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Lexmark C52x, C53x (5022-xxx)

1. JFAN1 1 1 rez r zZ 5 r JOPP1 JPH1 J1 F wu or Q roz Q Q OM 3 0 gt gt L Aol rO 5 g OC o e gt OO HooooooooO A O O GOIJLVPS1 Pooouo0dooo4 O Ir OOOOOOOOOL Ao EV F4 OO booosocogd EIFS ef mf ff a O PoU BETH N JucarTt 42 J1 IE Joe g STRANS1 J800 l i JUSB1 CO rara 6 O O ee O o i JCART2 o2 22 E J31 sour 2 z A F HOO Bali tio JTRAY 1 JDC2 z JTRANS2 1e ae oo 1 oo oo oo oo oo oo AA oo S oo IJOPT1 rat oo 1 oo S oo J5 oo oo o oo y oo 1 JBUMP1 Ok oa Jd ddI ISI ISIS ISIS III IIS IS II II54 i ai oS ee cP 1 oo 119971991999191919911971197111111111 oo 0 7 a 0 5 18 Service Manual Connector listing models C53x see System card network models C53x on page 5 18 Connector am V FHUSB_ 5 JB_USB_RD JB_USB_ RD Ground Ground V_BF 5 SW S_BIN_FB Ground VS_BUMP_LED S BUMP_ENC Ground V_BUMP_M V_BUMP_M CART1_HALL_U CART2_HALL_U Ground JBIN1 JBUMP1 JCART1 V_CART1_WIND_V CART2_HAL
2. VS_TRAY_ 5V_NMT O O o0 S_TRAY_INPUT O O O 1 VS_TRAY_INPT_LED 5V 00 00 aoo o T Thermistor AY_PICK_M O SS O o a PHOTO_TRAN Transparency Motor METRY FICK IM Q 00 Q 00 h J31 PHOTO_LED 6 Input Asm GND gt 2 ae T 12C_DATA i flag sensor S TRAY_ENC 00 D oo a z 7 8 VS_TRAY_ENC_LED 00 oo 12C_CLK BiG sensor t t oo oo Network GND a Autoconnect APUL ay O O 45V ao i O connection L 12C_DATA_TB VS_JTRANS 1 3 3V O O Transport card 12C_CLK_TB TPS_SNS_RIN TRANS_THERM_SNS TPS_SNS TPS_PWM1 Tfee TPS ar VS_5V_TPS VS_JTRANS 9 3 3V oe 5V 51 Autoconnect 12C_DATA SI OPT_PCTL o o 9 1 2 et oo i sH OPT_PSIZE ae i al 33 System board Thermistor oo A OPT_TYPE oo YS e oar Autoconnect foils 6 4 2 A SERIAL_TRANSMIT oe d5 TPS Out PR 500 Sheet option ENEE mee 3 3V a 22 PLEV 33 LED On l O oo JJJJJJJJJJJJJJJJJJJJJJJJJ1 J J J E 1111111111111111 111111111111111 5V Rtn a HOSTS eS 141S 1211 aper level sensor P PEELE EC ES Transport CPU aae B SED A Bump align A Motor 5 500 Sheet option card motor
3. 5V Cc ne OPT_PLEV OPT_PCTL _ 5 6 120 CIK OPT_PSIZE oO z 0 Thermistor O VPE JOPT1 Q 7S can Autoconnect rosaa SEG TPS Out 500 Sheet option EEE Ea AIS 3 3V Por V_BUMP_M Sy O OQ T ev am O O VBUMP Me stem board z tolelsi7lelsi4isielh CND JBUMP1 Paper level sensor S_BUMP_ENC propo st7 s s 4 3 2 1 7 1 0 VS_BUMP_LED i O oe OL gt O A O O O O TED A Bump align a Motor 6 500 Sheet option card motor 24V Typ Ple Psize 24V_Rtn Transport CPU 5V_Rtn Lexmark C53X 5022 24V
4. MPF pick tire Diagnostic aids 3 33 5022 xxx Once the paper is fed onto the transfer belt the photoconductor drums in conjunction with the transfer belt pull the print media through the paper path Photoconductor drums Transfer belt 3 34 Service Manual 5022 xxx Once the print media exits the transfer belt it enters the fuser where heat and pressure are applied to bond the toner permanently to the media The fuser rollers continue to turn and pull the print media through the paper path until it reaches the exit drive roll The exit drive roll pulls the print media from the fuser rollers and delivers it to the fuser output drive roll Once the print media reaches the fuser output drive roll the roller pushes the print media into the output bin Fuser output Fuser exit drive roll drive roll Paper exit flag Fuser backup roll Fuser exit idler roll Fuser hot roll Diagnostic aids 3 35 5022 xxx If the page is to be duplexed the fuser output drive roll continues to pull the media until it clears the paper exit flag and then reverses the rotation of the roller in order to pull the media back into the printer duplex assembly The media is then routed down through the duplex path until it reaches the bump aligner roll Once in this position it enters the EP path for the second time Fuser output drive roll Paper exit flag The paper exit flag serves two purposes When i
5. 7 3 Operator panel assembly C534n C534dn 7 3 Bezel C532N 558 eee nee ee Re Re Se SS eR ee Re ee 7 3 Bezel CSS2dn lt 2 ee rere re ee er rr re re rere teense 7 3 Bezel C534n eee eee eee ee ee ee ee ee eee eee 7 3 Bezel C534dn 2 ee ere ee ee er re rnnr 7 3 Paniheddacsemply Cook Ue ee 7 9 Front door assembly C532n C534n 7 7 7 7 7 5 Duplex front door assembly C530dn C532dn C534dn rrr rrr errr ee 7 5 Front door parts packet C53x 2 2 creer ret re rr et ee ener eee 7 5 PxXifilay COVE COJ Sao Ses eo es eee SaaS es eee eee eee Seas Peas 7 3 Tray assembly 550 sheet C532n C532dn C534n C534dn 7 15 Paper tray assembly single feeder C532 C534n rere ree eee 7 15 system card support shield C53x 22 e enter re ree rr eee reece eee 7 9 Pane Pace Cook See ress ase a a ese ane oe eee ee eee ee ae See aa 7 5 Parts packet cables C53X rs ee reer re re rt re rt ee re erence eee 7 19 MPF paper tray assembly 250 sheet C530dn C532dn C534dn 7 15 Option tray assembly 550 sheet option includes tray C532n C532dn C534n C534dn 7 15 Bin full sensor with cable C53xX 28sec m ester n cee eee et eee es 7 3 Front access do
6. 7 5 EP drive assembly C52x eee eee 7 7 Smart chip card 052x only 7 77 77 77 7 9 High voltage power supply 052x 7 7 7 11 Top access cover assembly non network 0524 7 3 Front access door cover assembly non duplex C520n C522n C524 C524n 7 3 Operator panel assembly C52x 7 77 77 77 7 3 Outer DEZE seSeS ese feet a ee er ee a ee eee ea eee 7 3 Toner level sensor 2c rrr rt tr rr et rr er ne reer cere eeee 7 11 Printhead assembly C52x 22 cece cree re re eee rt eee ce ee 7 9 Front door assembly C520n C522n C524n 2 r rr reer rr rr rrr rere 7 5 Duplex font Weer assembly Co240n S oes2 ceseeer ses een ee tee oS ere ets ere mee eae 7 5 Front door parts packet C52x 2s rere e te rr er re tt eet eee e eee 7 5 Pxililay COVO Coe 6 Sree e Serer seer se eee See ee Seg See eee Se eRe eae 7 3 Tray assembly 500 sheet C522n C524 C524n C524dn 7 15 Paper tray assembly single feeder C520n C522n 2 rr rrr errr ree ee 7 15 Right cover reer rr re ee ee ee ee eee eee 7 3 Eides a a Ba 7 3 Rear cover 2 ne ee em ee RR ee RR ee eee ee 7 3 Transier contact asse
7. Service Manual Lexmark C520 C522 C524 C530 C532 C534 5022 XXX e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index 5022 xxx 1 General information The Lexmark C52x and C53x color laser printers deliver superior text and brilliant graphics The following models are available Lexmark C534dn dtn Duplex network 550 sheet tray Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charts symptom tables and service checks to determine the symptom and repair the failure You may find that the removals in the Repair information chapter will help you identify parts After you complete the repair perform tests as needed to verify the repair Begin at Start on page 2 1 Options and features The following options or features are available Some options are not available in every country Contact your point of purchase for options available in your country Memory options of 128MB 256MB and 512MB SDRAM Flash memory options of 32MB and 64MB Hard disk 40GB with adapter models C524 C524n and C524dn and models C534n C534dn and C534dtn Media handling operations 500 sheet optional tray assembly for models C522n C524 C524n and C524dn and 550 sheet optional tray assembly for models C532n C532dn C534n and C534dn Duplex not an option available only on mod
8. 4 62 Service Manual 5022 xxx 4 Disconnect the five connectors C from the HVPS C Installation notes Be sure to replace the spring when replacing the HVPS See the illustration for proper orientation Wy YYYYYY Repair information 4 63 5022 xxx Left bellcrank removal See Left bellcrank assembly on page 7 5 for the part number 1 Remove the left cover See Left cover removal on page 4 20 2 Remove the C clip A g t A A 3 Remove the left bellcrank 4 64 Service Manual 5022 xxx Low voltage power supply LVPS removal See Low voltage power supply 115 230 V on page 7 7 for the part number 1 Remove the right side cover See Right cover removal on page 4 26 2 Remove the rear cover See Rear cover removal on page 4 25 3 Unplug the JLVPS1 connector A from the system card 4 Remove the five LVPS mounting screws B 5 Disconnect the cable from the LVPS C JF ia 6 Remove the cable from the cable guide and remove the LVPS Repair information 4 65 5022 xxx Installation note When installing the new LVPS make sure the voltage switch D is set for the proper value 115 V or 230 V depending on the country 4 66 Service Manual 5022 xxx Multipurpose feeder MPF swing arm assembly removal models C52x only See MPF swing arm assembly C52x on page 7 5 for the part number 1 Open the to
9. 4 92 Service Manual 5022 xxx Waste toner assembly removal Not a FRU 1 Press release latch A 2 Swing front of waste toner away from printer and remove Repair information 4 93 5022 xxx 4 94 Service Manual 5022 xxx 5 Locations and connectors Locations Covers Outer bezel C52X Bezel C53X Inner bezel C52X Operator Panel C52X Exit tray cover Rear Top access cover assembly Front access cover Paper tray dust cover with spring Locations and connectors 5 1 5022 xxx Front Fuser cable cover Paper pick mechanism assembly MPF swing arm assembly models C52X only Front door assembly Deflector assembly a a Bellcrank amp assembly Printer pad Bump aligner gears Front Pare ail cap TON Right front door Left front door assembly restraint assembly restraint cable cable 5 2 Service Manual 5022 xxx Right EP drive assembly _ Bump aligner motor 5 V interlock switch Locations and connectors 5 3 5022 xxx Rear Printhead assembly Smart chip card C52x only System card support shield an System card 1 aS ae 5 4 Service Manual 5022 xxx Left Toner level sensor High voltage power supply Transfer contact assembly Locations and connectors 5 5 5022 xxx Top Top cover camshaft assembly Top access door 24V interlock switch with cable 5
10. Print Resolution Set to 1200 dpi print quality problems should be checked at different resolution settings Toner Darkness Set to 4 default Color Saver Set to OFF RGB Brightness RGB Contrast RGB Saturation Set to 0 Color Balance Select Reset Defaults to zero out all colors Check the paper type texture and weight settings against what is loaded in the printer Once the printer has been restored to its default levels do the following Inspect the transfer belt for damage Replace if damaged Inspect the OPCs and toner cartridges for damage Replace if damaged If paper other than 20lb plain letter A4 paper is being used load 20lb plain letter A4 and print the Print Quality pages to see if the problem remains Use Tray 1 to test print quality problems Print the Print Quality Pages and looked for variations in the print from what is expected N eS An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Measure all voltages from the connector to the printer ground Print quality background Service tip Some background problems can be caused by rough papers non Lexmark toner cartridges or if the media texture is set to the rough setting Some slick or coated papers may also cause background problems Some problems occur with printers that run a large amount of graphics in a humid environment Step Que
11. An error has occurred in the fuser Tray 1 motor has failed Fuser motor has failed EP Drive assembly cartridge 1 motor has failed EP Drive assembly cartridge 2 bottom motor has failed Bump aligner motor has failed POR the printer If the error message persists see 110 xx Mirror motor service check on page 2 27 POR the printer If the error message persists see 111 xx 112 xx 113 xx and 114 xx Printhead error service check on page 2 27 POR the printer If the error message persists see 111 xx 112 xx 113 xx and 114 xx Printhead error service check on page 2 27 POR the printer If the error message persists see 111 xx 112 xx 113 xx and 114 xx Printhead error service check on page 2 27 POR the printer If the error message persists see 111 xx 112 xx 113 xx and 114 xx Printhead error service check on page 2 27 Remove and reseat the fuser POR the printer If the error message persists see 120 01 120 02 120 08 120 10 120 13 120 15 Fuser error service check on page 2 28 Remove and reseat the fuser POR the printer If the error message persists see 120 03 Fuser error service check on page 2 30 Remove and reseat the fuser POR the printer Check the camshaft follower on the left side If the error message persists see 120 04 120 07 Fuser error service check on page 2 30 Remove and reseat the fuser POR the prin
12. Diagnostic information 2 13 5022 xxx Service error codes and paper jam messages continued orem Omen 242 05 242 21 250 03 250 04 2 14 Service Manual While feeding from tray 2 the input sensor is not made The tray 2 autocomp or the redrive motor stalled While feeding from the MPF the input sensor did not break While feeding from the MPF the input sensor is made while the previous page is still in the aligner Ensure proper media is set for the type of paper used Fan media and stack it flat in the 500 sheet tray tray 2 Properly set media restraints in tray 2 Check the pick arm rolls tires and replace if worn If the previous actions do not fix the problem go to 147 xx 149 xx Motor 500 sheet 550 sheet option tray 2 motor error service check on page 2 37 Fan media and stack it flat in the 500 sheet tray tray 2 If the previous actions do not fix the problem go to 147 xx 149 xx Motor 500 sheet 550 sheet option tray 2 motor error service check on page 2 37 Ensure proper media is set for the type of paper used Fan media and stack it flat in the tray or MPF Properly set media restraints in the paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Replace the MPF swing arm assembly See Multipurpose feeder MPF swing arm assembly removal models C52x only on page 4 67 If the previous actio
13. 925 01 Fan Error Fan has stalled POR the printer If the error message persists see 925 01 Fan error service check on page 2 47 945 01 Transfer Roll Yellow transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 945 02 Transfer Roll Cyan transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 2 16 Service Manual 5022 xxx Service error codes and paper jam messages continued frre oweney ma 945 03 Transfer Roll Magenta transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 945 04 Transfer Roll Black transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 946 01 Transfer Roll Yellow transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 946 02 Transfer Roll Cyan transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 946 03 Transfer Roll Magenta transfer roll has failed POR the printer If the error message persists
14. Installation note Be sure the tab B is fully engaged Repair information 4 27 5022 xxx Top access cover assembly removal model C52x only See Top access cover assembly network C520n C522n C524n C524dn on page 7 3 or Top access cover assembly non network C524 on page 7 3 for the part number Remove the rear cover See Rear cover removal on page 4 25 Remove the left cover See Operator panel outer bezel removal on page 4 21 Remove the fuser See Fuser removal on page 4 60 Remove the four screws A exposed after removing the fuser MANT 5 Remove the operator panel See Operator panel assembly removal on page 4 23 6 Remove the exit tray See Exit tray cover removal on page 4 15 4 28 Service Manual 5022 xxx 7 Remove the screw B exposed after removing the exit tray 8 If the top access door is open close it Warning Ensure that the top access door is closed before removing the linkage screw Failing to close the door leaves the linkage under a load which may result in the linkage screw being catapulted away from the printer when removed Repair information 4 29 5022 xxx 9 Remove the linkage screw C 4 30 Service Manual 5022 xxx 10 Remove the screw D from the rear D 11 Disconnect the cables for the fan at JFAN1 E the operator panel at JOPP1 F the high voltage power supply connector at JHVPS1 G and the bin full
15. Select Left Margin and press Select 2 Adjust the left margin until the points of the left alignment marks touch the edge of the page 3 Engine XX XX XXXX X Magenta Left Margin x T Font X XXXXX XX X Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Margin x Paper Source Tray 1 Formatted Size XXXXXX t 5S e Pressing the left arrow decreases the value and moves the left alignment marks to the left e Pressing the right arrow increases the value and moves the left alignment marks to the right Press Select Y to save the value 4 Print the Quick Test page and check the left alignment marks each time until you are satisfied Right Margin 1 Select Right Margin and press Select Engine XX XX XXXX X Magenta Left Margin x T Font X XXXXX XX X Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Margin X Paper Source Tray 1 Formatted Size XXXXXX A Adjust the right margin until the points of the left alignment marks touch the edge of the page e Pressing the left arrow decreases the value and moves the right alignment marks to the right e Pressing the right arrow increases the value and moves the right alignment marks to the left Press Select Y to save the value Print the Quick Test page and check the results Repeat if necessary When the registration is complete proceed to the color alignments Alignment cyan ye
16. on page 4 23 Replace the system card See System card removal on page 4 79 Check the operator panel assembly cable Is the cable damaged Measure the voltage between JOPP1 pin 2 and ground on the system card Is the voltage approximately 5 V dc 2 54 Service Manual Operator panel display all diamonds five beeps Replace the top access cover assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Go to step 2 Replace the operator panel assembly See Operator panel assembly removal on page 4 23 Replace the system card See System card removal on page 4 79 5022 xxx Print quality service check Note This symptom may require replacement of one or more CRUs Customer Replaceable Units designated as supplies or maintenance items which are the responsibility of the customer With the customer s permission you may need to install a developer toner cartridge or photoconductor unit Service tip Before troubleshooting any print quality problems do the following 1 Print a menu settings page and check the life status of all supplies Any supplies that are low should be replaced Note Be sure and keep the original menu page to restore the customer s custom settings if needed 2 Onthe menu page make sure the following is set to the default level Color Correction Set to Auto
17. e The developer roll located in the toner cartridge e The doctor blade located in the toner cartridge e The four transfer rolls located in the transfer belt Printhead assembly The printhead receives control and image data from the system card RIP Through the use of a laser unit the printhead irradiates the photoconductor drum with light and creates an invisible image called a latent or electrostatic image Photoconductor unit The photoconductor unit consists primarily of a charge roll and the photoconductor drum The charge roll charges the surface of the photoconductor drum to prepare it for the latent image drawn by the laser Once the photoconductor drum has been written to by the laser it is responsible for picking up toner from the cartridge developer roller and then transferring the image to the print media Toner cartridge This unit consists primarily of the developer roll and the toner adder roll The primary function of this unit is to supply charge toner to the photoconductor unit for transfer onto the print media The toner adheres to the electrostatic image on the surface of the photoconductor drum which is then transferred to the print media Fuser The fuser assembly uses heat and pressure to fuse the toner image onto the print media Diagnostic aids 3 45 5022 xxx Charging The primary component of the charging process is the high voltage power supply The following provides information that covers the
18. to save the value Print the Quick Test page and check the results Repeat if necessary When the registration is complete proceed to the color alignments Alignment cyan yellow and magenta 1 ey Press Back on the operator panel until you reach the top menu select ALIGNMENT MENU and press Select Select Cyan Select Top Margin and use the right and left arrow keys to select zero Press Select y to save the setting Select Left Margin Right Margin Bottom Margin Skew and Bow In each menu use the right and left arrow keys to select zero and press Select y to save the value lt is important to set all the values to zero before starting 4 8 Service Manual 5022 xxx 5 Select Quick Test in the Cyan menu and press Select Two pages print You may have to print these pages several times until you get T and Z aligned Do not go to step 2 until T and Z are aligned The first page is similar to the following Cyan Alignment Step 1 t ii B0 60 40 20 0 20 40 60 80 80 60 40 20 0 20 40 60 80 Top T Coarse Adjustment Skew Z Coarse Adjustment Top T Fine Adjustment Skew Z Fine Adjustment nN o 20 18 16 14 12 10 O 0 gt d onego IN bhahCnNaa a Z Qe_ i P Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value STEP 1 Adjust the Top T margin and Skew Z then confirm before going to
19. 24V 24V EAEE EE EEEE on LVPS_ZERO_XING 24V 8 OO OO 5V 5V Transport E JF motor V_C1V 6 EI V_JC1 3 6 E JFs Duplex Assembly Duplex M A driver card Enan Encoder Cartridge drive motor 2 00 8 6 DUPLEX_ENC DUPLEX_PWM VS_DUPLX 5V ENnaSag NC GND TRAY_NMT 3 3V VS_TRAY_ 5V_NMT GND ebleh S_TRAY_INPUT fe fe Cc VS_TRAY_INPT_LED 5V l A 1 a O x o0 So Q O Thermistor oo oo oO PHOTO_TRAN Transparency D 00 80 J31 D E PHOTO_LED Input Sensor GND oo QO 90 Ce 12C_DATA fla TRAY _ENC Q O Q ao Zo 72C_CLK g V_ENC_LED 5 o0 ie e r sensor nput tra ae 20 1 GND Autoconnect p y JTRAY2 o as aE TPS_THERM_SNS N C O B O O TPS_GAIN_ADJ TPS_SNS_RTN 6 F O Jt17 7 VS_JTRANS 9 3 3V TPS_SNS O O an i TRANS_THERM_SNS VS_5V_TPS a sport ca VS_JTRANS 5 5V_SW Trans_Belt_Sns JTRANS1 12C_CLK_TB VS_JTRANS 1 5V 12C_DATA_TB TPS Autoconnect
20. Replace the EP drive assembly See Problem solved Replace the system card Electrophotographic EP drive assembly See System card removal model C52x only on page 4 48 removal on page 4 79 Does the error clear 2 46 Service Manual 5022 xxx Models C53x only Turn the printer off and remove the rear cover Replace the JTRANS1 Go to step 2 Check the connector JTRANS1 for proper cable connection to the system card the cable for pinch points and the cable or connector for any other damage See Connector listing models C53x on page 5 19 for the location of the JTRANS1 connector Is the cable damaged Replace the EP drive assembly See Problem solved Replace the system card Electrophotographic EP drive assembly See System card removal model C52x only on page 4 48 or removal on page 4 79 Electrophotographic EP drive assembly removal model C53x only on page 4 51 Does the error clear 925 01 Fan error service check Replace the top access cover assembly See Problem solved Replace the system card Top access cover assembly removal See System card model C52x only on page 4 28 or Top removal on page 4 79 access cover assembly removal model C53x only on page 4 32 Does the error clear Diagnostic information 2 47 5022 xxx 945 XX 946 xx 947 xx Transfer roll error service check Turn the printer off and remove the rear
21. Select Supplies Menu and press Press to select Replace Supply Select Cyan PC Unit Magenta PC Unit Yellow PC Unit or Black PC Unit based on the photoconductor unit that was just replaced and then press lt color gt PC Unit Replaced displays Press to select Yes 4 70 Service Manual 5022 xxx Pick roll rubber tires removal and replacement See Pick arm roll on page 7 15 for the part number The autocompensator pick roll tires are located in the base printer There are also tires in all input options If you have additional input options and you are having problems with media picking replace these tires also Always replace the pick tires in pairs The tires come in a package of two Warning Remove only the rubber tires and not the pick tire assembly to avoid losing small parts 1 Remove the paper tray 2 Pull the autocompensator pick arm A down Repair information 4 71 5022 xxx 3 Remove the rubber tire B from the pick roll assembly C Repeat for the other pick roll assembly ome B C B Installation notes Install the new rubber tires with the surface texture D turning in the direction as shown Note Feel the rubber surface to verify it turns properly in the direction shown 4 72 Service Manual 5022 xxx Printer pad removal See Printer pad included in parts packet screws P N 40X1431 on page 7 5 for the part number 1 Slide the corner of t
22. Selections include Auto MP Feeder and Manual Paper MP Feeder is only available on some printer models Note If the Configure MP setting is changed to Manual a power on reset is performed and the value of the Paper Prompts menu item before the power on reset was MP Feeder then when the printer restarts the printer automatically changes the Paper Prompts setting to Manual Paper Load Manual overrides that would result in a change paper message are disabled for Paper or Env prompts that are set to Manual Manual Paper or Manual Env 3 24 Service Manual 5022 xxx Env Prompts Controls the source the printer selects for a change envelope source message The printer displays the change envelope message based on the size of the envelope requested and not by the envelope type Selections include Auto MP Feeder and Manual Env MP Feeder is only available on some printer models Note If the Configure MP setting is changed to Manual and a power on reset is performed and the value of the Env Prompts menu item before the power on reset was MP Feeder then when the printer restarts the printer automatically changes the Env Prompt setting to Manual Env Load Manual overrides that would result in a change paper message are disabled for Paper or Env prompts that are set to Manual Manual Paper or Manual Env Jobs on Disk Lets the user select whether or not the printer deletes all buffered jobs on the hard disk This menu item only appea
23. Using media Using letterhead Check with the manufacturer or vendor to determine whether the chosen preprinted letterhead is acceptable for laser printers Page orientation is important when printing on letterhead Use the following table for help when loading letterhead Process or paper source Printside Top of page Tray 1 Letterhead faceup Letterhead goes toward the front of the tray Tray 2 Letterhead faceup Letterhead goes toward the front of the tray Duplex two sided printing from Letterhead facedown Letterhead goes toward the rear of the tray trays 1 and 2 Multipurpose feeder Letterhead facedown Letterhead top edge enters first Manual feeder Letterhead facedown Letterhead top edge enters first Duplex two sided printing from Letterhead faceup Letterhead top edge enters last the multipurpose feeder Using transparencies Print samples on the transparencies being considered for use before buying large quantities When printing on transparencies e From MarkVision Professional the printer software or the control panel set the Paper Type to Transparency e Feed transparencies from the standard tray Tray 1 or the multipurpose feeder e Use transparencies designed specifically for laser printers Check with the manufacturer or vendor to ensure transparencies are able to withstand temperatures up to 180 C 856 F without melting discoloring offsetting or releasing hazardous emissions e Use transparencies that ar
