms
    98
Diagnostic Information

101
- Start
  101
  - Using Service Checks
    101
  - Confirm the Installation Status
    102
  - Power-On Reset Sequence
    102
  - Understanding the Printer Operator Panel
    103
  - Understanding the Home Screen
    105
    
    Other Buttons May Appear on the Home Screen
    106
  - Using the Touch-Screen Buttons
    108
    
    Sample Touch Screen
    108
    
    Other Touch-Screen Buttons
    109
    
    Features
    110
  - Error Code Messages
    111
  - Service Checks
    136
    
    Sensor (Registration) off Jam (too Long)
    136
    
    Sensor (Registration) Static on Jam
    137
    
    Sensor (Fuser Exit) on Jam
    138
    
    Sensor (Fuser Exit) off Jam
    139
    
    Sensor (Fuser Exit) off (too Short) Jam
    140
    
    Sensor (Fuser Exit) Static Jam
    141
    
    Sensor (Exit 2) on Jam
    141
    
    Sensor (Exit 2) off Jam
    143
    
    Sensor (Exit 2) on Jam in Standard bin or Finisher
    145
    
    Sensor (Exit 2) Static Jam
    146
    
    Sensor (Duplex Wait) on Jam
    147
    
    Sensor (Duplex Wait) on Jam
    148
    
    Sensor (Duplex Wait) Static Jam
    150
    
    Sensor (Registration) on Jam (Duplex Paper Feed)
    150
    
    Sensor (Registration) on Jam (Duplex Paper Feed)
    152
    
    Sensor (Pre-Feed) on Jam (Tray 1 Feed)
    154
    
    Sensor (Registration) on Jam (Tray 1 Feed)
    155
    
    Sensor (Pre-Feed) on Jam (Tray 2 Feed)
    156
    
    Sensor (Tray 2 Feed-Out) on Jam (Tray 2 Feed)
    158
    
    Sensor (Registration) on Jam (Tray 2 Feed)
    160
    
    Sensor (Tray 2 Feed-Out) Static Jam
    162
- Sensor (Pre-Feed) on Jam (Tray 3 Media Feed)
  162
- Sensor (Tray 3 Feed-Out) on Jam (Tray 3 Media Feed)
  164
- Sensor (Tray 2 Feed-Out) on Jam (Tray 3 Media Feed)
  166
- Sensor (Registration) on Jam (Tray 3 Media Feed)
  167
- Sensor (Tray 3 Feed-Out) Static Jam
  169
- Sensor (Tray 4 Feed-Out) on Jam (Tray 4 Media Feed)
  170
- Sensor (Tray 3 Feed-Out) on Jam (Tray 4 Media Feed)
  173
- Sensor (Tray 2 Feed-Out) on Jam (Tray 4 Media Feed)
  175
- Sensor (Registration) on Jam (Tray 4 Media Feed)
  177
- Sensor (Pre-Feed) on Jam (Tray 4 Media Feed)
  178
- Go Back
  178
- Sensor (Tray 4 Feed-Out) Static Jam
  180
- Sensor (Registration) on Jam (MPF Pick)
  181
- Switch (Sheet Through) Static Jam
  183
- Sensor (Sheet Through) on Jam
  183
- Sensor (ADF Pre-Registration) on Jam ADF Simplex Side 1
  186
- Sensor (ADF Pre-Registration) off Jam
  188
- Sensor (ADF Pre-Registration) Static Jam
  190
- Sensor (ADF Registration) on Jam ADF Simplex Side 1
  191
- Sensor (ADF Registration) on Jam Side 2
  193
- Sensor (Adf Registration) on Jam Side
  193
- Sensor (ADF Registration) off Jam
  195
- Sensor (ADF Inverter) on Jam (Inverting)
  197
- Sensor (ADF Registration) off Jam (Inverting)
  199
- Sensor (ADF Width APS 1) Static Jam
  202
- Sensor (ADF Width APS 2) Static Jam
  203
- Sensor (ADF Width APS 3) Static Jam
  204
- Sensor (ADF Registration) Static Jam
  204
- Sensor (ADF Inverter) off Jam (Inverting)
  205
- Sensor (ADF Inverter) on Jam 2
  207
- Sensor (Adf Inverter) on Jam
  207
- Sensor (ADF Inverter) off Jam
  209
- Sensor (ADF Inverter) Static Jam
  212
- Sensor (ADF Pre-Registration) on Jam Side 2
  213
- Sensor (Adf Pre-Registration) on Jam Side
  213
- Sensor (ADF Pre-Registration) off Jam on Inverting
  215
- Size Mismatch Jam (MIX-Size)
  217
- Size Mismatch Jam (no MIX-Size)
  219
- Invalid Combine Size Jam
  220
- Too Short Size Jam
  221
- Too Long Size Jam
  223
- Scanner Cable Missing or Unplugged
  224
- Image Pipeline ASIC Failure
  224
- Scanner Communication Failure
  225
- Scanner Communication Failure
  226
- Scanner Communication Failure
  227
- Scanner Unit Assembly - ADF Communication Failure
  228
- Scanner Communication Failure (by Scanner)
  228
- Scanner Unit Assembly Communication Failure
  229
- Sensor (Scanner HP) Failure
  230
- Scanner Carriage over Run Failure
  231
- ADF RAM Test Failure
  231
- ADF EEPROM Failure
  231
- ADF Pick Roll Position Lift up Failure