24. Wiring diagrams Wiring diagrams are attached to the end of this document Diagrams are designed for 11 x 17 in or A3 paper Print the individual wiring diagram pages separately on larger paper for best effect Locations and connectors 5 23 5022 xxx 5 24 Service Manual 5022 xxx 6 Preventive maintenance Scheduled maintenance The operator panel displays 80 Replace Fuser at 120K page count interval The fuser assembly and the transfer roll should be changed at this interval to maintain the print quality and reliability of the printer The following maintenance items are available for the customer Maintenance items Fuser assembly 115 V 40X3569 Fuser assembly 230 V 40X3570 Fuser assembly 100 V 40X3571 Transfer belt assembly C52x 40X1401 Transfer belt assembly C53x 40X3572 Preventive maintenance 6 1 5022 xxx 6 2 Service Manual 5022 xxx 7 Parts catalog How to use this parts catalog The following legend is used in the parts catalog Asm Part f Units o Index Units mach Description e Asm index identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and the item number 1 e Part number identifies the unique number that identifies this FRU e Units mach refers to the number of units actually used in the base printer or product e Units FRU refers to the number of units packaged together and identified by the part number e NS Not shown in the Asm Index col
25. and remove the 5 V interlock switch 4 54 Service Manual 5022 xxx Front door assembly removal See the part number for the Front door assembly for the specific model you need on page 7 5 1 Remove the front access cover assembly See Front access door cover assembly removal on page 4 16 2 Remove the rear cover See Rear cover removal on page 4 25 3 For C52x only Disconnect the JTRANS1 cable A from the system card For C53x only Disconnect the JTRANS2 cable A from the system card Note If you have a duplex model also disconnect the JDOUPLX1 cable B from the system card Pa i JT Repair information 4 55 5022 xxx 4 Models C52x only Disconnect the cable C from the right side of the frame Be careful not to lose the grounding clip D Ye ee A es 5 Remove the gearbox shield See Gearbox shield removal on page 4 19 6 Close the front door assembly 7 Release the left and right front door assembly cable restraint springs E from the front door assembly oa 8 Open the front door assembly 4 56 Service Manual 5022 xxx 9 Unwrap and remove the cable from the left and right pulleys F L p Pa Z sen 7y vy Repair information 4 57 5022 xxx 11 Open the front door assembly slide it to the right and remove You need to press firmly to slide the front door assembly to the right Installation note See Front door assem
26. continue printing If printing continues order a replacement waste toner box immediately If the problem persists open the front access door and check the bump aligner shaft for binding Clear the binding if possible If not possible contact your next level of service Replace the waste toner box using the instruction sheet that comes with the replacement waste toner box Ensure that there is no interference between the waste toner box and the printer If the problem persists open the front access door and check the bump aligner shaft for binding Clear the binding if possible If the problem persists replace the system card See System card removal on page 4 79 If the problem persists contact your next level of service Diagnostic information 2 23 5022 xxx User status and attendance messages continued 82 Waste toner box missing 83 Transfer belt missing 83 Transfer belt life warning 83 Replace transfer belt 84 lt color gt PC Unit life warning 84 Replace lt color gt PC Unit 2 24 Service Manual Insert the waste toner box Inspect the top cover camshaft assembly for proper operation When the top access cover is closed the printer should mechanically interlock Check the JBUMP1 connection cable connected to the system card for defects and proper connection If the cable wiring or the cable connection is defective replace the bump aligner motor See Bump aligner motor removal
27. magnetic 2 Phillips screwdriver magnetic short blade Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1819128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 General information 1 13 Acronyms C CRU DIMM DRAM EP EPROM ESD FRU GB HVPS LASER LCD LED LVPS MPF MS NVRAM OPT PC pel POR POST PWM RIP SDRAM SIMM SRAM TAR Vac V dc 1 14 Service Manual Cyan Customer Replaceable Unit Dual Inline Memory Module Dynamic Random Access Memory ElectroPhotographic process Erasable Programmable Read Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High Voltage Power Supply Black Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Magenta Multipurpose Feeder Microswitch Nonvolatile Random Access Memory Optical Sensor Photoconductor Picture element Power On Reset Power On Self Test Pulse Width Modulation Raster Imaging Processor Synchronous Dual Random Access Memory Single Inline Memory Module Static Random Access Memory Toner Adder Roller Volts alternating current Volts direct current Yellow 5022 xxx 2 Diagnostic information Start CAUTION Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic card or assembly for personal safety
28. non duplex C520n C522n C524 C524n Front access door cover assembly duplex C5380dn C532dn C534dn Front access door cover assembly non duplex C532n C534n Left cover Bin full sensor with cable C520n C522n C524n C524dn Bin full sensor with cable C53x Parts catalog 7 3 5022 xxx Front Assembly 2 7 4 Service Manual 5022 xxx Assembly 2 Front Units Units Description mach FRU p 40X1446 40X1432 40X1420 40X3593 40X1419 40X1418 40X3592 40X3590 40X3615 40X3614 40X1435 40X1447 40X1405 40X3573 40X3614 Fuser cable cover included in parts packet P N 40X1430 C52x Fuser cable cover included in parts packet P N 40X3598 C53x Printer pad included in parts packet screws P N 40X1431 Right bellcrank assembly Bump aligner gear kit including e Align idler gear 1 e First reduction gear 1 e Second reduction gear 1 e Grease packet 1 e Washers 3 Front door parts packet C52x including e A Right cable assembly 1 e B Front door cap 1 e C Left cable assembly 1 Front door parts packet C53x including e A Right cable assembly 1 e B Front door cap 1 e C Left cable assembly 1 Duplex front door assembly C524dn Front door assembly C520n C522n C524n Duplex front door assembly C530dn C532dn C534dn Front door assembly C532n C534n Deflector assembly C53x Bump aligner roller and spring MPF swing arm assembly C52x Left bellcrank as
29. see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 946 04 Transfer Roll Black transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 947 01 Transfer Roll Yellow transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 947 02 Transfer Roll Cyan transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 947 03 Transfer Roll Magenta transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 947 04 Transfer Roll Black transfer roll has failed POR the printer If the error message persists see 945 xx 946 xx 947 xx Transfer roll error service check on page 2 48 950 00 950 29 NVRAM Mismatch between operator panel POR the printer If the error message persists see Mismatch assembly NVRAM and system card 950 00 950 29 EPROM mismatch failure on NVRAM page 2 50 950 30 950 60 NVRAM Mismatch between system card POR the printer If the error message persists see Mismatch NVRAM and smart chip card or 950 30 950 60 EPROM mismatch failure on printhead NVRAM page 2 50 951 01 951 99 NVRAM
30. sensors bin full 7 12 exit sensor service check 2 52 input sensor service check 2 52 locations 5 8 theory 3 42 toner level 4 83 7 10 serial number location 1 13 viewing 3 16 service checks 110 xx Mirror motor 2 27 111 xx 114 xx Printhead error 2 27 120 01 120 02 120 08 120 10 120 13 120 15 Fuser error 2 28 120 03 Fuser error 2 30 120 04 120 07 Fuser error 2 30 140 xx Autocomp motor error 2 32 142 xx fuser motor error 2 33 143 xx EP drive asm top cartridge motor 2 34 144 xx EP drive asm bottom cartridge motor error 2 35 145 xx bump aligner motor error 2 36 146 xx duplex motor error 2 36 147 xx 149 xx 500 550 sheet option motor error 2 37 147 xx 149 xx 500 sheet option motor error 2 37 148 xx MPF motor error 2 37 906 01 906 04 fuser motor error 2 33 906 05 906 08 bump aligner motor error 2 36 910 01 transparency sensor error 2 38 920 01 POST error 2 38 920 02 POST error 2 38 920 03 POST error 2 38 920 04 POST error 2 39 920 05 POST error 2 39 920 06 POST error 2 40 920 07 POST error 2 40 920 08 POST error 2 40 920 09 920 12 POST error 2 41 920 13 POST error 2 43 920 14 POST error 2 44 920 15 POST error 2 45 920 16 POST error 2 45 920 17 POST error 2 46 920 18 POST error 2 46 920 19 POST error 2 46 925 01 fan error 2 47 945 xx 946 xx 947 xx Transfer roll error 2 48 950 00 950 29 EPROM mismatch failure 2 50 950 30 950 60 EPROM mismatch
31. 1 Select Button Test from HARDWARE TESTS in the Diagnostics mode gt Button Test o ooo O ooo E O Oooo eo 000 2 Press each button one at a time and an X appears in the box that represents that button When you press Back or Stop the test ends Press Back or Stop to cancel the test DRAM Test This test checks the validity of DRAM both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test Select DRAM Test from HARDWARE TESTS in DIAGNOSTICS The power indicator blinks indicating the test is in progress Note Turn off the printer to exit the test before the test is complete DRAM Test 128M P JHHHHHF F 7HHHHF P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 99 999 F represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count is reached the test is stopped the power indicator turns on solid and the final results appear If the test fails SDRAM Error appears for approximately three seconds and the failure count increases by 1 Diagnostic aids 3 11 5022 xxx CACHE Test The CACHE Test is used to verify the processor CACHE is functioning properly 1 Sele
32. 2 Select Single or Continuous e The single Duplex Quick test cannot be canceled e The printer attempts to print the Quick Test Page from the default paper source e Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet The single test stops automatically when a single duplex sheet is printed and the continuous test continues until you press Stop Print Test duplex This test provides service personnel with a way to verify the function of the printer s duplex hardware After the user selects this test the device automatically executes a continuous print test that generates a duplexed color output page To stop the test the user must press Stop While this test executes the power indicator light blinks green and the panel displays DUPLEX TESTS Printing The paper you choose to print the page on should be either Letter or A4 To run the Print Test duplex 1 Select Print Test from DUPLEX TESTS The printer executes a continuous print test that generates a duplexed color output page 2 To stop the test press Stop Diagnostic aids 3 13 5022 xxx Top Margin duplex This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex top marg
33. 610mm 440 mm 558 mm 29 4 kg Printer duplex unit C534dtn 24 in 17 3 in 22 in 64 0 Ib 550 sheet assembly 610mm 440 mm 558 mm 29 0 kg Optional 500 sheet C52x models 5 in 16 5 in 20 4 in 7 25 b assembly only 127 mm 420 mm 518 mm 3 29 kg Optional 550 sheet C53x models 5 in 16 5 in 20 4 in 7 0 Ib assembly only 420 mm 3 2 kg MPF configuration C52x C53x models 19 in 17 3 in 26 6 in 57 5 b printer with 484 mm 440 mm 676 mm 26 1 kg multipurpose feeder extended and exit tray extended Primary tray A4 letter size media 19 in 17 3 in 20 2 in configuration printer 484 mm 440 mm 512 mm with paper tray adjuster extended and output bin installed Legal size media Note A buffer of 12 in 804 8 mm is needed on the back of the printer General information 1 5 5022 xxx Media specifications Paper and specialty media guidelines Media guidelines Media characteristics The following media characteristics affect print quality and reliability Consider these characteristics when evaluating new media stock Weight The printer can automatically feed media weights from 60 to 176 g m 16 to 47 lb bond grain long Media lighter than 60 g m 16 Ib might not be stiff enough to feed properly causing jams For best performance use 90 g m 24 Ib bond grain long media For media smaller than 182 x 257 mm 7 2 x 10 1 in we recommend 90 g m or heavier media Curl Curl is the
34. 7 20 KOCOT a etc 6 I ca a Re a Da a a a E 7 20 MarkNet N8050 802 119 wireless print server rest of world C524 C524n C524dn C534n C534dn 7 20 40 0 GB hard disk assembly C524n C524dn C534n C534dn C534dtn 7 20 Forms card C524 C524n CS524dn 2 ce ect rer re ee eer eee eee 7 20 Bar code card C524 C524n C524dn 7 7 20 Fuser assembly 115 V lt ss 460420 e se ee eee eee er eee eee eee ee eee es 6 1 7 15 Fuser assembly 230 V lt 262 sence ees cc eee ere ee eee eto ees 6 1 7 15 Fuser assembly 100 V lt lt lt 20s ees see ee ee i ee ei tn ee eee 6 1 7 15 Transfer belt assembly C53x 2 ee ec rte tre reece ee eee ee eee 6 1 7 15 Paper pick mechanism assembly C53x 02 2 rect r reece e ree eeee 7 5 Low voltage power supply 115 230 V 22 ee ee ee ee eee ce eee 7 7 System card network C530dn CS532n C532dn 7 9 System card network C534n 22 e eee ree te re er eee ee ere eeee 7 9 System card network C534dn 7 77 7 7 7 9 EP drive assembly C53x 22 c cre cr rt re er re eee eens 7 7 High voltage power supply C53xK 2 cece rece ree rte eee eee ee eee 7 11 Front access door cover assembly non duplex C532n C534n 7 3 Operator panel assembly C530dn C532n C532dn
35. 9 and A through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs e The default standard model Configuration ID is used instead e Configuration ID is the only function available in DIAGNOSTICS e Unless the menu is in DIAGNOSTICS Check Config ID displays 3 16 Service Manual 5022 xxx To set the configuration ID 1 Select Printer Setup from the Diagnostic mode 2 Select Configuration ID from the Printer Setup menu Submitting Selection displays followed by the value for Configuration ID 1 3 Enter the Configuration ID 1 e To select a digit or character to change press lt or P until the digit or character is underlined e To change a digit or character press A to increase or W to decrease the value e When the last digit is changed press Qto validate the Configuration ID 1 lf Invalid ID appears the entry is discarded and the previous Configuration ID 1 is displayed on the screen If the process is successful Submitting Selection appears on the display followed by the current value for Configuration ID 2 4 Repeat the steps for entering the Configuration ID and press D If the Configuration ID 2 is validated Submitting Selection appears and a check y appears next to Printer Setup 5 Restart the printer EP Setup EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value Sometimes this is u
36. C5 C6 B6 28 to 32 Ib 105 to 120 g m Input and output capacities The following table outlines the input and output source capacities by media type Maximum Approximate reference height capacity Standard 250 sheet tray Plain paper 250 sheets 75 g m Optional 500 sheet tray C52x or Plain paper 57 6 mm 500 sheets 80 g m Optional 550 sheet tray C53x 550 sheets 75 g m Multipurpose feeder Plain paper 100 sheets 75 g m Various quantities Manual feed slot Single sheet 1 sheet Standard 250 sheet output bin Plain Paper 250 sheets 75 g m 1 20 Ib xerographic paper at ambient environment 2 Capacity may vary and is subject to media specifications and printer operating environment Note Paper input is limited to below the input source indicator on the tray Print area The printable area is limited to within 4 2 mm 0 167 in of all edges of the media Any information placed outside this specified printable area does not print 1 12 Service Manual 5022 xxx Serial number and machine type The serial number is located on the label on the rear of the right cover and on the service tag located on the inside right frame of the printer The service tag also contains the configuration IDs machine type and model information Config IDs Machine type Serial number Serial number Tools required for service Flat blade screwdriver 1 Phillips screwdriver magnetic 2 Phillips screwdriver
37. Front access door cover assembly removal See Front access door cover assembly for the part number for the models you need on page 7 3 Remove the paper tray Remove the right cover See Right cover removal on page 4 26 Disconnect the transfer belt cable A Press the two tabs B on either side of the transfer belt assembly and lift out the transfer belt assembly Note Leave the photoconductor units on the transport belt when removing m ade a Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photoconductor unit on page 4 2 for additional information Model C52x Model C53x 4 16 Service Manual 5022 xxx 5 Looking down at the keyed end of the restraint C twist the end clockwise slide the restraint upward through the slit D and slip the end of the restraint through the keyed hole E Repeat for the other side ol 6 Close the front access door Repair information 4 17 5022 xxx T Remove the four screws F that attach the pivot pin to the front access door cover 8 Remove the front access cover assembly 4 18 Service Manual 5022 xxx Gearbox shield removal Not a FRU 1 Remove the paper tray 2 Remove the right cover See Right cover removal on page 4 26 3 Remove the four scr
38. Go to step 2 Set the switch for the proper the low voltage power supply LVPS country voltage Is the voltage level 115 230 properly set Turn the printer off and remove the rear cover Replace the fuser cable Go to step 3 Check the connector JFUSER1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Remove the fuser See Fuser removal on Go to step 4 Replace the appropriate page 4 60 Check the AC and DC cable autoconnects on both the fuser and the printer for damage Are the connectors damaged 2 30 Service Manual 5022 xxx Check for the following continuity between DC Goto step 5 Replace the DC fuser cable autoconnect and JFUSER1 I mal 3 517 9 rag 2 141618 10 configuration DC autoconnect JFUSER1 DC autoconnect JFUSER1 Is continuity present Reinstall the fuser See Fuser removal on Problem solved Go to step 7 page 4 60 Does the error clear Check for continuity between the following pins Go to step 6 Replace the AC fuser cable of the AC autoconnect and the pins of the connector that connects to the LVPS z pin 1 ad LVPS connector LVPS connector AC autoconnect Is continuity present Replace the fuser See Fuser removal on Problem solved Replace the system card page 4 60 See System card removal on page 4 79 Does the error clear Diagnostic
39. Install printer covers when you are not working on the printer and do not put unprotected ESD sensitive parts ona table e If possible keep all ESD sensitive parts in a grounded metal cabinet case e Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 5022 xxx Handing the photoconductor unit The following precautions must be observed when handling the photoconductor unit The photoconductor unit is a supply item you will have to remove during some of the repair procedures Transportation storage Use the specified carton whenever moving or storing the photoconductor unit Handling e The optical photoconductor roller in the photoconductor unit exhibits the greatest light fatigue after being exposed to strong light over an extended period of time Never expose it to direct sunlight Cover the photoconductor unit when you remove it from the printer e Use care not to contaminate the surface of the optical photoconductor roller with an oil based solvent fingerprints and other foreign matter e Do not scratch the surface of the optical photoconductor roller Parts not to be touched Any part where the mounting screws are used to meet a printer alignment set at the factory must not be removed disassembled or adjusted 4 2 Service Manual 5022 xxx Adjustments Printhead alignment Overview When reinstalling th
40. Japanese font card Bar code card C524 C524n C524dn Bar code card C534n C534dn PrintCryption card C524 C524n C524dn PrintCryption card C534n C534dn Forms card C524 C524n C524dn Forms card C534n C534dn MarkNet N8000 fast ethernet print server C524 C524dn MarkNet N8020 gigabit ethernet print server C524 C524dn C534n C534dn MarkNet N8030 fiber ethernet print server C524 C524dn C534 C534dn MarkNet N8050 802 11g wireless print server US Americas C524 C524dn C534n C534dn MarkNet N8050 802 119 wireless print server rest of world C524 C524n C524dn C534n C534dn Parallel 1284 B interface card adapter C524 C524n C524dn C534n C534dn Serial interface card adapter C524 C524n C524dn C534n C534dn 40 0 GB hard disk assembly C524n C524dn C534n C534dn C534dtn Printer relocation kit Options tray relocation kit Index Numerics 1xx service error codes 2 7 2 8 24 V interlock switch locations 5 6 parts catalog 7 12 removal 4 85 theory 3 55 2xx paper jam codes 2 8 2 15 3x 8x attendance messages 2 19 2 26 5 V interlock switch locations 5 3 parts catalog 7 6 removal 4 54 theory 3 54 9xx service error codes 2 15 2 18 A accessing service menus 3 1 acronyms 1 14 adjustments 4 3 Align Motor Test 3 8 alignment diagnostics menu 3 7 printhead 4 3 Auto Align Adj 3 23 Auto Color Adj 3 23 B bellcrank left bellcrank 4 64 parts catalog 7 5 right bellcrank 4 77 bezel inner C52x 4 22 7 oute
41. MOTOR TESTS from DIAGNOSTICS 2 Select Mirror Motor Test The panel displays Mirror Motor Test After the test completes the panel displays either Pass or Fail To stop the test press Stop 3 8 Service Manual 5022 xxx Motor Calibration This test is run to match the fuser motor speed to the belt motor speed 1 Select MOTOR TESTS from DIAGNOSTICS 2 Select Motor Calibration The printer generates eight pages as part of this test To stop the test press Stop Servo Laser Test 1 Select MOTOR TESTS from DIAGNOSTICS 2 Select Servo Laser Test The panel displays Servo Laser Test After the test completes the panel displays either Pass or Fail To stop the test press Stop Print Tests Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options The contents of the Print Test Page varies depending on the media installed in the selected input source Check each Test Page from each source to assist in print quality and paper feed problems To run the Print Test Page 1 Select PRINT TESTS from the DIAGNOSTICS 2 Select the media source Tray 1 Tray 2 if installed MP Feeder 3 Select Single or Continuous Diagnostic aids 3 9 5022 xxx e lf Single is selected a single page is printed lf Continuous is selected printing continues until Stop is pressed to cancel the test
42. Manual 5022 xxx Multipurpose feeder MPF swing arm assembly removal models C52x only See MPF swing arm assembly C52x on page 7 5 for the part number 1 Open the top access door 2 Open the front access door 3 Remove the three mounting screws A 4 Remove the swing arm assembly from the frame Installation note Refer to the following illustration if the swing arm crank comes loose from the swing arm assembly Make sure the end of the spring B is under the retaining tab C on the swing arm crank after installation Note Spring end B is shown disengaged from swing arm crank ss cuit _ z gt gt A A _ _ _ E Repair information 4 67 5022 xxx Paper pick mechanism assembly removal See Paper pick mechanism assembly C52x on page 7 5 or Paper pick mechanism assembly C53x on page 7 5 for the part number 1 Remove the rear cover See Rear cover removal on page 4 25 2 Disconnect the JTRAY1 A and JTRAY2 B connectors from the system card Lr A N A B 3 Remove all toner cartridges 4 For models C52x only If installed remove the MPF swing arm assembly See Multipurpose feeder MPF swing arm assembly removal models C52x only on page 4 67 4 68 Service Manual 5022 xxx 5 Remove the three mounting screws C 6 Release the front locking tabs D 7
43. OPT_PSIZE OPT _PCTL 0 5 20 Service Manual 5022 xxx Connector listing models C53x see System card network models C53x on page 5 18 continued Connector JOPP1 JPH1 lI2C_DATA5 OP V_PANEL 5V lI2C_CLK_OP Ground I2CIRQ5_R 3 3 V dc Ground Ground D_VDO_C D VDO C Ground D_VDO_Y D_VDO_Y Ground PH_EMS1_SNS R VDO_BOOST1 VDO_LPOW1 VDO_LADJO1 VDO_HADJO1 PH _EMSO VDO_BOOSTO0 VDO_LPOWO VS_ 5VPH_NVX_R PH EOS THERM_SNS 5V_PH I2C_CLK_PH lI2C_DATA_PH VDO_LENA PH _EMS2_ SNS R VDO_BOOST2 VDO_LPOW2 VDO_LADJ23 VDO_HYSNC1 PH_EMS3_SNS_R VDO_BOOST3 VDO_LPOW3 Ground 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2 28 29 30 Locations and connectors 5 21 5022 xxx Connector listing models C53x see System card network models C53x on page 5 18 continued ee e JPH1 continued D VDO K 34 D_VDO_M 35 D_VDO_M 36 Ground Ground e ss se sew S SB C E e eoms e feve 1 JTRANS1 V_TRANS_PHA V_TRANS_PHA V_TRANS_PHB JTRANS2 JTRAY1 V_TRANS_PHB JTRAY2 VS_5V_TPS 5 22 Service Manual ar ii V_JTRANS 9 3 3V TPS_PWM1 TPS_SNS_RTN TPS_THERM_SNS Ground l2C_CLK_TB I2 DATA TB V_TRANS 1 3 3V Ground N C VS_TRAY_INPT_LED 5V S_TRAY_INPUT Ground VS_TRAY 5V_NMT TRAY_NMT 3 3v Ground VS_TRAY_ENC_LED S_TRAY_ENC Ground V_TRAY_PICK_M V_TRAY_PICK_M TPS_SNS i Z O 5022 xxx
44. Power On Self Test Check for correct POST functioning of the base printer by observing the following 12 The main drive motor turns on 14 15 16 Oe PRA ee The LED turns on The main fan turns on The operator panel turns on A partial row of pixels appears The operator panel display clears Another row of pixels appears The operator panel display clears again The operator panel displays system information For example 206MB S00Mhz The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start The operator panel LED starts blinking Aclock face appears on the display The following errors or messages may appear e Close Dooror Insert Cartridge display if the upper front cover is open or the print cartridge is missing e Any cartridge errors such aS Defective Cartridge or Missing Cartridge Ready appears on the display The EP drive assembly drives the developer shaft located in the toner cartridge The exit rollers turn The printer calibrates Diagnostic information 2 5 5022 xxx Symptom tables Printer symptom table Dead printer Go to Dead printer service check on page 2 51 Operator panel one or more buttons do Go to One or more operator panel buttons fail on not work page 2 53 Operator panel display is blank Printer Go to Operator panel display blank five beeps and LED sounds five beeps off on page 2 53 Operator pan
45. Printhead removal on page 4 74 Diagnostic information 2 45 5022 xxx 920 17 POST power on self test error service check Turn the printer off and remove the rear cover Replace the top access Go to step 2 Check the connector JBIN1 for proper cover assembly See Top connection to the system card the cable for access cover assembly pinch points and the cable or connector for removal model C52x any other damage only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Is the cable damaged Replace the top access cover assembly Top Problem solved Replace the system card access cover assembly removal model See System card C52x only on page 4 28 or Top access removal on page 4 79 cover assembly removal model C53x only on page 4 32 Does the error clear 920 18 POST power on self test error service check Turn the printer off and remove the rear cover Replace the option cable Go to step 2 Check the connector JOPT1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the 500 sheet assembly C52x Problem solved Replace the system card models or the 550 sheet assembly C53x See System card models removal on page 4 79 Does the error clear 920 19 POST power on self test error service check Models C52x only
46. Replace the transfer belt Contact your next level of transfer belt See Transfer belt Support removal on page 4 91 Print quality residual image Service tip Install a new print cartridge if available before doing this service check Residual image can be caused by the photoconductor cleaning blade and other parts inside the print cartridge Is there any toner contamination on the fuser Replace the fuser See Contact your next level of assembly Fuser removal on support page 4 60 Diagnostic information 2 59 5022 xxx Print quality solid color page Service tip A solid color page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum Questions actions Replace the photoconducior unit for the color in question Does this fix the problem Check the high voltage contact from the HVPS to the photoconductor charge roll Ensure the contact springs are properly mounted and that the charge roll contact spring is making good contact with the HPVS spring that runs through the left printer frame See Transfer contact assembly removal on page 4 92 to view the proper mounting and for removal procedures High volt power supply High volt contact path Note Printer is shown with components removed for clarity Are the spring s defective Turn the printer off and check the
47. Select A page similar to this one prints Top left alignment marks Top right alignment marks Left margin alignment marks Lexmak C2X Quick Teg Printer lformaton Margin Settings Page Count XX Top Margin x PSAC XX Bottom Margin x Installed Memory xxx MB Left Margin x Processor Speed xxxMHZz Right Margin x Serial Number XXXXXXX Skew x CalStat XXXX Cyan Top Margin x CalSet X XX X XX X XX Cyan Left Margin XX X XX X XX Cyan Right Margin x Engine ID XX Cyan Skew X FSpeed XXX Cyan Bow x Printer Revision Levels Yellow Top Margin x Loader XX XX XXXX X Yellow Left Margin x Kernel XXX XX XXXX X Yellow Right Margin x Base XX XX XXXX X Yellow Skew X Network XXX XX XXXXX X Yellow Bow X Network Drvr XX XX XXXX X Magenta Top Margin Engine XX XX XXXX X o ee Font X XXXXX XX X agenta Rig argin H 1 Magen Skew ae Right margin magenta Bow x Dup Top Margin x alignment Paper Source marks Formatted Size Bottom margin alignment marks Repair information 4 5 5022 xxx 9 Adjust the screw to adjust the skew and straighten the image on the paper If the top right alignment marks are lower than the top left alignment marks rotate the alignment screw counterclockwise a full revolution and print the Quick Test page Repeat adjusting the screw and printing the Quick Test until the top alignment marks are the same distance from the top of the media Note One rotation of the printhead alignment screw equals approximately 0
48. Slide the paper pick mechanism forward until the rear locking tabs E release 8 Lower the paper pick mechanism and remove through the front of the printer Note Make sure the JIRAY1 and JI RAY2 connectors do not bind when passing through the frame access hole Repair information 4 69 5022 xxx Photoconductor unit removal Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and ee place the photoconductor units on a clean surface See Handing the photoconductor unit on page 4 2 for additional information Open the top access door Open the front access door Lift the right end handle A of the photoconductor unit releasing from the mount Lift the unit up and away from the left side of printer ensuring the left end of the photoconductor is released from the holding pin B B Installation note If a new photoconductor unit is installed reset the life count value in the printer memory e fa message appears on the operator panel 1 When 84 lt color gt PC Unit Life Warningor84 Replace lt co or gt PC Unit appears select Supply Replaced and then press Replace Supply displays Select Cyan PC Unit Magenta PC Unit Yellow PC Unit or Black PC Unit based on the photoconductor unit that was just replaced and then press lt color gt PC Unit Replaced displays Select Yes and then press to clear the message o message appears Press
49. Step 2 Press the up or down buttons until a check appears at the setting in need of adjustment Press Select Then use the lt and gt buttons to enter the new value Press Select to save scales then use the coarse adjustment scales at the top of the page lt P NOTE If the alignment values cannot be determined by using the fine adjustment STEP 2 Go to the next page to adjust the Left L margin Right R margin and Bow P STEP 3 Reprint these pages to confirm final settings Go To Step 2 Repair information 4 9 5022 xxx 6 Determine the line under Fine Adjustment that is closest If the value is beyond the Fine Adjustment scale use either of the Coarse Adjustment scales Top T Coarse Adjustment O 240 160 80 If the alignment is not close enough to use the fine adjustment get close to the ideal value by using the coarse adjustment marks Select the block that is most filled by the color on the left or approximate if 80 60 40 20 O 20 40 60 80 none of the blocks are completely filled and enter it in for the new value Reprint the quick test page and then use the fine adjustment 80 160 Oo wait 240 Top T Fine Adjustment 20 18 5 First locate the line of the color that you 4 are aligning that lines up best with the D sacle line In this example it is 18 If none 0 of the colored lines match up use the D coarse adjustment to get close reprint this A page and then
50. T a ee t w i 3 Snap into place 4 Replace the screw on the right side Repair information 4 47 5022 xxx Electrophotographic EP drive assembly removal model C52x only See i or for the part number Remove the low voltage power supply See Open the top access door Open the front access door Remove all the toner cartridges Disconnect the JTRANS2 connector A from the system card Se A 4 48 Service Manual 5022 xxx T Remove the six inner screws D D D 8 Remove the nine outer screws E Note Access the top two screws through the top cover 9 Remove the EP drive assembly from the printer Repair information 4 49 5022 xxx Installation note Ensure that the top access door is open and EP drive is retracted when installing the new EP drive assembly Note When retracted the upper F and lower retraction plates G will be fully forward If not slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers 4 50 Service Manual 5022 xxx Electrophotographic EP drive assembly removal model C53x only See EP drive assembly C53x on page 7 7 for the part number Remove the right cover See Right cover removal on page 4 26 Open the top access door Open the front access door Remove all the toner cartridges Remove the six inner screws A oS a A A 6 Disconnect JCART1 B JC
51. VDO_BOOST1 VDO_LPOW1 VDO_LADJO1 VDO_HADJO1 PH _EMSO VDO_BOOSTO0 VDO_LPOWO VS_ 5VPH_NVX_R PH EOS THERM_SNS 5V_PH I2C_CLK_PH I2C_DATA_PH VDO_LENA PH _EMS2_SNS R VDO_BOOST2 VDO_LPOW2 VDO_LADJ23 VDO_HYSNC1 PH_EMS3_SNS_R VDO_BOOST3 VDO_LPOW3 Ground O Locations and connectors 5 15 5022 xxx Connector listing models C52x see System card network models C52x on page 5 11 or System card non network models C52x on page 5 12 continued Connector JPH1 continued 3 b D_VDO_K 2 D VDO_ K 33 Ground 4 D_VDO_Y D_VDO_Y 36 Ground e fse e fess S_SB_C e eoo e eme 3 3 V dc JTRANS1 VS_JTRANS 1 5V 11 13 oO O1 ie T Ground I2C_DATA_TB TRANS BELT SNS PE a5 VS_5V_TPS I2C_ CLK _SB VS_JTRANS 5 5V SW TRANS THERM SNS VS_JTRANS 9 3 3V TPS_GAIN_ADJ TPS THERM SNS V_TRANS_PHA TPS_SNS TPS_SNS_RTN N C JTRAN2 V_TRANS_PHA V_TRANS_PHB V_TRANS_PHB VS_TRAY_INPT_LED 5V S_TRAY_INPUT Ground VS_TRAY 5V_NMT TRAY_NMT 3 3v Ground N C JTRAY1 5 16 Service Manual 5022 xxx Connector listing models C52x see System card network models C52x on page 5 11 or System card non network models C52x on page 5 12 continued a a JTRAY2 VS TRAY ENC LED V_ TRAY PICK M V_ TRAY PICK M Locations and connectors 5 17 5022 xxx System card network models C53x
52. aligner roller Repair information 4 43 5022 xxx Contact springs removal See Contact springs on page 7 17 for the part number 1 Remove all the toner cartridges 2 Remove the screw A and the spring cap B of the appropriate contact spring A B 3 Press the lower half C D of the springs and remove the springs N A a Mis 4 44 Service Manual 5022 xxx Installation notes When installing make sure the top half E of the spring is under the straight spring F This is typical for both types of springs Also make sure the bottom half D G of both springs are compressed and locked by the appropriate locking tabs H 1 F E Repair information 4 45 5022 xxx Deflector assembly removal models C53x only See Deflector assembly C53x on page 7 5 for the part number 1 Remove the right cover See Right cover removal on page 4 26 2 Remove the screw A securing the deflector assembly on the right side CA pe 3 Place a flathead screwdriver between the deflector assembly and the right side frame and lever the deflector away from the frame a p g 4 Pivot the deflector out and remove 4 46 Service Manual 5022 xxx Installation notes 1 Align the two studs A to the two alignment holes B in the left side frame B A 2 Align the stud C with the alignment hole D on the right frame uae pi i ii afinar pi
53. and to prevent damage to the printer Use the handholds on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Use the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer They will lead you to solutions or service checks including use of various tests Symptom tables If your printer completes the Power on self test POST sequence on page 2 5 without an error and you have a symptom go to Symptom tables on page 2 6 Locate your symptom and take the appropriate action Service errors 1XX XX 9XX XX lf a service error code appears while you are working on the printer go to Service error codes and paper jam messages on page 2 7 and take the indicated action for that error Service error codes are indicated by a three digit error code followed by a period and additional numbers in the format XXX YY In most cases five digits are shown Paper jam messages 2xxX xx User attendance messages that indicate a paper jam these have been included with the service error codes since repeated instances may indicate an underlying service issue Go to 2xx paper jam messages on page 2 8 User status and attendance messages e User status messages provide the user with information on the current status of the print
54. any data received through the serial port Make sure the Serial Buffer menu item is not set to Disabled If this does not fix the problem replace the PCI card Press W until Continue appears and then press to clear the message The printer discards any data received through the USB port Make sure the USB Buffer menu item is not set to Disabled If this does not fix the problem replace the system card See System card removal on page 4 79 Turn off and unplug the printer Remove the excess flash memory Plug in the printer and turn it on If this does not fix the problem replace the system card See System card removal on page 4 79 This printer does not support the 500 sheet assembly Turn off and unplug the printer Remove the 500 sheet paper tray assembly Plug in the printer and turn it on If this does not fix the problem replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to clear the message and continue printing Install a different hard disk before performing any operations that require a hard disk If this does not fix the problem replace the system card See System card removal on page 4 79 5022 xxx User status and attendance messages continued 62 Disk full 63 Unformatted disk 64 Unsupported disk format 80 Fuser life warning 80 Replace fuser 82 Waste toner box nearly full 82 Replace waste to
55. appropriate side cover that corresponds to the damaged pad It is necessary to remove the corresponding side cover to see if the pad fully seats in the installation holes B Repair information 4 73 5022 xxx Printhead removal See Printhead assembly C52x on page 7 9 or Printhead assembly C53x on page 7 9 for the part number Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the toner cartridges 2 Remove the exit tray cover See Exit tray cover removal on page 4 15 3 Disconnect the transfer belt cable A 4 Press the two tabs B on either side of the transfer belt assembly and lift out the transfer belt assembly Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photoconductor unit on page 4 2 for additional information C52x C53x 5 Remove the system card support shield See System card suppo
56. be functioning properly See Exit sensor service check on page 2 52 Check the duplex paper path for damage that would obstruct the print If damage is found replace the duplex front door assembly See Front door assembly removal on page 4 55 The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 Check for anything in the duplex paper path that might cause the paper to jam This includes the paper guides in tray 1 If clearing the paper jam does not fix the problem and the paper is fan folded replace the front access assembly See Front door assembly removal on page 4 55 If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Diagnostic information 2 11 5022 xxx Service error codes and paper jam messages continued orem Omen ooo 230 04 230 05 230 21 241 03 241 04 2 12 Service Manual During duplex printing the input sensor is made while the previous page is still in the aligner Possible causes e Defective input sensor e Faulty system card During duplex printing the input sensor is not made Possible causes e Obstructed duplex path e Defective input sensor e Faulty system card e Faulty duplex drive Duplex motor stalled Possible causes e Obstructed duplex path e Defective duplex motor e Faulty system card While feeding from tray 1 the input sensor does not break P
57. be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw Once black skew is adjusted the mounting screws will be fully tightened There is one printhead that houses the four color planes The black plane is aligned to the printer and the color planes are internally aligned to black Electrical alignment is done to fine tune the alignment of the color planes to the black plane once the printhead is installed The first step in aligning the printhead is to set the skew for black Printhead mechanical alignment Skew black 1 During installation of the printhead the printhead s lower right corner slot as seen when looking through the rear of the printer and the hole in the frame A should have been visually aligned Repair information 4 3 5022 xxx 2 Remove the paper exit tray for access to the printhead alignment screw B Enter Diagnostic mode turn off the printer press and hold W and gt turn on the printer and release the buttons when the clock graphic displays Select REGISTRATION Select Skew Adjust this setting to zero and press Select Q Press Back Sore p 4 4 Service Manual 5022 xxx 8 Scroll down to Quick Test and press Select A page similar to this one prints Top left alignment marks Top right alignment marks Left margin alignment marks Lexmak C2X Quick Teg Printer lformaton Margin Set
58. causes e Faulty cable connector e Faulty fuser motor e Faulty system card During duplex printing retract the exit sensor is never made Possible causes Damaged paper exit sensor or paper exit sensor flag Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system card During duplex printing retract the exit sensor broke early Possible causes e Damaged paper exit sensor or paper exit sensor flag e Faulty fuser e Faulty system card During duplex printing the exit sensor never broke Possible causes e Damaged paper exit sensor or paper exit sensor flag e Obstructed duplex e Faulty fuser e Faulty system card During duplex printing the input sensor is never made Possible causes e Obstructed duplex path e Defective input sensor e Faulty system card e Faulty duplex drive Check for anything in the paper path that might cause the paper to jam The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to 142 xx and 906 01 906 04 Motor fuser error service check on page 2 33 Check for anything in the paper path that might cause the paper to jam The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 The fuser exit sensor may not
59. failure 2 50 dead printer 2 51 exit sensor 2 52 input sensor 2 52 5022 xxx operator panel 2 53 print quality 2 55 service error codes 2 7 service tag location 1 13 Servo Laser Test 3 9 Size Sensing 3 22 skew 3 5 4 3 smart chip card C52x locations 5 4 parts catalog 7 8 removal 4 78 specifications acoustics 1 4 data streams 1 2 dimensions 1 5 electrical 1 3 environment 1 4 media 1 6 memory configuration 1 2 performance factors 1 2 power requirements 1 3 resolution 1 2 Start 2 1 symptoms print quality 2 6 printer 2 6 system card connectors C52x 5 11 5 12 connectors C53x 5 18 locations 5 4 parts catalog 7 8 removal 4 79 system card support shield parts catalog 7 8 removal 4 81 T test pages print quality test pages 3 10 3 21 Quick Test 3 6 quick test duplex 3 12 theory electrical interlock 24 V interlock switch 3 55 5 V interlock switch 3 54 electrophotographic EP process charging 3 46 cleaning 3 53 developing 3 50 exposing 3 49 fusing 3 52 main components 3 44 transferring 3 51 electrophotographic process EP 3 44 paper path 3 30 main components 3 32 mechanical drive 3 37 paper sensing 3 42 print media transport 3 33 toner cartridges location 5 7 Index l 5 5022 xxx toner level sensor locations 5 5 parts catalog 7 10 removal 4 83 Toner Patch Sensing TPS 3 23 tools required 1 13 top cover camshaft assembly installation 4 87 locations 5 6 parts catalog 7 12 removal 4 86 transfe
60. from the operator panel Navigation arrow buttons A V Press these buttons to scroll up or down through menus menu items or settings called menu item values or to scroll between screens and menu values Each press moves one item in the list or a different setting for a menu item lt 4 Press these buttons to scroll items that wrap off of the screen For menu items with numeric values such as Copies press ED and hold this button to scroll through the values Release the button when the needed number appears 2 2 Service Manual 5022 xxx Binion oF ah a Indicator light The two toned light emitting diode called the indicator light on the operator panel gives information about the status of the printer using the colors red and green Indicator light status Loff Printer power is off Printer power is off is off a green Printer is warming up processing data or printing a job Solid green Printer is on but idle Solid red Operator intervention is required 5 Stop Press to stop or suspend all job activity The functions as a x stop button If printing pressing causes the Stop screen to appear on the display Sug Press to open the administration menus These menus are only available when the printer is in the Ready state e Press to return to the previous screen Note This button is only active if appears on the top left of the screen 8 USB direct port Model C534 only Insert a USB fla
61. if a z i aai mi nn v 1 E i 7 10 Service Manual Assembly 5 Left 40X1416 40X1428 40X1411 40X3579 Toner level sensor Transfer contact assembly High voltage power supply C52x High voltage power supply C53x 5022 xxx Parts catalog 7 11 5022 xxx Assembly 6 Top 7 12 Service Manual 5022 xxx Assembly 6 Top Units Units 6 1 40X3613 1 1 Top cover camshaft assembly 2 40X1437 1 1 Top access door 24 V interlock switch Parts catalog 7 13 5022 xxx Customer replaceable units CRUs Assembly 7 1 14 Service Manual Assembly 7 CRUs 5022 xxx Units Units Description mach FRU p mnOnoa u nWicn A A 40X3569 40X3570 40X3571 40X3607 40X1439 40X3600 40X1423 40X3595 40X1404 40X1424 40X3599 40X3596 40X1401 40X3572 40X0297 40X0288 40X0296 40X0278 40X0286 40X361 1 40X0287 40X0282 40X0279 40X0275 40X3609 40X0280 40X0276 40X0274 40X3610 i i i i i i l i i i i ee a a a eo Fuser assembly 115 V Fuser assembly 230 V Fuser assembly 100 V Pick arm roll Option tray assembly 500 sheet option includes tray C522n C524 C524n C524dn Option tray assembly 550 sheet option includes tray C532n C532dn C534n C534dn Tray assembly 500 sheet C522n C524 C524n C524dn Tray assembly 550 sheet C532n C532dn C534n C534dn MPF paper tray assembly 250 sheet C524 C524n C524dn Paper tray assembly single feeder C520n C522
62. mD a eR eae 7 11 System card support shield C52x eee eer rer er ee et re tence eee 7 9 Parts packet C52xX 2 ere cert re re rt rr ee rr tere ce ne reece cee 7 5 Parts packet cables C52x 2 eee err ere te mnnn 7 19 Parts 206 Co ORC Co Car a a D e a e a a D ea a E T 7 5 7 20 Bump aligner gear kit eee eee ee eeee e 7 5 Bump aligner motor ef rrr eee e 7 7 Contact springs kit 2 2 2 ee ere ret eee re rt err ere re erences 7 17 MPF swing arm assembly C52x 7 5 Part number index l 7 5022 xxx 40X1436 40X1437 40X1439 40X1440 40X1443 40X1445 40X1446 40X1447 40X1448 40X1449 40X1450 40X1451 40X1454 40X1455 40X1508 40X1509 40X1510 40X1512 40X1513 40X1514 40X1515 40X1562 40X2610 40X2663 40X2664 40X3569 40X3570 40X3571 40X3572 40X3573 40X3574 40X3575 40X3576 40X3577 40X3578 40X3579 40X3581 40X3582 40X3583 40X3585 40X3586 40X3587 40X3588 40X3589 40X3590 40X3592 40X3593 40X3594 40X3595 40X3596 40X3597 40X3598 40X3598 40X3599 40X3600 40X3601 40X3602 40X3604 40X3605 Front door 5 V interlock switch 7 7 7 7 Top access door 24 V interlock switch lt 086 0008 nent ete oe ee oe es 7 13 Option tray assembly 500 sheet option includes tray C522n C524 C524
63. occurs Toner Patch Sensing TPS is a diagnostic mechanism that automatically adjusts the printer toner density and alignment settings When TPS executes the printer generates toner patches on the transfer belt It then uses these to calculate the appropriate amount of adjustment if necessary When an event initiates a TPS operation the printer performs a toner density calibration an alignment calibration or both of the calibrations Selections are On default and Off Auto Color Adj Sets the suggested number of pages which the printer should print between consecutive calibrations Selections are Off and the values between 100 and 1000 in increments of 50 The default is 500 pages If the printer exceeds the set value while printing a job it completes the current job and any other jobs received while printing the current job before it initiates a calibration The printer does not cancel or suspend an active job in order to perform a calibration If a user is in any of the menus including the Configuration Menu and the Diagnostics mode an automatic color adjust calibration does not occur Diagnostic aids 3 23 5022 xxx Enforce Color Order Lets the system support person set whether the color order of the cartridges inside the printer is enforced and if messages appear From top to bottom as indicated by the color labels in the printer the enforced toner cartridges order is yellow cyan magenta and black When On is selec
64. off and remove the rear cover Replace the JCART2 cable Go to step 2 Check the connector JCART2 for proper The cable parts packet connection to the system card the cable for contains one cartridge pinch points and the cable or connector for motor cable that works for any other damage either of the cartridge motors Is the cable damaged Remove the right cover Check for the following Go to step 3 Replace the JCART2 cable continuity between JCART2 and bottom The cable parts packet cartridge connector contains one cartridge motor cable that works for either of the cartridge motors gt sage ILULL np eii fix LS ap kebel ein oe a ERENT ly is M i P EN i 7 N F l Bottom cartridge motor connector Is continuity present Replace the EP drive assembly See Problem solved Replace the system card Electrophotographic EP drive assembly See System card removal model C52x only on page 4 48 or removal on page 4 79 Electrophotographic EP drive assembly removal model C53x only on page 4 51 Does the error clear 2 44 Service Manual Models C52x only 920 15 POST power on self test error service check 5022 xxx Turn the printer off and remove the rear cover Check the connector JTRANS1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage See System card network models C52x on page
65. on page 4 40 If the JBUMP1 connector is damaged on the system card replace the system card See System card removal on page 4 79 Check the bump aligner shaft and the mechanical system for binds Replace the bump aligner motor See Bump aligner motor removal on page 4 40 If the problem persists replace the system card See System card removal on page 4 79 Insert the transfer belt For models C52x Check connector JTRANS1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage If the connector is damaged on system card replace the system card See System card removal on page 4 79 For models C53x Check connector JTRANS2 for proper connection to the system card the cable for pinch points and the cable connector for any other damage If the connector is damaged on the system card replace the system card See System card removal on page 4 79 If the JTRANS1 cable model C52x or the JTIRANS2 cable model C53x is damaged replace the front door assembly See Front door assembly removal on page 4 55 Replace the transfer belt assembly See Transfer belt removal on page 4 91 If the problem persists replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the message and continue printing Order a replacement transfer belt When print quality is reduced i
66. on the page tighten the printhead mounting screws in the following order Top middle lower left and lower right 11 Reinstall the paper exit tray and the fuser cable cover Replace the covers 4 6 Service Manual 5022 xxx Registration black Top Margin 1 Select Quick Test REGISTRATION in the Diagnostics mode or use the last Quick Test you used to adjust skew Top left alignment marks Top right alignment marks Lexmark C524 Quick Test 2 Select Top Margin and press Select 3 Adjust the values until both top alignment marks are on the top edge of the print e Increasing the value right arrow moves the alignment marks down on the print e Decreasing moves them up 4 Press Select to save the value 5 Print the Quick Test page and check the top alignment marks Repeat adjustment of the top margin and printing of the Quick Test page until top margin is set Bottom Margin 1 Select Bottom Margin and press Select 2 Adjust the bottom margin until the points of the bottom margin alignment marks are visible and touching the edge of the paper e Increasing the value right arrow moves the alignment marks up on the page e Decreasing the value left arrow moves the marks down on the page 3 Press Select to save the value 4 Print the Quick Test page and repeat this process until the bottom margin is adjusted Bottom margin alignment marks Repair information 4 7 5022 xxx Left Margin 1
67. page 4 32 Diagnostic information 2 53 5022 xxx Operator panel display blank five beeps LED on Service tip The printer has detected a problem with the system card the operator panel assembly cable part of the top cover access assembly or the operator panel assembly if POST does not complete The printer emits five beeps and sticks in a continuous pattern until the printer is turned off Check for ground between JOPP1 pin 4 and ground Is the voltage approximately 0 V dc Check the operator panel assembly cable Is the cable damaged Replace the operator panel assembly See Operator panel assembly removal on page 4 23 Go to step 2 Replace the top cover access assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Replace the system card See System card removal on page 4 79 Operator panel display all diamonds no beeps Check the operator panel assembly cable Is the cable damaged Measure the voltage between JOPP1 pin 2 and ground on the system card Is the voltage approximately 5 V dc Replace the top access cover assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Go to step 2 Replace the operator panel assembly See Operator panel assembly removal