  232
- Scanner Unit Assembly Connection Failure
  233
- Scanner Unit Assembly EEPROM Failure
  233
- Scanner Unit Assembly EEPROM Sub System Failure
  234
- Scanner Cooling Fan Failure
  234
- Image Processing Failure
  235
- Scanner Controller Card Assembly Failure 1
  235
- Scanner Controller Card Assembly Failure 2
  236
- Exposure Lamp Failure
  236
- White Reference/Exposure Lamp Illumination Failure
  237
- CCD Failure
  239
- CCD Initialization (Lamp On) Failure
  239
- CCD Initialization (Lamp Off) Failure
  240
- Scanner Communication Failure
  240
- Sensor (ADF Width APS X) Failure
  241
- Scanner Unit Assembly Software Logic Failure
  243
- Switch (Platen Interlock) Open
  243
- Go Back
  243
- Hard Drive Failure
  244
- System Software Error
  245
- RAM Read/Write Check Failure
  247
- NVM Data Failure
  248
- NVM Read/Write Cannot be Executed Failure
  248
- CPU Power to Access NVM Failure
  249
- RFID ASIC Failure
  249
- PPM Data Failure
  250
- Zero Cross Failure
  250
- Transport Motor Stop Failure
  250
- Transport Motor Failure
  251
- PC Cartridge Unit Motor Failure
  252
- Printhead Assembly Failure
  253
- Toner Add Motor Assembly Failure
  253
- Fuser Cooling Fan Failure
  254
- PC Cartridge Cooling Fan Failure
  254
- LVPS Cooling Fan Failure
  255
- Sensor (Exit 1 Media Shift HP) Failure
  256
- Sensor (Exit 2 Media Shift HP) Failure
  257
- Exit 2 Unit Assembly Connection Failure
  258
- Fuser Unit Assembly on Time Failure
  258
- Over Heat Temperature Failure
  259
- Center Thermistor Failure
  259
- Rear Thermistor Failure
  260
- Pressure Roll Thermistor Failure
  260
- Fuser Operating Temperature Failure
  260
- PC Cartridge RFID Data Write Failure
  261
- PC Cartridge RFID Communication Failure
  261
- Sensor (ATC) Failure
  262
- Laser Power Failure
  262
- Toner Cartridge RFID Data Write Failure
  263
- Toner Cartridge RFID Communication Failure
  263
- RIP Card Assembly Communication Failure
  263
- Media Tray 1 Lift up / no Media Tray Failure
  264
- Media Tray 2 Lift up / no Media Tray Failure
  265
- Tray 3 Lift up / no Tray Failure
  267
- Tray 4 Lift up / no Tray Failure
  268
- RIP Card Assembly NVRAM Failure
  270
- Operator Panel Assembly NVRAM Failure
  270
- RIP Card Assembly NAND CRC Failure
  270
- RIP Card Assembly Processor Failure
  271
- RIP Card Assembly Processor over Temperature Failure
  271
- RIP Card Assembly Cooling Fan Failure
  271
- RIP Card Assembly FPGA Failure
  272
- 2TM/TTM Controller Card Assembly Communication Failure
  272
- Exit Interface Card Assembly Communication Failure
  273
- Duplex Controller Card Assembly Communication Failure
  273
- Engine Flicker Communication Failure
  274
- Duplex Controller Card Assembly Type Failure
  274
  - 2TM/TTM Left Door Assembly Open
    275
  - Duplex Left Door Assembly Open
    276
  - Exit 2 Left Door Assembly Open
    276
  - Media Size Mismatch in Width
    277
  - Media Size Mismatch in Width
    278
  - No Media in the Select Media Tray
    279
  - Paper Is Installed (Short Edge) in the Media Paper Tray
    281
  - PC Cartridge End of Life
    281
  - PC Cartridge RFID Failure
    282
  - PC Cartridge Set Failure
    282
  - Printer Front Door Open
    283
  - Printer Left Door Open
    284
  - Printer Left Lower Door Open
    285
  - Scheduled Maintenance Required
    285
  - Standard bin 1 Full
    285
  - Standard bin 2 Full
    286
  - Scanner Missing Failure
    287
  - Switch (ADF Left Cover Interlock) Open
    288
  - Toner Cartridge Empty
    288
  - Toner Cartridge Near Empty
    290
  - Toner Cartridge Failure
    290
  - Toner Cartridge RFID Failure
    291
  - Toner Cartridge Set Failure
    291
  - Tray 1 Media Size Failure
    292
  - Tray 2 Media Size Failure
    293
  - Tray 1 Media Size Mismatch in Length
    293
  - Tray 2 Media Size Mismatch in Length
    295
  - Tray 3 Media Size Failure
    297
  - Tray 4 Media Size Failure
    298
  - Tray 3 Media Size Mismatch in Length
    299
  - Tray 4 Media Size Mismatch in Length
    301
  - Image Quality Trouble
    303
    