68. particular test you will be given the choice to run the motor in forward or reverse Other times there will only be the option to run the motor in forward direction Before you run any particular motor test ensure you have configured the printer as directed in the following table Setup requirements Motor test Notes Front access door Closed Select Forward or Reverse Closed Select Forward or Reverse Not applicable Remove all paper from the input source tray to avoid hile performing this test Select F Not applicable sey S ile performing this test Select Forward Open Top access cover Align Motor Test Closed Bottom Closed cartridge Top cartridge Closed i To run the motor tests 1 Close the top access cover and front access door 2 Enter MOTOR TESTS 3 Open the top access cover and front access door activate the top right bellcrank by hand close the top access cover 4 Remove the toner cartridges if you plan to test for any length of time 5 Run the desired motor tests To finish Open Open 1 Open the top access cover 2 Deactivate the top right bellcrank 3 Close the top access cover and the front access door 1 Select MOTOR TESTS from DIAGNOSTICS 2 Select the motor that you need to test and press Select Y 3 Select the direction if a choice is offered Forward or Reverse Press Select QD 4 Press Stop to end the test Mirror Motor Test 1 Select
69. printer If the error message persists Failure replace the system card See System card removal on page 4 79 990 xx Option Error Tray 2 failure Replace 500 sheet assembly 2 18 Service Manual 5022 xxx User status and attendance messages User status and attendance messages rs 3x through 8x attendance messages 31 Defective or Missing e Reseat the specified toner cartridge lt color gt Cartridge e For models C52x Inspect the smart chip card contacts A for damage contamination or positioning error If damaged contact your next level of service A Inspect the toner cartridge contacts for damage contamination Replace the toner cartridge if defective Inspect the JSBTN1 cable connection Properly connect the cable if not connected properly Replace the cable if damaged For models C52x Replace the smart chip card See Smart chip card removal models C52x only on page 4 78 If the problem still exists replace the system card See System card removal on page 4 79 32 Unsupported Check to see if the toner cartridge is a supported cartridge Cartridge Note Once the cartridge shipped with the printer is exhausted it must be replaced by a supply cartridge refer to the User s Guide for part numbers If the specified toner cartridge is a supported cartridge reseat the cartridge For models C52x Inspect the smart chip card contacts A for damage contamination or positioning error If da
70. quality and cause jams or other paper handling problems e Check with the manufacturer or vendor to ensure the card stock can withstand temperatures up to 180 C 356 F without releasing hazardous emissions e Do not use preprinted card stock manufactured with chemicals that may contaminate the printer Preprinting introduces semi liquid and volatile components into the printer e Use grain long card stock when possible Storing media Use these media storage guidelines to help avoid jams and uneven print quality e For best results store media where the temperature is 21 C 70 F and the relative humidity is 40 e Store media in cartons when possible on a pallet or shelf rather than on the floor e Store individual packages of media on a flat surface e Do not store anything on top of individual media packages Supported sizes The following tables provide information on standard and optional sources for both input and output trays and bins mown i ff weon i fo pases fe smse wesson i fe prawtesnom e SEDES 7 3 4 Envelope 3 718x7 1 2 EEA Media Sizes lt 250 Tray lt 500 Tray Manual P SA elt PRG Feed Slot kh S S 148 x 210 to 215 9 x 355 6 mm 5 83 x 8 27 to 8 5 x 14 in 1 10 Service Manual 5022 xxx Media Sizes continued Ari N B5 Envelope 176 x 250 mm o fw J Other Envelope 60 5 10 215 9 mm r ter 57 410 215 9 mm T 1 Lower feed reliability might be encountered
71. remove the left front mounting screw C and flip the right lock D back Continue to hold the lever arm A up and remove the right front mounting screw E release the lever arm Remove the e clip F Slide the lever arm A and the spring G off the shaft Warning When removing the right rear mounting screw be careful not to damage or remove the spring that mounts over the screw Remove the rear mounting screws H Remove the top cover camshaft assembly 4 86 Service Manual 5022 xxx Installation notes Warning Do not install the camshaft assembly by reversing the removal procedures The camshaft assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed or the printer will not work correctly 1 Ensure the EP drive assembly is engaged by sliding the upper retraction plate A fully to the rear N fi y t ne 4 is inf f Ea i a Remove the camshaft from the package and place the left and right mounting brackets B on a flat surface Rotate the lever arm C all the way up as if the top access door were open hold the lever arm C in place and rotate the camshafts down D to the closed position Release the lever arm C Remove the e clip E Slide the lever arm C and the spring F off the shaft Aub oO N Repair information 4 87 5022 xxx T Place the left side of the camshaft assembly through th
72. remove the option and check the base printer for correct operation If the base printer operates correctly replace the 500 sheet option assembly Warning Observe all necessary ESD precautions when removing and handling the system card or any installed option cards or assemblies See Handling ESD sensitive parts on page 4 1 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 Remove any input and output paper handling options from the printer Check the AC line voltage Go to step 2 Inform the customer Is the line voltage correct Is the AC line cord damaged Replace the line cord Go to step 3 Go to step 4 Replace the system card See System card removal on page 4 79 Is the JLVPS1 cable correctly installed at Go to step 5 Reseat the JLVPS1 cable JLVPS1 on the system card Go to step 6 Replace the LVPS See Low voltage power supply LVPS removal on page 4 65 Turn the printer off Disconnect the JLVPS1 cable from the system card Turn the printer on and measure the voltage between the JLVPS1 cable pin 1 and the JLVPS1 pin 14 black wire Does this measure approximately 5 V dc Check the system card for 5 V dc between JLVPS1 pin 1 and ground Is the voltage correct Diagnostic information 2
73. self test error service check on page 2 39 920 06 POST Error Input sensor not connected See 920 06 POST power on self test error service check on page 2 40 920 07 POST Error Narrow media sensor not connected See 920 07 POST power on self test error service check on page 2 40 920 08 POST Error Exit sensor not connected See 920 08 POST power on self test error service check on page 2 40 920 09 12 POST Error One toner sensor not connected See 920 09 12 POST power on self test error service check on page 2 41 920 13 POST Error Cartridge motor 1 top not connected See 920 13 POST power on self test error service check on page 2 43 920 14 POST Error Cartridge motor 2 bottom not See 920 14 POST power on self test error connected service check on page 2 44 920 15 POST Error Bad transfer belt NVRAM data See 920 15 POST power on self test error service check on page 2 45 920 16 POST Error Bad printhead NVRAM data See 920 16 POST power on self test error service check on page 2 45 920 17 POST Error Output bin cable not connected See 920 17 POST power on self test error service check on page 2 46 920 18 POST Error Tray 2 has failed See 920 18 POST power on self test error service check on page 2 46 920 19 POST Error Stepper motor not connected See 920 19 POST power on self test error service check on page 2 46
74. sensor at JBIN1 H for network printers only from the system card 12 On the left side unplug the connector J from CN1 on the high voltage power si HVPS F d Left side E H G F J 13 Lift and remove the top access cover assembly Repair information 4 31 5022 xxx Top access cover assembly removal model C53x only See Top access cover assembly network C532n C534n on page 7 3 or Duplex top access assembly network C530dn C532dn C534dn on page 7 3 for the part number Remove the right cover See Right cover removal on page 4 26 Remove the left cover See Operator panel outer bezel removal on page 4 21 Remove the rear cover See Rear cover removal on page 4 25 Remove the fuser See Fuser removal on page 4 60 Remove the four screws A exposed after removing the fuser ee I l Sa i eel Wf i Pa 4 We j J o 6 Remove the operator panel See Operator panel assembly removal on page 4 23 T Remove the exit tray See Exit tray cover removal on page 4 15 4 32 Service Manual 5022 xxx 8 Remove the screw B exposed after removing the exit tray 9 If the top access door is open close it Warning Ensure that top access door is closed before removing the linkage screw Failing to close the door leaves the linkage under a load which may result in the linkage screw being catapulted away from the printer when removed Repair inform
75. slot Paper wrapped in fuser Damaged paper exit sensor or paper exit sensor flag Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system card Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to 140 xx Autocomp tray 1 motor error service check on page 2 32 Fan media and stack flat in the tray or MPF Properly set media restraints in the paper tray If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Check for anything in the paper path that might cause the paper to jam The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 Check for anything in the paper path that might cause the paper to jam The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 Check for anything in the paper path that might cause the paper to jam Load paper in the manual feed slot See Paper jams in the multipurpose feeder or manual feeder on page 3 28 The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 Diagnostic information 2 9 5022 xxx Service error codes and paper jam messages continued moe Omen Bn 201 10 201 21 201 23 201 24 202 02 202 12 202 13 2 10 Service Manual Input se
76. stack it flat in the tray or MPF e Incorrect paper loading l l l If the previous actions do not fix the problem go e Paper pick mechanism failure to 148 xx MPF motor error service check e System card on page 2 37 242 03 While feeding from tray 2 the input Ensure proper media is set for the type of paper sensor does not break used Possible causes Fan media and stack flat in 500 sheet tray l tray 2 e Incorrect media setting ae Properly set media restraints in tray 2 e Incorrect paper loading l l i l Check the pick arm rolls tires and replace if e Incorrect media restraint setting worn e 500 sheet assembly failure Replace the 500 sheet assembly e Paper pick mechanism If the previous actions do not fix the problem go to 140 xx Autocomp tray 1 motor error service check on page 2 32 242 04 While feeding from tray 2 the input Ensure proper media is set for the type of paper sensor is made while the previous used page is still in the aligner Fan media and stack it flat in the 500 sheet tray Possible causes tray 2 e Incorrect media setting Properly set media restraints in tray 2 Incorrect paper loading Check the pick arm rolls tires and replace if Incorrect media restraint setting oe l Replace the 500 sheet assembly 500 sheet assembly failure l l l l l If the previous actions do not fix the problem go Paper pick mechanism to 140 xx Autocomp tray 1 motor error service check on page 2 32
77. tendency for media to curl at its edges Excessive curl can cause media feeding problems Curl can occur after the media passes through the printer where it is exposed to high temperatures Storing media unwrapped in hot humid cold or dry conditions even in the trays can contribute to media curling prior to printing and can cause feeding problems Smoothness Media smoothness directly affects print quality If media is too rough toner cannot fuse to it properly If media is too smooth it can cause media feeding or print quality issues Always use media between 100 and 300 Sheffield points however smoothness between 150 and 200 Sheffield points produces the best print quality Moisture content The amount of moisture in media affects both print quality and the ability of the printer to feed the media correctly Leave media in its original wrapper until it is time to use it This limits the exposure of media to moisture changes that can degrade its performance Condition media before printing by storing it in its original wrapper in the same environment as the printer for 24 to 48 hours before printing Extend the time several days if the storage or transportation environment is very different from the printer environment Thick media may also require a longer conditioning period Grain direction Grain refers to the alignment of the media fibers in a sheet of media Grain is either grain long running the length of the media or grain sho
78. the high voltage power supply connector at JHVPS1 F and the bin full sensor at JBIN1 G and USB at J1 H model C534 only from the system card an Ere Taig En inim ar W F T RE i E Lk py D G F E H Repair information 4 35 5022 xxx 13 Disconnect the ground cable J al 14 Lift and remove the top access cover assembly 4 36 Service Manual 5022 xxx Bin full sensor removal models C52x See Bin full sensor with cable C520n C522n C524n C524dn on page 7 3 for the part number Open the top access door Remove the fuser See Fuser removal on page 4 60 Disconnect the spring A Remove the seven screws B securing the inner access cover oe B A B 5 Remove the inner access cover 6 Turn the access cover over and press the back of the sensor to snap sensor C from the bracket N ae j z F 4 ee AA _ Se oe as T Remove the sensor and cable Repair information 4 37 5022 xxx Bin full sensor removal models C53x See Bin full sensor with cable C53x on page 7 3 for the part number 1 Remove the top access cover assembly See Top access cover assembly removal model C53x only on page 4 32 2 Remove the three screws A from the cable cover A 4 Remove the bin full sensor and cable 4 38 Service Manual 5022 xxx Bump aligner gear removal See the Bump a
79. the paper tray 2 Push up and back to relase the bump aligner spring 3 Lower the bump aligner spring to remove it 4 42 Service Manual 5022 xxx 4 Remove the bump aligner roller Repair information 4 43 5022 xxx Contact springs removal See Contact springs on page 7 17 for the part number 1 Remove all the toner cartridges 2 Remove the screw A and the spring cap B of the appropriate contact spring A B 3 Press the lower half C D of the springs and remove the springs N A a Mis 4 44 Service Manual 5022 xxx Installation notes When installing make sure the top half E of the spring is under the straight spring F This is typical for both types of springs Also make sure the bottom half D G of both springs are compressed and locked by the appropriate locking tabs H 1 F E Repair information 4 45 5022 xxx Deflector assembly removal models C53x only See Deflector assembly C53x on page 7 5 for the part number 1 Remove the right cover See Right cover removal on page 4 26 2 Remove the screw A securing the deflector assembly on the right side CA pe 3 Place a flathead screwdriver between the deflector assembly and the right side frame and lever the deflector away from the frame a p g 4 Pivot the deflector out and remove 4 46 Service Manual 5022 xxx Installation notes 1 Align the two studs A
80. to return to EVENT LOG EXIT DIAGNOSTICS Press Select to exit DIAGNOSTICS The printer performs a power on reset and returns to normal mode Diagnostic aids 3 19 5022 xxx Configuration menu CONFIG MENU Available tests The tests display on the operator panel in the order shown for models C53x The order differs slightly in models C5ex Configuration menu Reset Fuser Cnt See Reset Fuser Cnt on page 3 21 Color Lock Out see Color Lock Out on page 3 21 For models C52x Black Only Mode Jobs on Disk if hard disk is installed Disk Encryption if hard disk is See Disk Encryption on page 3 25 installed Duplex Gloss See Duplex Gloss on page 3 25 Font Sharpening See Font Sharpening on page 3 26 Exit Config Menu This selection exits Configuration Menu and Resetting the Printer displays The printer performs a POR and returns to normal mode 3 20 Service Manual 5022 xxx Reset Fuser Cnt Resets the fuser count value to zero The Event Log records each time that a user executes the Reset Fuser Count operation See Event Log on page 3 23 for more information This setting only appears if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID To reset the fuser count 1 Select Reset Fuser Cnt from the CONFIG MENU 2 Press YY 3 Press Q to select Reset Resetting Fuser Count Value appears 4 Select Motor Calibration See Motor Ca
81. to the two alignment holes B in the left side frame B A 2 Align the stud C with the alignment hole D on the right frame uae pi i ii afinar pi T a ee t w i 3 Snap into place 4 Replace the screw on the right side Repair information 4 47 5022 xxx Electrophotographic EP drive assembly removal model C52x only See i or for the part number Remove the low voltage power supply See Open the top access door Open the front access door Remove all the toner cartridges Disconnect the JTRANS2 connector A from the system card Se A 4 48 Service Manual 5022 xxx T Remove the six inner screws D D D 8 Remove the nine outer screws E Note Access the top two screws through the top cover 9 Remove the EP drive assembly from the printer Repair information 4 49 5022 xxx Installation note Ensure that the top access door is open and EP drive is retracted when installing the new EP drive assembly Note When retracted the upper F and lower retraction plates G will be fully forward If not slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers 4 50 Service Manual 5022 xxx Electrophotographic EP drive assembly removal model C53x only See EP drive assembly C53x on page 7 7 for the part number Remove the right cover See Right cover removal on
82. transfer belt and corrects any media skew as it comes out of the paper trays or MPF Transfer belt The transfer rolls located inside the transfer belt unit are an integral part of the electrophotographic process and the transfer belt advances the print media through the printer Fuser The fuser bonds toner to the print media and advances the print media through the last portion of the paper path The paper exit sensor is also located in the fuser and a flag is present on all fusers that activates the bin full sensors on network model printers Duplex Duplex capability is present only on the C524dn or C524dtn model printers The duplex function is built into the front access door and uses a two pass method for rerouting the paper down and back through the paper path for a second time To accomplish the two pass method the paper is fed partially out of the printer and is then reversed back into the printer 3 32 Service Manual 5022 xxx Print media transport The print media is picked from the input source and fed to the bump aligner roll The media movement is detected by a sensor located in the paper pick mechanism It does not matter where the media comes from Tray 1 Tray 2 or the MPF it will enter the electrophotographic process at the bump aligner drive The bump aligner motor drives the bump aligner roll which feeds the paper to the transfer belt pick tire Pick tire Backup aligner roll
83. 0 PPDS Emulation Activates or deactivates the Personal Printer Data Stream PPDS emulation language This menu item only appears if the PPDS interpreter is available Download Emuls Lets the system support person turn the download emulator off This menu item only appears if one download emulator is installed The only selection is Disable An Enable value is unnecessary because the printer automatically re enables all download emulators after two instances of a power on reset for the printer To re enable these emulators a user would perform another power on reset after exiting the CONFIG MENU Demo Mode Lets marketing personnel or merchandisers demonstrate the printer to potential customers by printing the demo page Selections include Deactivate default and Activate Select Deactivate to turn Demo Mode off or select Activate to turn Demo Mode on Factory Defaults Sets the majority of printer values back to their factory default settings Warning This selection cannot be reversed so this operation should only be used as a last resort to fix any printer problem When factory default settings are restored e All downloaded resources fonts macros symbol sets in the printer memory RAM are deleted e All menu settings return to the factory default setting except The Display Language setting in the Setup Menu All settings in the Parallel Menu Serial Menu Network Menu Infrared Menu LocalTalk Menu and U
84. 4 Print the Quick Test page and repeat this process until the bottom margin is adjusted Bottom margin alignment marks Repair information 4 7 5022 xxx Left Margin 1 Select Left Margin and press Select 2 Adjust the left margin until the points of the left alignment marks touch the edge of the page 3 Engine XX XX XXXX X Magenta Left Margin x T Font X XXXXX XX X Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Margin x Paper Source Tray 1 Formatted Size XXXXXX t 5S e Pressing the left arrow decreases the value and moves the left alignment marks to the left e Pressing the right arrow increases the value and moves the left alignment marks to the right Press Select Y to save the value 4 Print the Quick Test page and check the left alignment marks each time until you are satisfied Right Margin 1 Select Right Margin and press Select Engine XX XX XXXX X Magenta Left Margin x T Font X XXXXX XX X Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Margin X Paper Source Tray 1 Formatted Size XXXXXX A Adjust the right margin until the points of the left alignment marks touch the edge of the page e Pressing the left arrow decreases the value and moves the right alignment marks to the right e Pressing the right arrow increases the value and moves the right alignment marks to the left Press Select Y
85. 5 11 for the location of JTIRANS1 Is the cable damaged Replace the transfer belt assembly See Transfer belt removal on page 4 91 Does the error clear Models C53x only Replace the front door assembly See Front door assembly removal on page 4 55 Problem solved Go to step 2 Replace the system card See System card removal on page 4 79 Turn the printer off and remove the rear cover Check the connector JTRANS2 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage See Connector listing models C53x on page 5 19 for the location of JTRANS2 Is the cable damaged Replace the transfer belt assembly See Transfer belt removal on page 4 91 Does the error clear Turn the printer off and remove the rear cover Check the connector JPH1 large printhead cable for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the system card See System card removal on page 4 79 Does the error clear Replace the front door assembly See Front door assembly removal on page 4 55 Problem solved Replace the printhead See Printhead removal on page 4 74 Problem solved Go to step 2 Replace the system card See System card removal on page 4 79 Go to step 2 Replace the printhead See
86. 5 millimeter movement of the top edge print alignment marks Straight Skewed s o ed n 10 When the top right and top left alignment marks are both showing and are even on the page tighten the printhead mounting screws in the following order Top middle lower left and lower right 11 Reinstall the paper exit tray and the fuser cable cover Replace the covers 4 6 Service Manual 5022 xxx Registration black Top Margin 1 Select Quick Test REGISTRATION in the Diagnostics mode or use the last Quick Test you used to adjust skew Top left alignment marks Top right alignment marks Lexmark C524 Quick Test 2 Select Top Margin and press Select 3 Adjust the values until both top alignment marks are on the top edge of the print e Increasing the value right arrow moves the alignment marks down on the print e Decreasing moves them up 4 Press Select to save the value 5 Print the Quick Test page and check the top alignment marks Repeat adjustment of the top margin and printing of the Quick Test page until top margin is set Bottom Margin 1 Select Bottom Margin and press Select 2 Adjust the bottom margin until the points of the bottom margin alignment marks are visible and touching the edge of the paper e Increasing the value right arrow moves the alignment marks up on the page e Decreasing the value left arrow moves the marks down on the page 3 Press Select to save the value
87. 5022 xxx 910 01 Transparency sensor error service check Turn the printer off and remove the rear cover Replace the paper pick Go to step 2 Check the connector JTRAY1 for proper mechanism See Paper connection to the system card the cable for pick mechanism assembly pinch points and the cable or connector for removal on page 4 68 any other damage Is the cable damaged Check the transparency sensor for correct Go to step 3 Remove the paper pick mounting mechanism properly install the transparency sensor and reinstall paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Is the transparency sensor properly mounted in the paper pick mechanism Replace the paper pick mechanism See Problem solved Replace the system card Paper pick mechanism assembly removal See System card on page 4 68 removal on page 4 79 Does the error clear 920 01 POST power on self test error service check Replace the bump aligner motor See Bump Problem solved Replace the system card aligner motor removal on page 4 40 See System card removal on page 4 79 Does the error clear 920 02 POST power on self test error service check Replace the paper pick mechanism See Problem solved Replace the system card Paper pick mechanism assembly removal See System card on page 4 68 removal on page 4 79 Does the error clear 920 03 POST power on self
88. 51 5022 xxx Turn the printer off Connect the JLVPS1 cable Replace the faulty part Contact your next level of to the system card Remove one option feature support at a time and turn the printer on to isolate the failing part Warning Observe all the ESD precautions see Handling ESD sensitive parts on page 4 1 and turn the printer off before any feature or option cards are removed or replaced Is a failing part found Exit sensor service check Verify the paper is loaded properly in the Go to step 2 Load paper in the manual manual feed slot See Loading media in the feed slot See Clearing multipurpose feeder or manual feeder on paper jams in the manual page 3 28 feeder on page 3 29 Is the paper properly loaded in the manual feed slot Is the exit sensor flag damaged Replace the fuser See Go to step 3 Fuser removal on page 4 60 Is the JFUSER1 properly connected to the Go to step 4 Reseat the connector system card Place a voltmeter between the JFUSER1 pin 7 Replace the system card Replace the exit sensor and ground Initially the meter should indicate See System card 5 V dc Activate the exit sensor flag removal on page 4 79 Does the voltage drop to 0 V dc Input sensor service check Is the input sensor flag damaged Replace the paper pick Go to step 2 mechanism See Paper pick mechanism assembly removal on page 4 68 Is the JTRAY cable connector
89. 6 Service Manual CRU and FRUs Fuser Top access door Toner cartridges r a Pa ea a Front access door Transfer belt Waste toner assembly Left side of printer 550 sheet assembly C53x 500 sheet assembly C52x 5022 xxx Locations and connectors 5 7 5022 xxx Sensors Paper exit duplex entry sensor and flag Input bin full sensor and flag Multifunction transparancy Input sensor sensor Toner level sensor Toner patch sensor TPS _ a k Eg CC k ESN 5 8 Service Manual 5022 xxx Motors Transfer belt motor Top cartridge motor Bottom cartridge motor Bump aligner motor Duplex motor duplex models only Locations and connectors 5 9 5022 xxx Printer cards Smart chip card C52X only High voltage power supply System card 5 10 Service Manual 5022 xxx Connectors System card network models C52x Jo FJJCARTI j STRANS2 F JCART2 JDUPLX1 1 OO Qa eI IO o o oo 4 OO JTRAY2 JTRAY1 p fe JTRANS1 JOPT de JUSB1 ol AO 4 JDC2 sump Locations a
90. 666 in or 0 1693 mm 10 to 10 Each increment corresponds to an approximate shift of 4 pels at 600 dpi Each increment corresponds to 1 1200 of an inch A positive offset moves text up the page and widens the bottom margin while a negative offset moves text down the page and narrows the bottom margin A positive change moves the image down the page and increases the top margin A negative change moves the image up and decreases the top margin A positive change moves the image to the left and a negative change moves the image to the right No compression occurs A positive change moves the image to the right and a negative change moves the image to the left A positive value causes the right end of the scan line to move down the page A negative value causes the right end of the scan line to move up the page The left end Stays fixed 5022 xxx 5 Continue changing the settings by repeating steps 2 through 4 6 Print another copy of the Quick Test to verify your changes 7 To exit REGISTRATION press Back Skew One printhead houses the four color planes The black plane is aligned to the printer and the color planes are internally aligned to black Electronic alignment fine tunes the alignment of the color planes to the black plane once the printhead is installed See Printhead mechanical alignment on page 4 3 for instructions on setting printhead alignment This must be performed before color s
91. ART2 C and JTRANS2 D connectors from the drive assembly 0 j j F k i _ 3 lt a E i r F i k 5 4 i j j r ja f f 1 j amp ka a x Repair information 4 51 5022 xxx 7 Remove the nine outer screws E Note Access the top two screws through the top cover 8 Remove the EP drive assembly from the printer 4 52 Service Manual 5022 xxx Installation note Ensure that the top access door is open and the EP drive is retracted when installing the new EP drive assembly Note When retracted upper F and lower retraction plates G will be fully forward If not slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers Repair information 4 53 5022 xxx Front access door 5 V interlock switch removal See Front door 5 V interlock switch on page 7 7 for the part number 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 65 2 Disconnect the JINT1 connector A from the system card 3 Open the top access door 4 Remove the gearbox shield See Gearbox shield removal on page 4 19 5 Remove the interlock switch mounting screw B from the right side of the printer B 6 Remove the cable from cable guide and remove the 5 V interlock switch 4 54 Service Manual 5022 xxx Front door assembly removal See the part number for the Front door assembly for the specific model you ne
92. Cyan L value R value P 0 M M Current New Cyan Cyan P value P value Repeat steps 2 through 11 for yellow and magenta Right R i Adjustment i R 0 Right R Fine Adjustment 54 Coarse 300 0 300 240 42 30 0 T New Cyan R value Note Start each color group by setting the Top Margin Left Margin Right Margin Bottom Margin Skew and Bow to zero 4 12 Service Manual 5022 xxx Printer removal procedures Precautions to take before maintenance work Do not implement any operation removal or modification and so on which is not presented in this manual 1 Turn the printer power off and unplug the power cable from the outlet prior to starting AN removals or checks 2 Prior to starting any repairs read and understand the warnings in this manual e High temperature e High voltage e Laser radiation Confirm the direction of all parts and screw lengths during removal replacement Utilize the proper cleaning procedures solvents during maintenance Confirm that all parts and covers are properly installed and assembled prior to starting the print test ae Repair information 4 13 5022 xxx Cover removals Outer bezel C52X Bezel C53X Inner bezel C52X Operator Panel C52X Exit tray cover Rear cover Top access cover assembly Front access cover Paper tray dust cover with spring 4 14 Service Manual 5022 xxx Exi
93. HVPS doctor developer contact spring 8 Parts catalog 7 17 5022 xxx Assembly 9 Cable parts packet 7 18 Service Manual 5022 xxx Assembly 9 Cable parts packet Units Units Descriotion mach FRU p 40X1430 Cables C52x including A Cartridge motor cable 1 B Fuser AC cable 1 C Fuser DC cable 1 D Smart chip cable 1 E Option cable 1 Fuser cable cover 1 see Front on page 7 4 for part identification and location e Duplex cable 1 40X3598 Cables C53x including A Cartridge motor cable 1 B Fuser AC cable 1 C Fuser DC cable 1 E Option cable 1 F Transport motor cable 1 Fuser cable cover 1 see Front on page 7 4 for part identification and location Duplex cable 1 Parts catalog 7 19 5022 xxx Assembly 10 Miscellaneous Units Units Deecintion mach FRU p 40X1431 40X1508 40X1509 40X1510 40X1454 40X1455 40X1515 40X1514 40X1513 40X1512 40X2664 40X4237 40X4199 40X4239 40X2663 40X4238 40X1375 40X1376 40X1377 40X1378 40X1562 40X0291 40X0290 40X2610 7377018 7377200 7 20 Service Manual a a a ee a Sa ee Parts packet screw contains one of each screw used in the printer with the exception of the parts specifically called out 128 MB SDRAM 100 pin 256 MB SDRAM 100 pin 512 MB SDRAM 100 pin 32 MB flash card 64 MB flash card Korean font card Traditional Chinese font card Simplified Chinese font card
94. If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope Note The Print Test Page always prints on one side of the paper regardless of the duplex setting 4 Press Back to return to PRINT TESTS Print quality test pages Prt Quality Pgs The print quality test consists of five pages Pages one and two contain a mixture of graphics and text The remainder of the pages only contain graphics The test prints on the media in the default tray Lexmark C534 Print Quality Test Fa i a Badia AT aE This test may be printed from either Configuration Menu or the Diagnostics mode To run the print quality pages from the Diagnostics mode select PRINT TESTS and Print Quality Pgs from the menu Once the test is started it cannot be canceled When the test pages print the printer returns to the original screen To run the Print Quality Test Pages select Prt Quality Pgs from PRINT TESTS The message Printing Quality Test Pages is displayed 3 10 Service Manual 5022 xxx Hardware Tests Panel Test This test verifies the operator panel LCD function To run the Panel Test 1 Select HARDWARE TESTS from DIAGNOSTICS 2 Select Panel Test The Panel Test continually executes 3 Press Stop to cancel the test Button Test This test verifies the operator panel button function To run the Button Test
95. Interlock switch fs a a a Wi ri n D a ram for HVPS fuser motor and bump align motor HAEAEGHE Senses front door and top cover Printhead Thermistor Fe Exit ol lo sensor f 5 Bin full sensor Lt imi 5V Interlock for laser driver Switch Autoconnect T GND a Fuser CRU Yellow cartridge ata 2 n Z a 92525 GND zla z z z 5 Cyan cartridge om iE o gt aaa mjin PIE Jol gt lol lel al S e a n aja He OC oo oo O oi 5 5 SIS UCT aja ioe 7 GND r7 TIE ol Hil 22o Magenta cartridge bara y a z z 52 z 2 2 12 Z s1579 Hihshish7H912123 9 F GND 2 fam 2 r D Black cartridge 5 sl ae cc x x x j j EE T l oza T 2 7 Sir o o Cartridge drive Fl z zjx olol o o al H Siz Z El z e olz u T ZIN lalol ZI Elov wl a aa 3 clo gt gt izlZ ra gt OFF 18 oc AAA E IE AMPAR RIEKIE 99 motor 1 z a8 39 EE B SREE as E E gasi e SIS FP SEs blaska elkasiga 3 3 ll SS oc H el OIS Slafar or e O79 El Zl jE gza olol Jojo la Sisir Salz gas sa Ssa lolol lolo siga u wz zu gaap wuulelelelole SAAS Saz olll AsO Jala AA R R Err N RA a OA LAAT yi R aa zS g gael ald Vols ISIS 1S LIE ES E s s5 s 2 5 al len oile BSR S gt gt 9 gt gt 9 2 8 8 18 1818 ale sfololSiz 8 81 8 8 iz S18 8 gt ea 2 w cal al 2 2 cl solo gt lo SEPEISIRIRR lxx SESS SSS SASL lalallala SS aS SSi eal SjalSiSlS SialS S GlalalGlalals gt 9 Slals 124 6 sfop2apafiepsj2oj22i24 1 2 3 4 5 iy2ysi4tstey7
96. L_U CART2_ HALL _W Ground JCART2 O V_CART2_WIND_V V_24V_CVR COVER_OPEN_SNS VS_DUPLX 5 V DUPLEX_PWM DUPLEX_ENC Ground V_24VD Ground FAN_FG Ground 24VC FAN1_PWM JCVR1 JDUPLX1 l Z O JFAN1 0 5022 xxx CART1_ HALL V CART1_FG 5V SW V_CART1_WIND_U V_CART1_WIND_W CART2_HALL V CART2_ FG 5V SW V_CART2_WIND_U V_CART2_WIND_W Locations and connectors 5 19 Connector listing models C53x see System card network models C53x on page 5 18 continued Connector JFUSER1 V_FUSER_M VS_FUSER_LED Ground FUSER_EXIT_SNSD FUSER _HR_SNS Ground HV_EMPTY_C HV_EMPTY_Y Ground TONER_C TONER_Y HV_CHRG_PWM HV_XFER_PWM_C HV _XFER_PWM_M HV _XFER_PWM_Y CORE_CURR_SNSD HV _XFER_PWM_K VS_JINT 1 5V_SW Ground VS_INT 5V_PH 5 Vdc 5 Vdc LVPS ZERO_XING 24 V dc Ground Ground Ground LVPS_ BRON MM_REF MM_LOCK MM_START Ground 24 V dc VS_JOPT 1 5V_SW S_OPT_ENC Ground 24VC OPT_PLEV V_FUSER_M S_ FUSER_ENC GND BR_THERM VS_FUSER 5V FUSER _HR_THM_RTN V_24VD HV _EMPTY_M HV_ENPTY_K 5V SW TONER_M TONER_K TONER_CHK XFER_SERVO_C XFER_SERVO_M XFER_SERVO_Y HVPS_ID XFER_SERVO K 10 JHVPS1 10 12 14 16 18 20 22 24 1 13 15 17 19 2 23 JINT1 JLVPS1 5 V dc 5 V dc 24 V dc 24 V dc Ground Ground Ground LVPS_HRON 10 12 14 16 13 15 JMIRR1 JOPT1 NO SERIAL_TRANSMIT OPT_TYPE Ground
97. Lpetsl4ispel7 sfofopiipahishap sieht 7s 9j2of2 y22 23 24 25f26 2 7 28 29 30 31 32 33 34435 36 il2lsl4islel ls Uls 719 Gelso hti Oles Gllslalisier Lpelsl4ispel7 sfofopipahishapspieh 7st oj2of2 y22 23 24 25f26 2 7 28 29 30 31132 33 34435 36 i in el4lelsho tm eh 4 6 8hopahahefisj2oj2aie A JPH1 etre J1 JFAN1 JSBTN1 AAT 2 ara Z JOPP1 7 L LVPS_BRON Jrz LPS HRON E ENG LJ E eno a aa i coooooooonon S 11 12 11 12 O m eno tA i ja oooog Pen 7 aw A RRIJLVPSI OO no in eek ic tvs zeno Xna aw 8 E OO a ev aie EE OHoOooooo0ood A 5V E T g Transport SA a Oe F4 oo OOOO 0g O ne motor V_CART1_WIND_V V_CART1_WIND_W O LILI IC V_CART1_WIND_U F O IO OI C CARTI HALL W CART1_FG 5 Gg gogogaga CART1_HALL_U CART1_HALL_V oe ca Duplex Assembly 0 MOOOOOOOO Duplex V_Trans_PHB Ss M V_Trans_PHB driver card O O Encoder Cartridge drive motor 2 V_CART2_WIND_W V_CART2_WIND_U CART2_FG CART2_HALL_V _ J800 oak DUPLEX_ENC DUPLEX_PWM TRAY_NMT 3 3V PHU UL
98. P Defaults 3 17 factory defaults 3 22 Index l 1 5022 xxx deflector assembly parts catalog 7 4 removal 4 46 Demo Mode 3 22 diagnostic aids 3 1 diagnostics menu accessing 3 1 ALIGNMENT 3 7 available tests 3 2 Base Sensor Test Bin Full Test 3 15 Sensor Test 3 15 Duplex Tests Motor Test 3 14 Print Test duplex 3 13 Quick Test 3 12 Top Margin 3 14 Event Log Clear Log 3 19 Display Log 3 18 Print Log 3 18 exit diagnostics 3 19 Hardware Tests Button Test 3 11 CACHE Test 3 12 DRAM Test 3 11 Panel Test 3 11 Input Tray Tests 3 14 Motor Tests Align Motor Test 3 8 Bottom cartridge 3 8 Fuser 3 8 Mirror Motor Test 3 8 Motor Calibration 3 9 Servo Laser Test 3 9 Top cartridge 3 8 Transfer 3 8 Tray 1 3 8 Tray 2 3 8 Print Tests input source tests 3 9 Prt Quality Pgs 3 10 Printer Setup Configuration ID 3 16 DC Charge Adjust 3 17 Defaults 3 16 Dev Bias Adj 3 17 Engine Setting 1 4 3 16 EP Defaults 3 17 Fuser Temp 3 17 Model Name 3 16 Page Counts 3 16 Serial Number 3 16 Transfer Adjust 3 17 REGISTRATION 3 4 Bottom Margin 3 4 Left Margin 3 4 Quick Test 3 6 l 2 Service Manual Right Margin 3 4 Skew 3 5 Top Margin 3 4 dimensions 1 5 Disk Encryption 3 25 DRAM Test 3 11 duplex Motor Test 3 14 Print Test 3 13 Quick Test 3 12 theory 3 41 Top Margin 3 14 Duplex Gloss 3 25 E electrical interlock 3 54 24 V interlock switch 3 55 5 V interlock switch 3 54 electrophotographic EP drive assembly locations 5 3 parts ca
99. SB Menu Selections are Restore Base and Restore Network The Restore Network value only appears on printer models that have integrated network support Restoring Factory Defaults appears on the operator panel while factory defaults are restored 3 22 Service Manual 5022 xxx Energy Conserve Affects the values that appear in the Power Saver menu item in the Setup Menu This menu item only appears when the printer model does not support Automatic Power Saver or has deactivated Automatic Power Saver The menu item only affects the values that are displayed in the Power Saver menu item Select Off default to cause Power Saver to only display Disabled If Disabled is selected in Power Saver the printer deactivates the Power Saver feature Select On to cause Disabled to not appear on the operator panel for Power Saver Event Log Lets the system support person print a limited set of the information contained in the Diagnostics mode version of the printed Event Log For a sample of a printout see Event Log on page 3 18 The limited Configuration log and the full Diagnostics log printed versions show the same operator panel messages when they print and follow the same layout guidelines To print the event log 1 Select EVENT LOG from the Config Menu 2 Select Print Log 3 Press Select to begin printing the log Auto Align Adj Controls whether the printer executes the automatic alignment calibration after an initiating event
100. See Operator See System card the voltage on pin 6 and ground panel assembly removal removal on page 4 79 on page 4 23 If this does not fix the problem replace the top cover access assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Does the voltage measure approximately 3 3 V dc Operator panel display blank five beeps and LED off Service tip The printer has detected a problem with the system card the operator panel assembly cable part of the top cover access assembly or the operator panel assembly if POST does not complete The printer emits five beeps and sticks in a continuous pattern until the printer is turned off Is the operator panel assembly cable properly Go to step 2 Reinstall the cable installed at system card JOPP1 and at the operator panel assembly Measure the voltage between JOPP1 pin 2 Go to step 3 Replace the system card and ground on the system card See System card Is the voltage approximately 5 V dc Pow A OW BOGE ety Check continuity of the operator panel Replace the operator panel Replace the top cover assembly cable assembly See Operator access assembly See Top a panel assembly removal access cover assembly Is there continuity on page 4 23 removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on
101. Smart chip card or printhead NVRAM POR the printer Failure failure e For C52x if the error message persists replace the smart chip card See Smart chip card removal models C52x only on page 4 78 e For C53x if the error message persists replace the printhead See Printhead removal on page 4 74 952 01 952 99 NV CRC error has occurred This is Perform a POR to clear the error Failure n recoverable 953 01 953 99 NVRAM Operator panel assembly NVRAM POR the printer Replace operator panel assembly if Failure the error message persists See Operator panel assembly removal on page 4 23 Diagnostic information 2 17 5022 xxx Service error codes and paper jam messages continued 954 01 954 99 NVRAM System card NVRAM failure POR the printer If the error message persists Failure replace the system card See System card removal on page 4 79 955 01 955 99 Code System board memory failure POR the printer If the error message persists Failure replace the system card See System card removal on page 4 79 956 01 956 99 System Processor failure POR the printer If the error message persists card replace the system card See System card removal on page 4 79 958 01 958 99 Memory Processor failure POR the printer If the error message persists Failure replace the system card See System card removal on page 4 79 961 01 961 99 Memory Memory failure POR the
102. a jojo gt gt DL Lu Lu FIE Ole aelo 2la ejoj jawu u O u 32 plr Za 5 E Hel ul GND i he ales ai Magenta cartridge aT z 2 2 2 Z 2 8 yn Zz GND o S a i oc Black cartridge bara a zg 3 a r JES x x mamncge ONNE Bla z S E slala leelo El lalage 1 zo T Mt lz yO x sft aft 19 2 83 2 2 S Zlzle ral a bed dd ult st motor EIS OJ alg ulol lt ef Jel elox ho al el Dal2 2 al Ballz a Eladio eleloo lt 5 ae Alo sic OS lll HSI Jol z IB sizal S QI lolol ara a S Olr lq S Ale a a T S aq a ola jae Z olo a gt S elo aalo aai Eesel gSISlo SSS jojo Hatol elol ollesssa T wa d zZ 5 Z Zz Zz Zz Zz 2 ay s 8 sis Tle SISSIES SSIS SSSss SlalalGlalal z S S S S T S SIL T PJalalSiz S SiSiSyiz SiLlSlalal Glal als TPB sis CEECEE ss 72h spe gfe 23 HBanBEou JFAN1 JSBTN1 EVR z eee Zo E JOPPI JPH1 JFUSER1 JHVPS1 2 a J gt or Main Fan FO m O lt LVPS_BRON LVPS_HRON Tell GND GND 14 Sb ono 2a aw JLVPS1 A
103. age and continue printing The job may not print correctly Cancel the current job If this does not fix the problem replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to clear the message and continue printing Install different flash memory before downloading any resources to flash If this does not fix the problem replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to clear the message and continue printing Downloaded fonts and macros not previously stored in flash memory are deleted Delete fonts macros and other data stored in flash memory Install a larger capacity flash memory card If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the message and continue printing Format the flash memory before storing any resources on it If the error message remains replace the flash memory If this does not fix the problem replace the system card See System card removal on page 4 79 Make sure the serial link is set up correctly and the appropriate cable is in use Make sure the serial interface parameters protocol baud parity and data bits are set correctly on the printer and host computer Press w until Continue appears and then press to clear the message an
104. and left arrow keys to zero out all settings Press Select after you zero out each setting Note Itis important to zero out all settings to make the adjustment easier Scroll to Quick Test in the same color menu Press Select two pages print On the pages make sure all the Current Values are set to zero If not go back two steps and repeat Look at the coarse and fine adjustments on the top left of the page and enter the best number for the top adjustment in the T space Transfer this number over to the computation area for Z On the operator panel use A and W to locate Top Margin Press Select and then use lt or P gt to enter the setting computed for T Press Select to save Repeat this process for skew Z Add the T value and the current Z value to obtain the new skew Z value Reprint the Quick Test page and observe the results Make additional adjustments if necessary before proceeding on to Quick Test step two page Obtain left L right R and Bow P value using the same method as obtaining T from Quick Test Step 1 Reprint the Quick Test to ensure the settings are correct Make additional adjustments as required Press Back to return to ALIGNMENT See Printhead mechanical alignment on page 4 3 for printout samples and additional information Diagnostic aids 3 7 5022 xxx Motor tests The motor tests are run primarily to locate noises in the printer General motor tests In some instances when you enter a
105. assembly network C520n C522n C524n C524dn on page 7 3 or Top access cover assembly non network C524 on page 7 3 for the part number Remove the rear cover See Rear cover removal on page 4 25 Remove the left cover See Operator panel outer bezel removal on page 4 21 Remove the fuser See Fuser removal on page 4 60 Remove the four screws A exposed after removing the fuser MANT 5 Remove the operator panel See Operator panel assembly removal on page 4 23 6 Remove the exit tray See Exit tray cover removal on page 4 15 4 28 Service Manual 5022 xxx 7 Remove the screw B exposed after removing the exit tray 8 If the top access door is open close it Warning Ensure that the top access door is closed before removing the linkage screw Failing to close the door leaves the linkage under a load which may result in the linkage screw being catapulted away from the printer when removed Repair information 4 29 5022 xxx 9 Remove the linkage screw C 4 30 Service Manual 5022 xxx 10 Remove the screw D from the rear D 11 Disconnect the cables for the fan at JFAN1 E the operator panel at JOPP1 F the high voltage power supply connector at JHVPS1 G and the bin full sensor at JBIN1 H for network printers only from the system card 12 On the left side unplug the connector J from CN1 on the high voltage power si HVPS F d Left s
106. ation 4 33 5022 xxx 10 Remove the linkage screw C 4 34 Service Manual 5022 xxx 11 Disconnect the cables for the fan at JFAN1 D the operator panel at JOPP1 E the high voltage power supply connector at JHVPS1 F and the bin full sensor at JBIN1 G and USB at J1 H model C534 only from the system card an Ere Taig En inim ar W F T RE i E Lk py D G F E H Repair information 4 35 5022 xxx 13 Disconnect the ground cable J al 14 Lift and remove the top access cover assembly 4 36 Service Manual 5022 xxx Bin full sensor removal models C52x See Bin full sensor with cable C520n C522n C524n C524dn on page 7 3 for the part number Open the top access door Remove the fuser See Fuser removal on page 4 60 Disconnect the spring A Remove the seven screws B securing the inner access cover oe B A B 5 Remove the inner access cover 6 Turn the access cover over and press the back of the sensor to snap sensor C from the bracket N ae j z F 4 ee AA _ Se oe as T Remove the sensor and cable Repair information 4 37 5022 xxx Bin full sensor removal models C53x See Bin full sensor with cable C53x on page 7 3 for the part number 1 Remove the top access cover assembly See Top access cover assembly removal model C53x only on page 4 32 2 R
107. bin full sensor 4 38 bin full sensor removal 4 37 bump aligner gear 4 39 bump aligner motor 4 40 bump aligner rollers and springs C53x 4 42 contact springs 4 44 covers exit tray cover 4 15 front access cover assembly 4 16 gearbox shield 4 19 left cover 4 20 operator panel assembly 4 23 operator panel inner bezel C52x 4 22 operator panel outer bezel 4 21 rear cover 4 25 right cover 4 26 top access cover assembly C52x 4 28 top access cover assembly C53x 4 32 deflector assembly C53x only 4 46 electrophotographic EP process drive assembly C52x 4 48 electrophotographic EP process drive assembly C53x 4 51 front access door 5 V interlock switch 4 54 front door assembly 4 55 front door assembly restraint cable 4 59 fuser 4 60 fuser cable cover 4 61 high voltage power supply HVPS 4 62 left bellcrank 4 64 low voltage power supply LVPS 4 65 multipurpose feeder MPF swing arm assembly C52x only 4 67 paper pick mechanism assembly 4 68 paper tray dust cover 4 24 ohotoconductor unit 4 70 pick roll rubber tires 4 71 precautions 4 13 printer pad 4 73 printhead 4 74 right bellcrank 4 77 smart chip card C52x 4 78 system card 4 79 system card support shield 4 81 toner level sensor 4 83 top access door 24 V interlock switch 4 85 top cover camshaft assembly 4 86 transfer belt 4 91 transfer contact assembly 4 92 waste toner assembly 4 93 Reset Fuser Cnt 3 21 restraint cable removal 4 59 S safety information XV
108. bly front cable removal on page 4 59 for proper installation of the cable restraints 4 58 Service Manual 5022 xxx Front door assembly front cable removal See the part number for the Front door parts packet for the model you need on page 7 5 Removal procedures are for either the left or the right front door assembly restraint cables Right restraint cable 1 PR Remove the front access cover assembly See Front access door cover assembly removal on page 4 16 Release the cable spring A from the front door assembly Remove the gearbox switch shield B See Gearbox shield removal on page 4 19 Remove the end of the cable C from the frame Left restraint cable 1 Remove the front access cover assembly See Front access door cover assembly removal on page 4 16 Close the top access door Release the cable spring D from the front door assembly Note In order to access the springs make sure the top access cover is closed Remove the end of the cable E from the frame i Installation note The shortest cable installs on the right side of the printer Repair information 4 59 5022 xxx Fuser removal See Fuser assembly 115 V on page 7 15 Fuser assembly 230 V on page 7 15 or Fuser assembly 100 V on page 7 15 for the part number CAUTION The fuser can be extremely hot Use care when handl
109. card the cable for pinch points and the cable or the connector for any other damage If the connector is damaged on system card replace the system card See System card removal on page 4 79 If the fuser cable is damaged replace the cable e Check for the following continuity between the DC autoconnect and FUSER1 mel 35 719 rat 2 1416 8 10 configuration DC autoconnect JFUSER1 If continuity is not present replace the fuser cable If the problem persists after replacing cable replace the system card See System card removal on page 4 79 Replace the specified toner cartridge Press W until Continue appears and then press to clear the message and continue printing If the message does not clear replace the smart chip card See Smart chip card removal models C52x only on page 4 78 lf the problem persists replace the system card See System card removal on page 4 79 Replace the specified toner cartridge Press W until Continue appears and then press to clear the message and continue printing If the message does not clear replace the smart chip card See Smart chip card removal models C52x only on page 4 78 If the problem persists replace the system card See System card removal on page 4 79 5022 xxx Service checks 110 xx Mirror motor service check Turn the printer off and remove the rear cover Replace the printhead See Go to step 2 Check the c
110. ce the paper tray Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to 145 xx and 906 05 906 08 Motor bump aligner error service check on page 2 36 5022 xxx Service error codes and paper jam messages continued frre wenn ma 200 22 200 25 201 06 201 07 201 08 Pick tray 1 motor stalled Possible causes e Faulty cable connector e Faulty pick motor e Faulty system card Input sensor is made when tray 1 is installed Possible causes e Improper placement of paper in tray 1 e Damaged input sensor flag or input sensor e Faulty system card Paper is jammed between the input sensor and the exit sensor Possible causes Damaged paper exit sensor or paper exit sensor flag Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system card Exit sensor is made early Possible causes e Damaged paper exit sensor or paper exit sensor flag Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system card Exit sensor is never made Possible causes Improper loading of manual feed
111. continuity of the HVPS cable Pin 2 Pin 1 Is there continuity 2 60 Service Manual Problem solved Go to step 2 Replace the transfer contact Go to step 3 assembly See Transfer contact assembly removal on page 4 92 Go to step 4 Replace the cable assembly Pin 23 5022 xxx Replace the HVPS See High voltage power Problem solved Replace the system card supply HVPS removal on page 4 62 See System card Did this solve the problem penover OE Page t Print quality vertical banding Replace the developer cartridge Diagnostic information 2 61 5022 xxx 2 62 Service Manual 5022 xxx 3 Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer Diagnostics menu 1 Turn off the printer The Diagnostics menu group contains the settings 2 Press and hold w and gt and operations used while manufacturing and servicing the printer See Diagnostics menu on page 3 2 for more information 3 Turn on the printer 4 Release the buttons when the clock graphic displays Configuration menu 1 Turn off the printer The Configuration menu group contains a set of 2 Press and hold Dand gt menus settings and operations which are infrequently required by a user General