    Troubleshooting
    303
    
    Image Quality
    304
    
    Faint Print (Low Contrast)
    304
1 I

306
- Blank Print (no Print)
  306
- Solid Black
  308
- Vertical Stripes
  313
- Horizontal Stripes
  315
- Partial Lack
  317
- After Image
  319
- Background (Fog)
  320
- Media Damage
  323
- No Fuse
  324
Diagnostic Aids

327
- Accessing Service Menus
  327
- Diagnostics Menus
  328
  - Entering Diagnostics Menus
    328
  - Available Tests
    328
  - Motor Tests
    331
  - Print Tests
    332
  - Hardware Tests
    333
  - Panel Test
    333
  - Button Test
    333
  - Dram Test
    334
  - Duplex Tests
    336
  - Input Tray Tests
    336
  - Output bin Tests
    338
  - Feed to All Bins
    338
  - Finisher Tests
    339
  - Staple Test
    339
  - Hole Punch Test
    340
  - Base Sensor Test
    342
  - Device Tests
    343
  - Quick Disk Test
    343
  - Disk Test/Clean
    343
  - Power off
    344
  - Printer Setup
    345
  - Engine Setting 1 to
    346
  - Model Name
    346
  - Configuration ID
    346
  - Edge to Edge
    347
  - Enable Edge to Edge Copy
    347
  - Reports
    348
  - Event Log
    348
  - Display the Event Log
    348
  - Clear the Event Log
    350
- Scanner Tests
  351
  - Asic Test
    351
  - Feed Test
    351
  - Printing the Registration Test Original Page
    352
  - Scanner Manual Registration
    352
  - Testing the Manual Scanner Registration
    353
  - Analyzing the Manual Scanner Registration Copies
    354
  - Manually Adjusting the Scanner's Registration
    354
  - Scanner Manual Registration Factory Defaults
    356
  - Exiting Diagnostics Menu
    358
  - Available Menus
    359
  - Configuration Menu
    359
  - Maintenance Counter Value: 20
    361
  - Reset Maintenance Counter
    361
- Registration
  362
  - Print Quality Pages (Configuration Menu)
    364
  - Size Sensing
    365
  - Go Back
    365
  - Panel Menus
    366
  - PPDS Emulation
    366
  - Factory Defaults
    367
  - Energy Conserve
    367
  - Min Copy Memory
    367
  - Format Fax Storage
    368
  - EVENT LOG (Configuration Menu)
    368
  - ADF Edge Erase
    368
  - FB Edge Erase
    368
  - Paper Prompts
    370
  - Envelope Prompts
    370
  - Jobs on Disk
    370
  - Disk Encryption
    370
  - Wipe Disk
    373
  - Font Sharpening
    375
  - Require Standby
    376
  - Short Edge Printing
    376
  - Tray Low Message
    376
  - LES Applications
    376
  - Key Repeat Initial Delay
    377
  - Key Repeat Rate
    377
  - Booklet Adjustments
    377
  - Exiting Configuration Menu
    378
- Repeating Defects
  380
Repair Information