112. cover Replace the top access Go to step 2 Check the connector JHVPS1 for proper cover assembly See Top connection to the system card the cable for access cover assembly pinch points and the cable or connector for removal model C52x any other damage only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Is the cable damaged Disconnect JHVPS1 from system card and Go to step 3 Replace the top access HVPS Check for the following continuity cover assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Pin 2 Pin 1 Error code Color JHVPS1 cable to HVPS 945 01 946 01 957 01 Yellow Pin Pinio pene ao 945 02 946 02 957 02 Cyan meere alll 945 04 946 04 957 04 Black Is continuity present 2 48 Service Manual 5022 xxx Remove the HVPS See High voltage power Goto step 4 Replace the transfer contact supply HVPS removal on page 4 62 assembly See Transfer Check for continuity between the contacts contact assembly yellow1 and yellow2 cyan1 and cyan2 removal on page 4 92 magental and magentaz2 or black1 and black2 on the transfer contact assembly f j A S 4 Gs CA Jind yellow2 yellow1 cyan1 cyan2 magenta magenta2 Is continuity present Replace the HVPS See High voltage power Problem
113. ct CACHE Test from HARDWARE TESTS in DIAGNOSTICS The machine initiates a POR of the printer and the following screen is displayed Resetting the Printer Upon completion of the POR the following screen is displayed CACHE Test x100 P HHH AF P represents the number of times the CACHE test has passed finished successfully Initially 000000 is displayed The maximum pass count is 999 999 F represents the number of times the CACHE test has failed finished with errors Initially 000000 is displayed The maximum fall count is 999 999 F JHHHHHF 2 To exit the test turn the printer off Duplex Tests Quick Test duplex This test prints a duplex version of the Quick Test that can be used to verify the correct placement of the top margin on the back side of a duplex page You can run one duplexed page Single or continue printing duplexed pages Continuous until Stop is pressed For information about changing the margin see Top Margin duplex on page 3 14 Note Before you set the duplex top margin be sure to set the registration See Registration on page 3 4 3 12 Service Manual Paj Car dea SAAANA 5022 xxx The paper you choose to print the page on should be either Letter or A4 To run the Quick Test duplex 1 Select Quick Test from DUPLEX TESTS
114. ct to save scales then use the coarse adjustment scales at the top of the page lt P NOTE If the alignment values cannot be determined by using the fine adjustment STEP 2 Go to the next page to adjust the Left L margin Right R margin and Bow P STEP 3 Reprint these pages to confirm final settings Go To Step 2 Repair information 4 9 5022 xxx 6 Determine the line under Fine Adjustment that is closest If the value is beyond the Fine Adjustment scale use either of the Coarse Adjustment scales Top T Coarse Adjustment O 240 160 80 If the alignment is not close enough to use the fine adjustment get close to the ideal value by using the coarse adjustment marks Select the block that is most filled by the color on the left or approximate if 80 60 40 20 O 20 40 60 80 none of the blocks are completely filled and enter it in for the new value Reprint the quick test page and then use the fine adjustment 80 160 Oo wait 240 Top T Fine Adjustment 20 18 5 First locate the line of the color that you 4 are aligning that lines up best with the D sacle line In this example it is 18 If none 0 of the colored lines match up use the D coarse adjustment to get close reprint this A page and then use the fine adjustment 6 8 T Enter the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the T value Th
115. ctor unit on page 4 2 for additional information 2 Disconnect the transfer belt cable A 3 Press the two tabs B on either side of the transfer belt assembly and lift out the transfer belt assembly Model C52x Model C53x Installation notes When you installed the new transfer belt and moved all the photoconductor units from the used one to the new one the alignment of the toner cartridges and photoconductor units may have changed For better color quality perform the Color Alignment procedure in the Configuration Menu See Color Alignment on page 3 24 1 Enter the Configuration Menu Turn off the printer press and hold and p turn on the printer and release the buttons when the clock graphic displays 2 Select Color Alignment See Color Alignment on page 3 24 Repair information 4 91 5022 xxx Transfer contact assembly removal See Transfer contact assembly on page 7 11 for the part number Remove the HVPS See High voltage power supply HVPS removal on page 4 62 Remove all the inside contact springs See Contact springs removal on page 4 44 Remove the four screws A and remove the transfer contact assembly Remove the eight springs B for reuse during installation Note The top spring may fall away from the transfer contact assembly during removal a ade ea Installation note For ease of installation put the transfer contact assembly on before installing the springs 5
116. d continue printing The job may not print correctly POR the printer If this does not fix the problem replace the PCI card Diagnostic information 2 21 5022 xxx User status and attendance messages continued 54 Network lt x gt software error 55 Unsupported option in slot lt x gt 56 Parallel port lt x gt disabled 56 Standard parallel port disabled 56 Serial port lt x gt disabled 56 Standard USB port disabled 58 Too many flash options installed 58 Too many trays attached 61 Remove defective disk 2 22 Service Manual Press W until Continue appears and then press to clear the message and continue printing The job may not print correctly Program new firmware for the network interface POR the printer If this does not fix the problem replace the PCI card Turn the printer off Unplug the power cord from the wall outlet Remove the unsupported option Connect the power cord to a properly grounded outlet Turn the printer on If this does not fix the problem replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to clear the message The printer discards any data received through the parallel port Make sure the Parallel Buffer menu item is not set to Disabled If this does not fix the problem replace the PCI card Press W until Continue appears and then press to clear the message The printer discards
117. d removal on page 4 79 POR the printer If the error message persists see 142 xx and 906 01 906 04 Motor fuser error service check on page 2 33 POR the printer If the error message persists see 145 xx and 906 05 906 08 Motor bump aligner error service check on page 2 36 POR the printer If the error message persists replace the system card See System card removal on page 4 79 Diagnostic information 2 15 5022 xxx Service error codes and paper jam messages continued moe Omen Ba 908 00 908 99 Engine Unrecoverable system software POR the printer If the error persists replace the Software error errors system card See System card removal on page 4 79 910 01 Transparency Transparency sensor failed See 910 01 Transparency sensor error service Sensor calibration check on page 2 38 920 01 POST Error Bump align motor not connected See 920 01 POST power on self test error service check on page 2 38 920 02 POST Error Tray 1 motor not connected See 920 02 POST power on self test error service check on page 2 38 920 03 POST Error Transfer belt not connected See 920 03 POST power on self test error service check on page 2 38 920 04 POST Error Fuser motor not connected See 920 04 POST power on self test error service check on page 2 39 920 05 POST Error Printhead motor not connected See 920 05 POST power on
118. de of the printer Note Make a note of the attachment of the printhead ground cable B to the second screw from the bottom for later installation Remove the four screws C from the inner right side of the support shield Pull the cables through the access holes on the right side of the printer For network printers Remove the two screws D attaching the parallel connector support plate For non network printers Remove the INA mounting plate screw E and the INA mounting plate f hian 2 7 bas r ag Repair information 4 81 5022 xxx 9 Remove the four mounting screws D from the top and bottom of the support shield Note Only the printhead cables come through the access holes in the system card support shield 10 Lower and remove the support shield Be careful not to damage the cables that route through the top frame of the printer 4 82 Service Manual 5022 xxx Toner level sensor removal See Toner level sensor on page 7 11 for the part number Note the locations of the toner sensors Yellow Cyan Magenta Black 1 Remove the HVPS See High voltage power supply HVPS removal on page 4 62 2 For yellow and cyan only Remove the transfer contact assembly See Transfer contact assembly removal on page 4 92 Note Do not remove the springs from the contact assembly as stated in the last step of the procedure Repair information 4 83 5022 xxx 3 For all colors I
119. e High voltage power Problem solved Replace the system card supply HVPS removal on page 4 62 See System card Does the error clear removal on page 4 79 2 42 Service Manual 5022 xxx 920 13 POST power on self test error service check Questions actions Turn the printer off and remove the rear cover Check the connector JCART1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the EP drive assembly See Electrophotographic EP drive assembly removal model C52x only on page 4 48 or Electrophotographic EP drive assembly removal model C53x only on page 4 51 Does the error clear Remove the right cover Check for the following continuity between JCART1 and top cartridge connector re ms i it pre E Bop S To cartridge motor connector 3 i Is continuity present Replace the JCART1 cable Go to step 2 The cable parts packet contains one cartridge motor cable that works for either of the cartridge motors Go to step 3 Replace the JCART1 cable The cable parts packet contains one cartridge motor cable that works for either of the cartridge motors Problem solved Replace the system card See System card removal on page 4 79 Diagnostic information 2 43 5022 xxx 920 14 POST power on self test error service check Turn the printer
120. e Test the MFP tray by inserting a sheet of paper and pushing up to sensor The sensor should change state TPS Open Closed Open the front access door Slip a piece of paper between the TPS and the transfer belt The sensor should change state Toner C Open Closed Remove the cyan toner cartridge Shine a flashlight on the toner level sensor The sensor should change state Toner K Open Closed Remove the black toner cartridge Shine a flashlight on the toner level sensor The sensor should change state Toner M Open Closed Remove the magenta toner cartridge Shine a flashlight on the toner level sensor The sensor should change state Toner Y Open Closed Remove the yellow toner cartridge Shine a flashlight on the toner level sensor The sensor should change state Top Door top Open Closed Open the top access cover assembly The sensor should access cover change state assembly Waste Toner OK Full Remove the waste toner box before entering the sensor test The actual test runs when the menu is entered Replace the waste toner box leave the menu and re enter the menu The state should be OK Press Back or Stop to exit the test Diagnostic aids 3 15 5022 xxx Printer Setup Defaults US Non US defaults changes whether the printer uses the US factory defaults or the non US factory defaults The settings affected include paper size envelope size PCL symbol set code pages and units of measure Warning Changin
121. e 0 12 0 14 mm 4 8 5 4 mil in thickness or 161 179 g m in weight e Print quality and durability depend on the transparencies used e To prevent print quality problems avoid getting fingerprints on the transparencies e Before loading transparencies fan the stack to prevent sheets from sticking together e We recommend Lexmark part number 12A8240 for letter size and Lexmark part number 12A8241 for A4 size transparencies Using envelopes e Print samples on the envelopes being considered for use before buying large quantities When printing on envelopes e From the control panel set the Paper Source based on the source in use From the control panel the printer software or MarkVision Professional set the Paper Type to Envelope and select the envelope size e Use envelopes designed specifically for laser printers Check with the manufacturer or vendor to ensure the envelopes can withstand temperatures up to 180 C 356 F without sealing wrinkling curling excessively or releasing hazardous emissions e For the best performance use envelopes made from 90 g m 24 Ib bond paper Use up to 105 g m 28 Ib bond weight for envelopes as long as the cotton content is 25 or less All cotton envelopes must not exceed 90 g m 24 Ib bond weight e Use only new envelopes 1 8 Service Manual 5022 xxx e To optimize performance and minimize jams do not use envelopes that Have excessive curl or twist Are stuck together
122. e 4 92 to view the proper mounting and for removal procedures l ae High voltage oS power supply High voltage D contact path Z Are the spring s defective Turn off the printer and check the continuity of Go to step 7 Replace the cable assembly the HVPS cable Pin 23 Pin 2 Pin 1 Is there continuity Replace the HVPS See High voltage power Problem solved Go to step 8 supply HVPS removal on page 4 62 Did this fix the problem Replace the printhead See Printhead Problem solved Replace the system card removal on page 4 74 See System card Did this fix the problem iia ee ade tr Diagnostic information 2 57 5022 xxx Print quality blurred or fuzzy print Blurred or fuzzy print is usually caused by a problem in the EP drive assembly or in the transfer belt assembly Check the EP drive assembly and transfer belt assembly for correct operation Blurred print can also be caused by incorrect feeding from one of the input paper sources paper trays or duplex paper path Check the high voltage spring contacts to ensure they are not bent corroded or damaged Replace as necessary Print quality half color page A photoconductor unit is not properly seated Reset the specific photoconductor unit Print quality horizontal banding Measure the distance between repeating Replace the print cartridge Replace the photoconductor bands unit See Photoconductor unit removal o
123. e 7 5 for the part number 1 Open the front access cover 2 Remove the gearbox switch shield See Gearbox shield removal on page 4 19 3 Remove the C clip A 4 Remove the right bellcrank Repair information 4 77 5022 xxx Smart chip card removal models C52x only See Smart chip card C52x only on page 7 9 for the part number Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the system card support shield See System card support shield removal on page 4 81 2 From the outside right of the printer disconnect the five connectors A 3 Remove the two mounting screws B and remove the smart chip card Pe e da ry ed 4 78 Service Manual 5022 xxx System card removal See the system card part number for the model you need on page 7 9 Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is n
124. e current value is automatically entered on the sheet At this point it should be zero Current New Cyan Cyan T value T value 8 Enter the New Cyan T value on the operator panel using the right and left arrows and press Select to save the value 9 Reprint the Quick Test and evaluate whether you are at zero changes 4 10 Service Manual 5022 xxx 10 Repeat this process for skew Z Don t forget to add the T value and the current cyan Z value to obtain the new skew Z value An example is shown below Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value STEP 1 Adjust the Top T margin and Skew Z then confirm before going to Step 2 Repair information 4 11 5022 xxx 11 Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin T the Skew Z and on the second page of the Quick Test page the Left Margin L Right Margin R and Bow P Left L Fine Adjustment 60 54 Left L Coarse tH 42 36 L 0 Current Cyan L value 12 48 Adjustment Cyan Alignment Step 2 Bow P Coarse Adjustment AERE 80 60 40 20 0 20 40 60 80 Bow P Fine Adjustment 20 N A 0O 0 i mi mi m md Onego LN I New Current Cyan Cyan L value R value P 0 M M Current New Cyan Cyan P value P value Repeat steps 2 through 11 for yellow and magenta Right R i Adjustment i R 0 Righ
125. e d seia ra e rr e aE E a ri 7 9 Bal codecard OJJAN CIJAdN ss lt 82 2 oscar tek E a Se mre Sees Sele 7 20 Fome card Usd Gootd see pa ees tet eee ease eee eee ae eee eee E eels eae e 7 20 PrintCryption card C534n C534dn a rr rrr rrr rrr errr errr eee 7 20 Printer relocation kit eee eee 7 20 Options tray relocation Kit lt lt lt s e s 2sseesnee eee eee eee eee eee 7 20 Part number index l 9 5022 xxx l 10 Service Manual k C52X 5022 sion Iri i for HVPS f tor and b li tor Wiring Diagram E eaten iy eed Li 3 5 7 9 iipishisfi 719 2 123 12 476 8 fopi2h ah efi sj2oj2a g J Printhead Thermistor Exit Ol Jo irror motor sensor f 5 Bin full sensor LI nsH2lihololsi7zlelsl4l3l211 Toroid 5V Interlock for laser driver O O ia Switch 7 8 5 6 Autoconnect 3 4 Motor mE O O GND i a Fuser CRU Yellow cartridge omj 4 Ble AE FB olS gt a x GND 7 Ela 2 z z 2 5 clo OlT o gt 2 z 2 2 Cyan cartridge gol bl ZZEE
126. e fuser carefully as it remains hot for a while after the printer stops running Always unplug connectors by holding the connector housing 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 in addition to all the usual precautions such as turning off power before removing electronic cards e Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part in the printer e Make the fewest possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture e Putthe ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the printer e Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins e If you need to put down the ESD sensitive part for any reason first put it into its special bag e Printer covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded e Prevent ESD sensitive parts from being accidentally touched by other personnel
127. e opening in the waste toner shutter G Make sure the cam H engages the waste toner shutter G Also make sure the drive pinion 1 engages the upper retraction plate J 8 Install the rear mounting screws K 9 Slide the spring L and the lever arm M onto the shaft 10 Install the e clip N 4 88 Service Manual 11 12 13 14 5022 xxx Rotate the lever arm O all the way up as if the top access door were open While still holding the lever arm O up flip the right lock P up and install the front mounting screws Q Warning Failure to place the camshaft assembly in the open position prevents the front access door from closing and may cause damage to the door Continue to hold the lever arm O up Flip the right lock P down and rotate the camshafts R up This is the open position Lower the lever arm O and make sure the left lock S and right lock P are positioned correctly in their respective channels T Repair information 4 89 5022 xxx Note If the left side of the camshaft assembly becomes disassembled use the following illustration 4 90 Service Manual 5022 xxx Transfer belt removal See Transfer belt assembly C52x on page 7 15 or Transfer belt assembly C53x on page 7 15 for the part number 1 Remove all photoconductor units See Photoconductor unit removal on page 4 70 Warning To avoid damaging the photoconductor drum hold the photoconductor un
128. e printer off and remove the rear cover Replace the fuser cable Go to step 2 Check the connector JFUSER1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Remove the fuser See Fuser removal on Replace the JFUSER1 Go to step 3 page 4 60 Check the DC autoconnects on cable both the fuser and the printer for damage Are the connectors damaged 2 40 Service Manual Check for the following continuity between the DC autoconnect and FUSER1 eo o e e e e mal 3 517 9 rag 2 141618 10 configuration DC autoconnect JFUSER1 DC autoconnect JFUSER1 Is continuity present Replace the fuser See Fuser removal on page 4 60 Does the error clear 5022 xxx Replace the DC fuser cable Go to step 4 Problem solved Replace the system card See System card removal on page 4 79 920 09 12 POST power on self test error service check Remove the left cover See Left cover removal on page 4 20 Check all the toner level sensor cables connected to the rear of the HVPS for proper connection to HVPS the cable for pinch points and the cable or connector for any other damage Are any of the cables damaged Turn the printer off and remove the rear cover Check the connector JHVPS1 for proper connection to the system card the cable for pinch points and the cable or connector for any o
129. e printhead it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer This allows the pages to be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw Once black skew is adjusted the mounting screws will be fully tightened There is one printhead that houses the four color planes The black plane is aligned to the printer and the color planes are internally aligned to black Electrical alignment is done to fine tune the alignment of the color planes to the black plane once the printhead is installed The first step in aligning the printhead is to set the skew for black Printhead mechanical alignment Skew black 1 During installation of the printhead the printhead s lower right corner slot as seen when looking through the rear of the printer and the hole in the frame A should have been visually aligned Repair information 4 3 5022 xxx 2 Remove the paper exit tray for access to the printhead alignment screw B Enter Diagnostic mode turn off the printer press and hold W and gt turn on the printer and release the buttons when the clock graphic displays Select REGISTRATION Select Skew Adjust this setting to zero and press Select Q Press Back Sore p 4 4 Service Manual 5022 xxx 8 Scroll down to Quick Test and press
130. e voltmeter can be placed on the metal frame to obtain ground Is voltage present Replace the bump aligner motor See Bump aligner motor removal on page 4 40 Does the error clear Go to step 2 Close the top access door Replace the top access door 24 V interlock switch See Top access door 24 V interlock switch removal on page 4 85 Go to step 3 Go to step 4 Replace the system card See System card removal on page 4 79 Replace the top access door 24 V interlock switch See Top access door 24 V interlock switch removal on page 4 85 Problem solved Is the top access door completely closed Turn the printer off and remove the rear cover Check the connector JDUPLX1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Close the front access door Turn the power on and check for 24 V dc between JCVR1 pin 1 red wire and ground Note The ground lead of the voltmeter can be placed on the metal frame to obtain ground Is voltage present Replace the duplex front door assembly See Front door assembly removal on page 4 55 Does the error clear 2 36 Service Manual o Go to step 2 Close the top access door Replace the duplex front door assembly See Front door assembly removal on page 4 55 Go to step 3 Go to step 4 Replace the system card See System card r
131. ed on page 7 5 1 Remove the front access cover assembly See Front access door cover assembly removal on page 4 16 2 Remove the rear cover See Rear cover removal on page 4 25 3 For C52x only Disconnect the JTRANS1 cable A from the system card For C53x only Disconnect the JTRANS2 cable A from the system card Note If you have a duplex model also disconnect the JDOUPLX1 cable B from the system card Pa i JT Repair information 4 55 5022 xxx 4 Models C52x only Disconnect the cable C from the right side of the frame Be careful not to lose the grounding clip D Ye ee A es 5 Remove the gearbox shield See Gearbox shield removal on page 4 19 6 Close the front door assembly 7 Release the left and right front door assembly cable restraint springs E from the front door assembly oa 8 Open the front door assembly 4 56 Service Manual 5022 xxx 9 Unwrap and remove the cable from the left and right pulleys F L p Pa Z sen 7y vy Repair information 4 57 5022 xxx 11 Open the front door assembly slide it to the right and remove You need to press firmly to slide the front door assembly to the right Installation note See Front door assembly front cable removal on page 4 59 for proper installation of the cable restraints 4 58 Service Manual 5022 xxx Front door assembly front cable removal See the part n
132. el display is blank Go to Operator panel display blank five beeps and LED off on page 2 53 Operator panel continuously displays all Go to Operator panel display blank five beeps and LED diamonds and does not complete POST off on page 2 53 Print quality symptom table Missing image at edge Go to Print quality missing image at edge on page 2 58 page 2 58 2 6 Service Manual 5022 xxx Error codes and messages Service error codes and paper jam messages 1xx service error codes 110 01 110 06 Mirror Motor 111 01 111 05 Printhead Error 112 01 112 05 Printhead Error 113 01 113 05 Printhead Error 114 01 114 05 Printhead Error 120 01 120 02 Fuser Error 120 03 Fuser Error 120 04 120 07 Fuser Error 120 08 120 10 120 13 120 15 Fuser Error 140 03 140 08 Autocomp Motor Error 142 09 142 18 142 20 142 25 142 27 Motor Error 143 09 143 18 143 20 143 25 Motor Error 144 09 144 18 144 20 144 25 Motor Error 145 09 145 18 145 20 145 25 Motor Error A mirror motor error has occurred An error has occurred in the cyan channel of the printhead An error has occurred in the magenta channel of the printhead An error has occurred in the yellow channel of the printhead An error has occurred in the black channel of the printhead An error has occurred in the fuser An error has occurred in the fuser An error has occurred in the fuser
133. el sheets Partial sheets may cause labels to peel off during printing resulting in a jam Partial sheets also contaminate the printer and the cartridge with adhesive and could void the printer and cartridge warranties e Do not print within 1 mm 0 04 in of the edge of the label of the perforations or between die cuts of the label e Be sure adhesive backing does not reach to the sheet edge Zone coating of the adhesive at least 1 mm 0 04 in away from edges is recommended Adhesive material contaminates the printer and could void the warranty e lf zone coating of the adhesive is not possible remove a 3 mm 0 125 in strip on the leading and driver edge and use a non oozing adhesive e Portrait orientation works best especially when printing bar codes e Do not use labels with exposed adhesive Using card stock Card stock is heavy single ply print media Many of its variable characteristics such as moisture content thickness and texture can significantly impact print quality Print samples on the card stock being considered for use before buying large quantities When printing on card stock e From MarkVision Professional the printer software or the control panel Set the Paper Type to Card Stock Set the Paper Weight to Card Stock Weight Setthe Card Stock Weight to Normal or Heavy General information 1 9 5022 xxx e Be aware that preprinting perforation and creasing may significantly affect the print