381
- Handling ESD-Sensitive Parts
  381
- Removal Procedures
  382
  - Before Starting Service Work
    382
  - Printer Front Left Cover Removal
    383
  - Switch (Printer Front Door Interlock) Removal
    384
  - Top Cover Assembly Removal
    385
  - Printer Front Door Assembly Removal
    386
  - Front Door Support Strap and Front Door Magnetic Catch Removal
    387
  - Front Inner Cover Removal
    388
  - Right Upper Cover Removal
    389
  - Right Lower Cover Removal
    390
  - Rear Motor Cover Removal
    391
  - Rear Lower Cover Removal
    392
  - Rear RIP Card Cover Removal
    393
  - Option Hookup Cover Removal
    394
  - Rear Upper Cover Removal
    395
  - Controller Box Lower Cover Removal
    397
  - Controller Box Side Cover Removal
    398
  - Switch (Media Size) Removal
    399
  - Media Feed Unit Assembly 1 Removal
    400
  - Media Feed Unit Assembly 2 Removal
    403
  - Remove the MPF Rear Cover. See
    403
  - Remove the MPF Feed Unit Assembly. See
    403
  - Remove the Printer Left Door Assembly. See
    403
  - Remove the Vertical Drive Gear Assembly. See
    403
  - MPF Rear Cover Removal" on Page
    403
  - Media Tray Side Guides Removal
    406
  - Tray
    406
Media Feed Unit Assembly 1 Removal

403
Component Locations

719
- Locations
  719
  - Printer Boards
    719
  - Hvps
    719
  - Printer Motors and Sensors
    720
  - Printer Switches
    725
  - Cables
    726
- TTM Components
  731
- Duplex Components
  732
- Exit 2 Components
  733
Preventive Maintenance

735
- Safety Inspection Guide
  735
- Lubrication Specifications
  736
- Scheduled Maintenance
  736
Parts Catalog

739
- How to Use this Parts Catalog
  739
- Assembly 1: Covers (1 of 2)
  740
- Assembly 2: Covers
  742
- Assembly 3: Media Feed Unit
  744
- Assembly 4: Media Feed Unit Exploded (Tray 1 and Tray 2)
  746
- Assembly 5: Media Tray
  748
- Assembly 6: MPF Unit
  750
- Assembly 7: MPF Unit Feed
  752
- Assembly 8: Left Lower Door and Transport
  754
- Assembly 9: Left Door and Transfer Roll
  756
- Assembly 10: Printer Left Door
  758
- Assembly 11: Registration
  760
- Assembly 12: Printhead, Cartridge Guides, and Fans
  762
- Assembly 13: Fuser
  764
- Assembly 14: Standard Exit 1
  766
- Assembly 15: Dual Unit Drive Motor
  768
- Assembly 16: Electrical
  770
- Assembly 17: Covers and Operator Panel
  774
- Assembly 18: Platen Glass
  776
- Assembly 19: Lens and Sensors
  778
- Assembly 20: Carriage Motor and Cooling Fan
  780
- Assembly 21: Full/Half Rate Carriage
  782
- Assembly 22: ADF Assembly
  784
- Assembly 23: ADF Covers and Components
  786
- Assembly 24: ADF Base
  788
- Assembly 25: ADF Feeder
  790
- Assembly 26: ADF Left Cover Components
  792
- Assembly 27: ADF Media Guide
  794
- Assembly 28: ADF Feeder Roll
  796
- Assembly 29: ADF Motor Unit
  798
- Assembly 30: ADF Document Tray
  800
- Assembly 31: 2000-Sheet Dual Input (TTM)-Covers
  802
- Assembly 32: 2000-Sheet Dual Input (TTM)-Tray 3
  804
- Assembly 33: 2000-Sheet Dual Input (TTM)-Tray 4
  806
- Assembly 34: 2000-Sheet Dual Input (TTM)-Feed and Transport
  808
- Assembly 35: 2000-Sheet Dual Input (TTM)-Feed and Transport
  810
- Assembly 36: 2000-Sheet Dual Input (TTM)-Media Feed Unit
  812
- Assembly 37: 2000-Sheet Dual Input (TTM)-Left Door
  814
- Assembly 38: 2000-Sheet Dual Input (TTM)-Drive and Electrical
  816
- Assembly 39: Duplex Outer
  818
- Assembly 40: Duplex Inner
  820
- Assembly 41: Exit 2 Outer
  822
- Assembly 42: Exit 2 Inner
  824
- Assembly 43: Electrical Cables
  826
- Assembly 44: Electrical Cables
  827
- Assembly 45: Electrical Cables
  828
- Assembly 46: Electrical Cables
  829
- Assembly 47: Electrical Cable
  830
- Assembly 48: Power Cords
  831
- Assembly 49: Miscellaneous
  832
Index

832
Part Number Index

841

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