134. elect EVENT LOG from DIAGNOSTICS 2 Select Display Log Up to three error codes display at a time Press A or W to view additional error codes Press to view additional details Press Back to return to the EVENT LOG menu Print Log Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather than CONFIG MENU The Event Log printed from DIAGNOSTICS includes e Detailed printer information including code versions e Time and date stamps e Page counts for most errors e Additional debug information in some cases Model and Event Log Serial number Lexmark E534 s n 20000000X Devroe ilori ej a y Printer information Panel display E Eram Log ivfermation when error occurred _ amie Page count i Thar Earliest error code The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis 3 18 Service Manual 5022 xxx To print the event log 1 Select EVENT LOG from DIAGNOSTICS 2 Select Print Log Press Back to return to EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Select Clear Log from the Event Log menu 2 Select YES to clear the Event Log or NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen Press Back
135. els C524dn C524dtn C530dn C532dn and C534dn dtn factory installed Integrated network options Token Ring Ethernet External serial adapter PRESCRIBE card assembly Barcode card assembly Parallel interface card MarkNet Print Servers Lexmark PrintCryption card Lexmark Forms card single byte and Simplified Chinese on models C534n C534dn and C534dtn General information 1 1 5022 xxx Lexmark Bar Code Card is available on models C534n C534dn and C534din Lexmark ImageQuick Card is available for the models C534n C534dn and C534dtn e DBCS font cards Simplified Chinese Traditional Chinese Japanese Korean Specifications Resolution e 1200 x 1200 dpi e 4800CQ Data streams e PostScript 3 emulation e PCL 5c and 6 XL emulation e PDF 1 5 emulation e PPDS if activated Memory configuration Memory type C534dn dtn q N LO O O O O O O O O Optional memory MB 128 256 and 512 MB available 100 pin DDR SDRAM unbuffered DIMMs Optional flash memory 32 and 64 MB available Performance factors Performance speed depends on e Interface to the host USB serial parallel network e Host system and application e Page complexity and content of the page e Printer options installed or selected e Available memory in the printer e Media size and type e Resolution 1 2 Service Manual 5022 xxx Power requirements Average nom
136. emoval on page 4 79 Replace the top access door 24 V interlock switch See Top access door 24 V interlock switch removal on page 4 85 Problem solved 5022 xxx 147 xx 149 xx Motor 500 sheet 550 sheet option tray 2 motor error service check Turn the printer off and remove the rear cover Replace the option cable Go to step 2 Check the connector JOPT1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the 500 sheet assembly or the Problem solved Replace the system card 550 sheet assembly See System card Does the error clear removal on page 4 79 Turn the printer off and remove the rear cover Replace the paper pick Go to step 2 Check the connector JTRAY2 for proper mechanism See Paper connection to the system card the cable for pick mechanism assembly pinch points and the cable or connector for removal on page 4 68 any other damage Is the cable damaged Measure the resistance across fuse F2 on the Replace the system card Go to step 3 system card See System card removal on page 4 79 EV F4 EV Fs Is the fuse blown Replace the paper pick mechanism See Problem solved Replace the system card Paper pick mechanism assembly removal See System card on page 4 68 removal on page 4 79 Does the error clear Diagnostic information 2 37
137. emove the three screws A from the cable cover A 4 Remove the bin full sensor and cable 4 38 Service Manual 5022 xxx Bump aligner gear removal See the Bump aligner gear kit on page 7 5 for the part number 1 Remove the paper pick mechanism assembly See Paper pick mechanism assembly removal on page 4 68 Close the front access door for better access to the gears Remove the three e clips and washers A Remove the gears aa Installation notes e When reinstalling the gears apply a light coat of the packaged grease e The following illustration shows proper orientation of the gears for installation The two gears are reduction gears with the largest of the two B located in the middle on the top B Repair information 4 39 5022 xxx Bump aligner motor removal See Bump aligner motor on page 7 7 for the part number 1 Remove the right side cover 2 Remove the bump aligner gears See Bump aligner gear removal on page 4 39 3 Remove the two bump aligner motor mounting screws A 4 40 Service Manual 5022 xxx 4 Disconnect the JBUMP1 connector B from the system card 4 on i h Di 4 5 Remove the bump aligner motor from the printer Repair information 4 41 5022 xxx Bump aligner rollers and springs removal models C53x See Bump aligner roller and spring on page 7 5 for the part number 1 Remove
138. er e User attendance messages are indicated by a two digit code that provides the user with information that explains a problem with a print cartridge option port and so on If a user error message displays see User status and attendance messages on page 2 19 or 2xx paper jam messages on page 2 8 Additional information e Operator panel and menus on page 2 2 e Power on self test POST sequence on page 2 5 e Theory of operation on page 3 30 Diagnostic information 2 1 5022 xxx Operator panel and menus Operator panel The operator panel consists of these items CO mmr Cac eo Oo O79 q f oe Button or light or Button or light Display m display shows messages and pictures that communicate the status of the printer The button functions as a select button Press this button to Note It has a check e Open a menu and display the first item in the menu called a menu mark icon item e Open a menu item and display the default setting e Save the displayed menu item as the new user default setting The printer issues a Saved or Submitted Selection message and returns to the menu item Note When a new setting is saved as the user default setting it remains in effect until new settings are saved or until factory defaults are restored Settings chosen from the software application can also change or override the user default settings selected
139. er cartridge The toner cartridge contains a toner adder roll developer roll and toner Toner is advanced toward the toner adder roll by three paddle assemblies The advanced toner clings to the electrically charged toner adder roll The toner on the toner adder roll is then electrically attracted to the developer roll because of the difference in electrical charge between the toner adder roll and the developer roll The toner uniformly coats the developer roll with help from the doctor blade and is introduced to the electrostatic image on the photoconductor drum The toner then transfers to the photoconductor drum Photoconductor unit Developer cartridge Photoconductor drum Developer roll Toner add roll Paddles TAR 3 50 Service Manual 5022 xxx Transferring After the toner is attracted to the photoconductor drum the image is ready for transfer onto the print media The print media is advanced in the paper path onto the transfer belt and is carried along the belt underneath each photoconductor unit The charged transfer roll s located inside the transfer belt pulls the image from the photoconductor drum to the print media This is a direct transfer method The main function of the transfer belt is to provide transport for the print media Toner is not transferred directly to the belt during the print process Photoconductor unit Photoconductor drum Transfer roll Diagnostic aids 3 51 5022 xxx Fusing Afte
140. eral motor tests on page 3 8 Tray 2 if installed Tests tray 2 motor located in the paper pick mechanism See General motor tests on page 3 8 Bottom Cartridge Tests the bottom cartridge motor located on the EP drive assembly See General motor tests on page 3 8 Top Cartridge Tests the top cartridge motor located on the EP drive assembly See General motor tests on page 3 8 Transfer Tests the transfer belt assembly motor located on the EP drive assembly See General motor tests on page 3 8 Mirror Motor Test Tests the mirror motor located in the printhead assembly See Mirror Motor Test on page 3 8 Motor Calibration Synchronizes the bump aligner and fuser motor speeds with the transfer belt soeed to ensure that output is printed correctly See Motor Calibration on page 3 9 Servo Laser Test Tests servo laser located in the printhead See Servo Laser Test on page 3 9 3 2 Service Manual 5022 xxx Diagnostics mode tests continued PRINT TESTS Tray 1 Tray 2 if installed Manual Feeder if installed MP Feeder Prt Quality Pgs See Print quality test pages Prt Quality Pgs on page 3 10 HARDWARE TESTS Panel Test See Panel Test on page 3 11 See Input source tests on page 3 9 Button Test See Button Test on page 3 11 DRAM Test See DRAM Test on page 3 11 CACHE Test See CACHE Test on page 3 12 DUPLEX TESTS if installed Quick Tes
141. es not break Possible causes e Incorrect media setting e Incorrect paper loading e Incorrect media restraint setting e Paper tray failure e Paper pick mechanism Input sensor is made when printer powers up or covers are closed Possible causes e Paper jam leaving page over sensor e Defective input sensor e Faulty system card Bump aligner motor stalled Possible causes e Faulty cable connector e 24 V interlock switch not working correctly e Faulty bump align motor e Faulty system card POR the printer If the error message persists see 146 xx Motor duplex error service check on page 2 36 POR the printer If the error message persists see 147 xx 149 xx Motor 500 sheet 550 sheet option tray 2 motor error service check on page 2 37 POR the printer If the error message persists see 148 xx MPF motor error service check on page 2 37 POR the printer If the error message persists see 147 xx 149 xx Motor 500 sheet 550 sheet option tray 2 motor error service check on page 2 37 Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Ensure proper media is set for the type of paper used Fan media and stack flat in the tray or MPF Properly set media restraints in the paper tray Check the pick arm rolls tires and replace if worn Repla
142. ews A 4 Remove the gearbox shield B There is a locking tab on the back of the gearbox shield Warning When removing the gearbox shield be careful not to damage the 5 V interlock switch arm ee i 3 Repair information 4 19 5022 xxx Left cover removal See Left cover on page 7 3 for the part number Place the printer on the table with the left side edge hanging over slightly Remove the waste toner assembly See Waste toner assembly removal on page 4 93 Open the top access door Open the front access door Remove the three screws A Press the locking tab B slide the cover down and lift the bottom out to remove the cover Warning Be careful not to damage the two small locking tabs C A ee a 4 20 Service Manual 5022 xxx Operator panel outer bezel removal See Outer bezel C52x on page 7 3 for the part number for the C52x models See the same page for the specific models for the bezels for the C53x models 1 Using a flathead screwdriver or similar tool unsnap the locking tabs A on the upper left and the upper right of the outer bezel Note The top portion of the operator panel disengages with the outer bezel Flex the top of outer bezel to disengage the operator panel 2 For models C52x Remove the outer bezel with the inner bezel B attached For models C53x Remove the bezel The bezel is one piece for this set of models Installation note When reinstalling or replacing
143. g this setting resets the printer to factory defaults and data may be lost It cannot be undone Page Counts You can view but not change any of the three counts displayed under PAGE COUNTS To view the Prt Color Pg Count the Prt Mono Pg Count or the Perm Page Count 1 Select PRINTER SETUP from DIAGNOSTICS 2 Select PAGE COUNTS 3 Select the page count you wish to view e Prt Color Pg Count e Prt Mono Pg Count e Perm Page Count Press Back to return to PRINTER SETUP Serial Number The serial number can only be viewed and changed To view or change the serial number 1 Select Serial number from PRINTER SETUP 2 Press Back to return to PRINTER SETUP Engine Setting 1 through 4 Warning Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cannot be changed Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the factory when the printer is manufactured However the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever the system board is replaced The IDs consist of eight digits The first seven digits in each ID are hexadecimal numbers while the last digit is a checksum of the preceding seven digits Each ID can contain a combination of the digits O through
144. ground lead of the voltmeter can be placed on the metal frame to obtain ground Is voltage present Replace the fuser See Fuser removal on page 4 60 Does the error clear Go to step 2 Close the top access door Lift the top access door to its widest position and put the right bellcrank A into its slot Go to step 3 Go to step 4 Go to step 5 Replace the system card See System card removal on page 4 79 Replace the fuser cable Replace the top access door 24 V interlock switch See Top access door 24 V interlock switch removal on page 4 85 Problem solved Diagnostic information 2 33 5022 xxx 143 xx Motor EP drive assembly top cartridge error service check Turn the printer off and remove the rear cover Replace the JCART1 cable Go to step 2 Check the connector JCART1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the EP drive assembly See Problem solved Replace the system card Electrophotographic EP drive assembly See System card removal model C52x only on page 4 48 or removal on page 4 79 Electrophotographic EP drive assembly removal model C53x only on page 4 51 Does the error clear Measure the resistance across fuse F4 andF5 Replace the system card Go to step 3 on the system card See System card removal o
145. he JIRAY1 and JI RAY2 connectors do not bind when passing through the frame access hole Repair information 4 69 5022 xxx Photoconductor unit removal Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and ee place the photoconductor units on a clean surface See Handing the photoconductor unit on page 4 2 for additional information Open the top access door Open the front access door Lift the right end handle A of the photoconductor unit releasing from the mount Lift the unit up and away from the left side of printer ensuring the left end of the photoconductor is released from the holding pin B B Installation note If a new photoconductor unit is installed reset the life count value in the printer memory e fa message appears on the operator panel 1 When 84 lt color gt PC Unit Life Warningor84 Replace lt co or gt PC Unit appears select Supply Replaced and then press Replace Supply displays Select Cyan PC Unit Magenta PC Unit Yellow PC Unit or Black PC Unit based on the photoconductor unit that was just replaced and then press lt color gt PC Unit Replaced displays Select Yes and then press to clear the message o message appears Press Select Supplies Menu and press Press to select Replace Supply Select Cyan PC Unit Magenta PC Unit Yellow PC Unit or Black PC Unit based on the photoconductor unit tha
146. he multipurpose feeder or manual feeder Note The multipurpose feeder can also be used as a manual feeder Loading media in the multipurpose feeder or manual feeder 1 Use the marks above the slot to adjust the width guide for standard paper sizes For odd sizes once the paper is isolated move the width guide until it lightly touches the sheet Warning Do not force the width guide against the paper or it could be damaged 2 When Load manual feeder with lt x gt appears on the display load a single sheet of paper flush with the right side of the slot and then press y Load an envelope with the flap side up ee 3 Push the paper in until it stops The printer pulls it in farther Note Maintain pressure on the paper or envelope until the printer takes the paper from your hand Clearing a paper jam in the multipurpose feeder When paper jams in the multipurpose feeder a 250 xx 201 08 or 200 11 Paper Jam message appears 1 Pull the paper down and out 2 Open the top access cover and close it 3 Load the paper and push the paper in until it stops The printer should pull it in farther Note Maintain pressure on the paper or envelope until the printer takes the paper from your hand 3 28 Service Manual 5022 xxx Clearing paper jams in the manual feeder When paper is not placed far enough into the manual feeder the display prompts you to insert paper If the paper is pushed far enough
147. he paper exit flag within a given time a paper jam error will be posted There is a similar paper flag bin full on the output of network machines This sensor indicates when the output bin is full The physical flag is located in the fuser on all machines however the electrical sensor is not present on the non network models The flag should move in and out of the sensor eye with every sheet until the bin is nearly full Once in this state the paper flag will break the sensor eye continuously Note Bin full sensor is located Paper exit duplex in top cover assembly entry sensor Paper exit duplex entry flag Bin full flag Fuser access door removed for clarity Diagnostic aids 3 43 5022 xxx Electrophotographic EP process Main components High voltage power supply Developer toner cartridge Transfer belt Photoconductor belt System card The system card is the brain of the printer During the print process an image is sent from a computer to the system card The raster image processor RIP portion of the system card converts the data into a raster image and feeds this data along with control information to the printhead 3 44 Service Manual 5022 xxx High voltage power supply HVPS Provides a high voltage charge to e The charge roll located in the photoconductor unit e The photoconductor drum located in the photoconductor unit e The toner adder roller TAR located in the toner cartridge
148. he printer containing the damaged pad over the corner of the table 2 Pull the pad A from the bottom of the printer Installation Note When installing the new pad remove the appropriate side cover that corresponds to the damaged pad It is necessary to remove the corresponding side cover to see if the pad fully seats in the installation holes B Repair information 4 73 5022 xxx Printhead removal See Printhead assembly C52x on page 7 9 or Printhead assembly C53x on page 7 9 for the part number Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the toner cartridges 2 Remove the exit tray cover See Exit tray cover removal on page 4 15 3 Disconnect the transfer belt cable A 4 Press the two tabs B on either side of the transfer belt assembly and lift out the transfer belt assembly Note Leave the photoconductor units on the transport belt when removing Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged peri
149. head assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Warning Be careful not to damage the printhead cable when removing the system card 1 Remove the rear cover See Rear cover removal on page 4 25 2 Disconnect all the connectors from the system card Warning Do not use tools to remove the printhead ribbon cable A It can be damaged and should be removed gently by hand When installing carefully line up the cable and press straight into the connector Repair information 4 79 5022 xxx 3 Remove the screw B from the USB connector 4 For models C52x only If a non network system card is installed also remove the two screws C from the parallel connector Network system card Non network system card ji wik kH IFFT l j l fi d l t h 1 5 VE fei bes es sa E T SSeS oe i a P r 6 Remove the system card 4 80 Service Manual 5022 xxx System card support shield removal See System card support shield C52x on page 7 9 or System card support shield C53x on page 7 9 for the part number Aa ed a OND Remove the right cover See Right cover removal on page 4 26 Remove the left cover See Left cover removal on page 4 20 Remove the LVPS See Lo
150. i il ii 4l hy AL vil Ue a i one ne roll Developer roll high Ign voltage voltage contact path contact path Diagnostic aids 3 47 5022 xxx Transfer belt The transfer belt houses four transfer rollers that provide image transfer from the photoconductor drum to the print media The transfer belt receives its high voltage charge through spring contacts located on the transfer contact assembly as shown in the following illustration For the sake of simplicity only one of the roller s high voltage paths is shown This path is typical for the other three rollers as well Transfer belt high voltage path Pil WALA mpa M 4 Su PrE iiss 3 48 Service Manual 5022 xxx Exposing The main components in the exposure process are the system card the printhead and the photoconductor unit The following illustration depicts a typical data path for a single color exposure Data is received from a computer into a port on the system card The system card s RIP function converts this data into raster information which is fed to the printhead along with other control data The data is converted by the printhead laser into light energy data that is directed to the light sensitive photoconductor unit System card Printhead Photoconductor unit Diagnostic aids 3 49 5022 xxx Developing The two primary components of the developing process are the photoconductor unit and the ton
151. ia and stack it flat in the tray or MPF Replace the MPF swing arm assembly Multipurpose feeder MPF swing arm assembly removal models C52x only on page 4 67 If the previous actions do not fix the problem go to 148 xx MPF motor error service check on page 2 37 900 00 900 99 Software Error 902 01 902 99 Engine Software Error 903 01 903 05 Engine Software Error 904 01 904 04 Interface Violation by RIP 905 xx Engine Software Error 906 01 906 04 Fuser Motor Error 906 05 906 08 Bumper Motor error 907 xx Engine Software Error Unrecoverable RIP software error Unrecoverable system software errors Unrecoverable system software errors Unrecoverable system software errors Unrecoverable system software errors Fuser motor has failed Bump aligner motor has failed Unrecoverable system software errors POR the printer If the error message persists replace the system card See System card removal on page 4 79 POR the printer If the error message persists replace the system card See System card removal on page 4 79 POR the printer If the error message persists replace the system card See System card removal on page 4 79 POR the printer If the error message persists replace the system card See System card removal on page 4 79 POR the printer If the error message persists replace the system card See System car
152. ice Manual 5022 xxx Gearbox shield removal Not a FRU 1 Remove the paper tray 2 Remove the right cover See Right cover removal on page 4 26 3 Remove the four screws A 4 Remove the gearbox shield B There is a locking tab on the back of the gearbox shield Warning When removing the gearbox shield be careful not to damage the 5 V interlock switch arm ee i 3 Repair information 4 19 5022 xxx Left cover removal See Left cover on page 7 3 for the part number Place the printer on the table with the left side edge hanging over slightly Remove the waste toner assembly See Waste toner assembly removal on page 4 93 Open the top access door Open the front access door Remove the three screws A Press the locking tab B slide the cover down and lift the bottom out to remove the cover Warning Be careful not to damage the two small locking tabs C A ee a 4 20 Service Manual 5022 xxx Operator panel outer bezel removal See Outer bezel C52x on page 7 3 for the part number for the C52x models See the same page for the specific models for the bezels for the C53x models 1 Using a flathead screwdriver or similar tool unsnap the locking tabs A on the upper left and the upper right of the outer bezel Note The top portion of the operator panel disengages with the outer bezel Flex the top of outer bezel to disengage the operator panel 2 For models C52x Remove the o
153. ide E H G F J 13 Lift and remove the top access cover assembly Repair information 4 31 5022 xxx Top access cover assembly removal model C53x only See Top access cover assembly network C532n C534n on page 7 3 or Duplex top access assembly network C530dn C532dn C534dn on page 7 3 for the part number Remove the right cover See Right cover removal on page 4 26 Remove the left cover See Operator panel outer bezel removal on page 4 21 Remove the rear cover See Rear cover removal on page 4 25 Remove the fuser See Fuser removal on page 4 60 Remove the four screws A exposed after removing the fuser ee I l Sa i eel Wf i Pa 4 We j J o 6 Remove the operator panel See Operator panel assembly removal on page 4 23 T Remove the exit tray See Exit tray cover removal on page 4 15 4 32 Service Manual 5022 xxx 8 Remove the screw B exposed after removing the exit tray 9 If the top access door is open close it Warning Ensure that top access door is closed before removing the linkage screw Failing to close the door leaves the linkage under a load which may result in the linkage screw being catapulted away from the printer when removed Repair information 4 33 5022 xxx 10 Remove the linkage screw C 4 34 Service Manual 5022 xxx 11 Disconnect the cables for the fan at JFAN1 D the operator panel at JOPP1 E
154. in See Registration on page 3 4 To set the Top Margin duplex 1 Print the Quick Test duplex a Select Quick Test from DUPLEX TESTS b Select Single C Hold the page to the light to see whether the top margin of the back aligns with the top margin of the front 2 Select Top Margin from DUPLEX TESTS 3 Use 4 or P to select the margin setting you need to change e Each increment shifts the duplex top margin by 1 100 of an inch e The Top Margin duplex range is 20 to 20 and the default value is 0 e An increase moves the top margin down and widens the top margin A decrease moves the top margin upward and narrows the top margin 4 Press Q 5 Print the Quick Test duplex again to verify the adjustment Repeat if necessary Motor Test duplex This test is used to determine whether or not the duplex unit paper feed drive system is working correctly 1 Select Motor Test from DUPLEX TESTS The duplex motor runs continuously until stopped The message Motor Running displays 2 To stop the test press Back or Stop Input Tray Tests If tray 2 is installed the INPUT TRAY TESTS menu appears This test is used to determine if the Tray 2 full sensor is sensing properly To run the Input tray test 1 Select INPUT TRAY TESTS from the Diagnostics mode 2 Select Sensor Test 3 Select Tray 2 Tray2 full displays 4 Toggle the sensor to change the display and determine whether the sensor is operati
155. inal power requirements for the base printer configuration 110 volt Power levels are shown in watts W Maximum current is given in Amperes A Lexmark C524 Lexmark C520n Lexmark C534n Lexmark Printing states C524n C524dn C522n i C534dn C530dn C532n C524dtn C534dtn C532dn Idle average power Power Saver off 105 W 105 W 120 W 120 W Printing average power Printing maximum average current Electrical specifications Low voltage model e 110 to 127 V ac at 47 to 63 Hz nominal e 99 to 137 V ac extreme High voltage model e 220 to 240 V ac at 47 to 63 Hz nominal not available in all countries e 198 to 259 V ac extreme 100 V model e 100 V acat 47 to 63 Hz nominal e 90to 110 V ac extreme Notes e Using a 220 to 110 power converter with the 110 V printer is not recommended e Using an inverter 12 V dc to 120 V ac for example to power the printer is not recommended General information 1 3 5022 xxx Environment Air Temperature Product Operating Air Temperature Product Power Off Wet Bulb Temperature Product Operating 22 8 C 73 0 F Maximum Web Bulb Temperature Product Power Off 26 7 C 80 1 F Maximum Altitude O to 3048 meters 10 000 feet Atmospheric Pressure 74 6 kPa Ambient Operating Environment 15 6 to 32 2 C 60 to 90 F and 8 to 80 RH Cartridges 40 C to 40 C 104 Fahrenheit Printer with Cartridges 40 C to 40 C 104 Fahrenheit Printer withou
156. information 2 31 5022 xxx 140 xx Autocomp tray 1 motor error service check Turn the printer off and remove the rear cover Replace the paper pick Go to step 2 Check the connector JT RAY2 for proper mechanism See Paper connection to the system card the cable for pick mechanism assembly pinch points and the cable or connector for removal on page 4 68 any other damage See Connectors on page 5 11 for the location of connectors Is the cable damaged Replace the paper pick mechanism See Problem solved Replace the system card Paper pick mechanism assembly removal See System card on page 4 68 removal on page 4 79 Does the error clear Measure the resistance across fuse F2 on the Replace the system card Go to step 3 system card See System card removal on page 4 79 lF E F4 E Fs Is the fuse blown 2 32 Service Manual 5022 xxx 142 xx and 906 01 906 04 Motor fuser error service check Is the top access door completely closed Turn the printer off and remove the fuser g es E i i Is the right bellcrank A out of its slot Turn the printer off and remove the rear cover Check the connector JFUSER1 for the proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Turn the printer power on and check for 24 V dc between JCVR1 pin 1 red wire and ground Note The
157. ing to avoid burns AN Turn off the printer Open the top access door Rotate the fuser thumbscrews A counterclockwise until loosened Grasp the handles B lift the fuser straight up and away from the printer B Installation note If you install a new fuser be sure to reset the fuser counter in the Configuration Menu To reset the counter 1 2 3 4 Enter the Configuration Menu Turn off the printer press and hold and p turn on the printer and release the buttons when the clock graphic displays Press Y for the Reset value Resetting Fuser Count Value appears Press to select Motor Calibration from the CONFIG MENU Calibrating displays and the printer prints several blank pages and then returns to the CONFIG MENU Select Exit Config Menu See Page Counts on page 3 16 4 60 Service Manual 5022 xxx Fuser cable cover removal See Fuser cable cover included in parts packet P N 40X1430 C52x on page 7 5 or Fuser cable cover included in parts packet P N 40X3598 C53x on page 7 5 for the part number a Open the top access door Open the front access door Remove the yellow and cyan toner cartridges Pull the locking tab A down on the left side of the cable cover B slide the cable to left lower and remove Repair information 4 61 5022 xxx High voltage power supply HVPS removal See High voltage power supply C52x on page 7 11 or High voltage p
158. inting Delete fonts macros and other data in printer memory Install additional printer memory lf this does not fix the problem replace the system See System card removal on page 4 79 The printer deleted some held jobs in order to process current jobs Press W until Continue appears and then press to clear the message If this does not fix the problem replace the system card See System card removal on page 4 79 5022 xxx User status and attendance messages continued 37 Insufficient memory some held jobs were lost 38 Memory Full 50 PPDS font error 51 Defective flash detected 52 Not enough free space in flash memory for resources 53 Unformatted flash detected 54 Serial option lt x gt error The printer was unable to restore some or all of the confidential or held jobs on the hard disk Press w until Continue appears and then press to clear the message If this message occurs again replace the hard drive If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the message and continue printing The job may not print correctly Cancel the current job Install additional printer memory If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the mess
159. into the manual feeder for the printer to sense it but not far enough to feed properly 200 xx 200 11 or 201 08 Paper Jam messages appear In either case push the paper farther into the manual feeder ee If the paper does not feed 1 Remove the paper or envelope 2 Open the top access cover and close it 3 Load the paper and push the paper in until it stops The printer should pull it in farther Note Maintain pressure on the paper or envelope until the printer takes the paper from your hand Diagnostic aids 3 29 5022 xxx Theory of operation Paper path Paper exit flag Fuser Transfer belt System card Bump roller align Input flag Paper pick mechanism Duplex MPF pick 3 30 Service Manual 5022 xxx Diagnostic aids 3 31 5022 xxx Main Components System card The system card provides the intelligence of the printer Command and control signals originate in the system card that make print media travel possible The system card controls the timing of the print media during the printing so the media arrives at certain positions in the print process at certain times Paper tray Houses the print media Paper pick mechanism Picks the print media from the paper tray The paper pick mechanism contains the paper pick input Sensor and the multifunction transparency sensor Bump aligner roll The bump aligner roll advances the print media onto the
160. is registration in the printer When small black text or fine black lines are being printed the printer checks to see if they are being printed on top of a colored background If so rather than remove the color from beneath the black content the printer leaves the color around the edge of the text or line The hole in the colored region is reduced in size which prevents the characteristic white gap that is caused by mis registration This menu item applies to PCL 5 emulation PCL XL PDF and PostScript Selections are Off and the values 1 through 5 with 2 as the default Values 1 through 5 indicate the amount of color remaining beneath the black content Each setting increments by 1 600 of an inch The more inaccurate the registration setting the higher the setting needs to be adjusted Selecting Off disables color trapping Diagnostic aids 3 21 5022 xxx Size Sensing Turns the automatic size sensing for print media input sources either to Auto or Off Selections include Tray 2 Sensing if the tray is installed Auto default and Off This is a two level menu that displays only those print media sources which support automatic size sensing Panel Menus Lets the system support person enable or disable the operator panel menus Selecting Enable the default prevents users from changing values for the printer Disable allows users to changes the values This menu item only appears when the PUL PASSWORD Environment variable is set to
161. its by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photoconductor unit on page 4 2 for additional information 2 Disconnect the transfer belt cable A 3 Press the two tabs B on either side of the transfer belt assembly and lift out the transfer belt assembly Model C52x Model C53x Installation notes When you installed the new transfer belt and moved all the photoconductor units from the used one to the new one the alignment of the toner cartridges and photoconductor units may have changed For better color quality perform the Color Alignment procedure in the Configuration Menu See Color Alignment on page 3 24 1 Enter the Configuration Menu Turn off the printer press and hold and p turn on the printer and release the buttons when the clock graphic displays 2 Select Color Alignment See Color Alignment on page 3 24 Repair information 4 91 5022 xxx Transfer contact assembly removal See Transfer contact assembly on page 7 11 for the part number Remove the HVPS See High voltage power supply HVPS removal on page 4 62 Remove all the inside contact springs See Contact springs removal on page 4 44 Remove the four screws A and remove the transfer contact assembly Remove the eight springs B for reuse during installation Note The top spring may fall awa
162. kew adjustment is attempted The following illustration shows proper alignment versus skewed alignment Straight Skewed Diagnostic aids 3 5 5022 xxx Quick Test The Quick Test contains the following information Print registration settings Alignment diamonds at the left right top and bottom Horizontal lines to check for skew General printer information including current page count installed memory serial number and code level To print the Quick Test page Note Print the Quick Test Page on letter or A4 paper 1 Select REGISTRATION from DIAGNOSTICS 2 Press wuntil the y appears next to Quick Test The message Quick Test Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again 3 6 Service Manual Alignment 5022 xxx Alignment is part of the process of adjusting the printhead and the color planes to the black plane and to each other Before you start perform the black alignment Registration See Registration on page 3 4 If you are replacing a new printhead perform the entire printhead alignment See Printhead alignment on page 4 3 To perform alignment 1 2 NE U RAPE 9 Select ALIGNMENT from DIAGNOSTICS Scroll until you reach the color that you desire to align Go to each submenu press Select and use the right
163. kout which opens the 24 V dc interlock switch When the top door is closed with the front access door also closed the drive retraction lockout trips the switch arm which closes the 24 V dc interlock switch Drive retraction Switch arm 24 V interlock lockout switch When the 24 V switch opens the normally open side of the switch is activated which signals the system card to disable a 24 V power supply output turning off all high voltage supplies the bump align motor the duplex motor and the fuser motor for safety considerations Diagnostic aids 3 55 5022 xxx 3 56 Service Manual 5022 xxx 4 Repair information Removal and cleaning precautions AN Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of removal unless otherwise specified Do not operate the printer anytime during removals If it is absolutely necessary to run the printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage parts such as the high voltage power supply After part replacement ensure the wiring harness is not caught or damaged Do not attempt to cut or extend the wiring harness Confirm the wiring harness connector is connected properly Be sure to handle th
164. l on page 4 92 Note Do not remove the springs from the contact assembly as stated in the last step of the procedure Repair information 4 83 5022 xxx 3 For all colors It is difficult to press both locking tabs at the same time Using a spring hook press the locking tab A and disengage the sensor on that side Press the other locking tab B and remove the sensor 4 84 Service Manual 5022 xxx Top access door 24 V interlock switch removal See Top access door 24 V interlock switch on page 7 13 for the part number 1 Remove the top access cover assembly See Top access cover assembly removal model C52x only on page 4 28 2 Disconnect the JCVR1 connector A from the system card 3 Remove the right cover See Right cover removal on page 4 26 4 Remove the mounting screw B and 24 V interlock switch C Repair information 4 85 5022 xxx Top cover camshaft assembly removal See Top cover camshaft assembly on page 7 13 for the part number 1 90 eo A PD Remove the top access door 24 V interlock switch See Top access door 24 V interlock switch removal on page 4 85 Remove the left cover See Operator panel outer bezel removal on page 4 21 Rotate the lever arm A all the way up as if the top access door were open hold the lever arm A in place and rotate the camshafts B down to the closed position While still holding the lever arm A up
165. libration on page 3 24 To cancel a reset press Back Color Lock Out Called Black Only Mode in C52x models Select On when printing for extended periods with only black toner This saves the toner cartridges cyan magenta and yellow and photoconductor units from excessive wear In addition to setting the values the cyan magenta and yellow toner cartridges and their matching photoconductor units must be removed from the printer Select Off default when printing with color toner Note Remove all the color supplies from the printer before selecting the On value from the operator panel Install all the color supplies before selecting the Off value from the operator panel Prt Quality Pgs To help isolate print quality problems print the Print Quality Test Pages The pages are formatted The Printing Quality Test Pages message appears then the pages print The message remains on the operator panel until all the pages print Press Select to print the pages The Print Quality Test Pages contain several pages The first page which is printed in English text only contains a mixture of text and graphics The information includes values of the Quality Menu settings in Settings and printer and toner cartridge configuration information The remaining pages only contain graphics For samples of the pages see Print quality test pages Prt Quality Pgs on page 3 10 Color Trapping Uses an algorithm to compensate for mechanical m
166. ligner gear kit on page 7 5 for the part number 1 Remove the paper pick mechanism assembly See Paper pick mechanism assembly removal on page 4 68 Close the front access door for better access to the gears Remove the three e clips and washers A Remove the gears aa Installation notes e When reinstalling the gears apply a light coat of the packaged grease e The following illustration shows proper orientation of the gears for installation The two gears are reduction gears with the largest of the two B located in the middle on the top B Repair information 4 39 5022 xxx Bump aligner motor removal See Bump aligner motor on page 7 7 for the part number 1 Remove the right side cover 2 Remove the bump aligner gears See Bump aligner gear removal on page 4 39 3 Remove the two bump aligner motor mounting screws A 4 40 Service Manual 5022 xxx 4 Disconnect the JBUMP1 connector B from the system card 4 on i h Di 4 5 Remove the bump aligner motor from the printer Repair information 4 41 5022 xxx Bump aligner rollers and springs removal models C53x See Bump aligner roller and spring on page 7 5 for the part number 1 Remove the paper tray 2 Push up and back to relase the bump aligner spring 3 Lower the bump aligner spring to remove it 4 42 Service Manual 5022 xxx 4 Remove the bump
167. llow and magenta 1 ey Press Back on the operator panel until you reach the top menu select ALIGNMENT MENU and press Select Select Cyan Select Top Margin and use the right and left arrow keys to select zero Press Select y to save the setting Select Left Margin Right Margin Bottom Margin Skew and Bow In each menu use the right and left arrow keys to select zero and press Select y to save the value lt is important to set all the values to zero before starting 4 8 Service Manual 5022 xxx 5 Select Quick Test in the Cyan menu and press Select Two pages print You may have to print these pages several times until you get T and Z aligned Do not go to step 2 until T and Z are aligned The first page is similar to the following Cyan Alignment Step 1 t ii B0 60 40 20 0 20 40 60 80 80 60 40 20 0 20 40 60 80 Top T Coarse Adjustment Skew Z Coarse Adjustment Top T Fine Adjustment Skew Z Fine Adjustment nN o 20 18 16 14 12 10 O 0 gt d onego IN bhahCnNaa a Z Qe_ i P Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value STEP 1 Adjust the Top T margin and Skew Z then confirm before going to Step 2 Press the up or down buttons until a check appears at the setting in need of adjustment Press Select Then use the lt and gt buttons to enter the new value Press Sele
168. ly the options made available in this menu group are used to configure a printer for operation See Configuration menu CONFIG MENU on page 3 20 for more information 3 Turn on the printer 4 Release the buttons when the clock graphic displays To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostics mode Diagnostic aids 3 1 5022 xxx Diagnostics menu Note Tray 2 refers to the 500 sheet tray located in the 500 sheet option assembly Diagnostics menu structure When the Diagnostics mode is entered each Diagnostics main menu item displays on the operator panel When a diagnostic test is selected from the main menu a sub menu displays and each individual test displays in the order shown Any options that are referred to in the menus are displayed when the option is installed Available tests The tests display on the operator panel in the order shown Diagnostics mode tests REGISTRATION Top Margin See Registration on page 3 4 Bottom Margin Left Margin Right Margin Skew See Skew on page 3 5 Quick Test See Quick Test on page 3 6 Cyan See Alignment on page 3 7 Yellow Magenta of alignment pages for each individual color Tests the bump aligner motor See General motor tests on page 3 8 Tests the fuser motor See General motor tests on page 3 8 Tray 1 Tests tray 1 motor located in the paper pick mechanism See Gen
169. m Remove the e clip F Slide the lever arm A and the spring G off the shaft Warning When removing the right rear mounting screw be careful not to damage or remove the spring that mounts over the screw Remove the rear mounting screws H Remove the top cover camshaft assembly 4 86 Service Manual 5022 xxx Installation notes Warning Do not install the camshaft assembly by reversing the removal procedures The camshaft assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed or the printer will not work correctly 1 Ensure the EP drive assembly is engaged by sliding the upper retraction plate A fully to the rear N fi y t ne 4 is inf f Ea i a Remove the camshaft from the package and place the left and right mounting brackets B on a flat surface Rotate the lever arm C all the way up as if the top access door were open hold the lever arm C in place and rotate the camshafts down D to the closed position Release the lever arm C Remove the e clip E Slide the lever arm C and the spring F off the shaft Aub oO N Repair information 4 87 5022 xxx T Place the left side of the camshaft assembly through the opening in the waste toner shutter G Make sure the cam H engages the waste toner shutter G Also make sure the drive pinion 1 engages the upper retraction plate J 8 I
170. maged contact your next level of service A Inspect the toner cartridge contacts for damage or contamination Replace the toner cartridge if defective Inspect JSBTN1 cable connection Properly connect the cable if not connected properly Replace the cable if damaged For models C52x Replace the smart chip card See Smart chip card removal models C52x only on page 4 78 If the problem still exists replace the system card See System card removal on page 4 79 Diagnostic information 2 19 5022 xxx User status and attendance messages continued 34 Short Paper 34 Incorrect Media 35 Insufficient memory to support Resource Save feature 37 Insufficient memory to collate job 37 Insufficient memory for Flash Memory Defragment operation 37 Insufficient memory some held jobs were deleted 2 20 Service Manual Press W until Continue appears and then press to clear the message and continue printing The printer does not automatically reprint the page that prompted the message Check the tray length and width guides to ensure the media is properly fitted Make sure the print job is requesting the correct size of media Adjust the Paper Size setting for the media size being used If the MP Feeder Size is set to Universal make sure the media is large enough for the formatted data Cancel the current job Replace the paper pick mechanism See Paper pick mechanism assembly removal
171. mechanical transfer of the high voltage through a set of springs to each subcomponent of the charging process Photoconductor unit charge roll The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the charge roll contact on the photoconductor unit It is essential that the contact springs are properly touching to provide a good flow If not print quality problems will occur High voltage power supply High voltage contact path Photoconductor unit photoconductor drum The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the photoconductor drum contact on the photoconductor unit It is essential that the contact springs are properly touching to provide a good flow If not print quality problems will occur High voltage power supply High voltage contact path 3 46 Service Manual 5022 xxx Toner cartridge The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the toner cartridge The toner cartridge contains three parts that are provided high voltage from the HVPS These three parts are the doctor blade the developer roll and the toner adder roll TAR It is essential that the contact springs are properly touching to provide a good flow If not print quality problems will occur High voltage Cleaner blade high power supply voltage contact path
172. metal cabinet case e Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 5022 xxx Handing the photoconductor unit The following precautions must be observed when handling the photoconductor unit The photoconductor unit is a supply item you will have to remove during some of the repair procedures Transportation storage Use the specified carton whenever moving or storing the photoconductor unit Handling e The optical photoconductor roller in the photoconductor unit exhibits the greatest light fatigue after being exposed to strong light over an extended period of time Never expose it to direct sunlight Cover the photoconductor unit when you remove it from the printer e Use care not to contaminate the surface of the optical photoconductor roller with an oil based solvent fingerprints and other foreign matter e Do not scratch the surface of the optical photoconductor roller Parts not to be touched Any part where the mounting screws are used to meet a printer alignment set at the factory must not be removed disassembled or adjusted 4 2 Service Manual 5022 xxx Adjustments Printhead alignment Overview When reinstalling the printhead it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer This allows the pages to
173. mp aligner motor Note If this motor is stalling or causing waste toner box full messages the vertical auger mechanism might be causing the problem 3 38 Service Manual 5022 xxx Photoconductor unit toner cartridge drive The photoconductor units four and toner cartridges four receive drive power from the EP drive assembly motors The top cartridge motor 1 on the EP drive assembly provides drive to the top two photoconductor units and toner cartridges yellow and cyan Likewise the bottom cartridge motor 2 drives the two bottom photoconductor units and toner cartridges When the printer s top access door is open the couplers for the toner cartridges and photoconductor units disengage Outside Cartridge motor 1 Cartridge motor 2 Photoconductor couplers Toner cartridge couplers Diagnostic aids 3 39 5022 xxx Transfer belt drive The transfer belt unit receives drive from a motor located on the EP drive assembly When the top access door is open the coupler for the transfer belt disengages Outside Inside Transfer belt Coupler motor Fuser drive The fuser drive motor is built into the fuser assembly and drives the fuser rollers to turn 3 40 Service Manual 5022 xxx Duplex drive The duplex motor is mounted on the front door assembly Drive is provided to three drive shafts in the duplex unit by a belt that is driven by the motor The drive shafts move the print media through the duplex uni
174. mponent and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer This error code indicates a mismatch between the system card and the smart chip card Models C52x only Has the smart chip card been recently Replace the smart chip card Replace the system card replaced with a new and not with a new and not previously installed smart previously installed system chip card See Smart chip card See System card card removal models removal on page 4 79 C52x only on page 4 78 2 50 Service Manual 5022 xxx Models C53x only Has the printhead been recently replaced Replace the printhead with Replace the system card with a new and not previously installed system card See System card removal on page 4 79 a new and not previously installed smart chip card See Printhead removal on page 4 74 Dead printer service check A dead printer is a condition where the display is blank the LED on the operator panel is off no fans turn no motors turn and the fuser lamp does not come on If a 500 sheet option assembly C52x models or a 550 sheet option assembly C53x models is installed
175. n Is the distance between bands either 27 or page 4 70 36mm Print quality horizontal line The photoconductor unit is defective Replace the photoconductor unit Print quality insufficient fusing _ Is the fuser properly installed Go to step 2 Install the fuser properly 2 Replace the fuser See Fuser removal on Problem solved Replace the LVPS see page 4 60 Low voltage power supply LVPS removal Does this fix the problem on page 4 65 Print quality missing image at edge Reseat the developer cartridge Print quality mottle 2 5mm speckles Keep running prints through and the problem normally clears up If the problem persists replace the developer cartridge Print quality narrow vertical line Replace the photoconductor unit See Problem solved Replace the print cartridge Photoconductor unit removal on page 4 70 2 58 Service Manual 5022 xxx Print quality random marks Service tip The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit developer roll or transfer belt Is there any loose or foreign material on the Replace the photoconductor Go to step 2 photoconductor unit unit See Photoconductor unit removal on page 4 70 Is there any loose or foreign material on the Replace the print cartridge Go to step 3 cartridge roll Is there any loose or foreign material on the
176. n MPF paper tray assembly 250 sheet C530dn C532dn C534dn Paper tray assembly single feeder C532n C534n Transfer belt assembly C52x Transfer belt assembly C53x Power cord USA Canada Bolivia Peru Power cord Argentina Power cord Australia New Zealand Power cord Austria Belgium Catalan Czechoslovakia Finland France Germany Greece Hungary Ireland Italy Netherlands Norway Paraguay Poland Portugal Russia Spain Sweden Turkey United Kingdom Power cord Austria Belgium Catalan Czechoslovakia Finland France Germany Greece Hong Kong Hungary Ireland Italy Netherlands Norway Paraguay Poland Portugal Russia Singapore Spain Sweden Turkey United Kingdom Power cord Brazil Power cord Chile Uruguay Power cord China Power cord Denmark Finland Norway Sweden Power cord lIsrael Power cord Japan Power cord Korea Power cord South Africa Power cord Switzerland Power cord Taiwan Parts catalog 7 15 5022 xxx Assembly 8 Contact springs 4 places 4 places 4 places 8 places 8 places 4 places 7 16 Service Manual 5022 xxx Assembly 8 Contact springs Units Units a index pm Umat fum pesoto OO 8 1 40X1434 1 1 Contact springs kit including A Torsion PCD contact spring 4 B Torsion CR contact spring 4 C Contact spring cap 4 D Charge roll contact spring 8 E HVPS TAR contact spring 4 F
177. n C524dn 7 15 Bin full sensor with cable network printers only 7 3 Front access door cover assembly duplex C524dn only 7 3 Ground contact plate C52x rec tr re cc rere rete ecee 7 7 right belicrank assembly 26 020 er cere er ee ee ee ees 7 5 Left bellcrank assembly lt lt 6 05 004 sects tee ees eee ee tee eee ese es 7 5 Inner bezel C524 C524n C524dn 7 3 Inner bezel C522n 7 3 Inner bezel C520n 7 3 Top access cover assembly network c 3 coer seer ete ene eee eee oe eee 7 3 32 MB flash card rere eee ee eee eee eee e 7 20 64 MB flash card 7 20 128 MB SDRAM 100 pin 7 20 256 MB SDRAM 100 pin 7 20 512 MB SDRAM 100 pin 7 20 Japanese font card 7 20 Simplified Chinese font card 7 20 Traditional Chinese font card lt lt lt 2 5 me eer ee ee ee ee en
178. n page 4 79 lF F4 E Fs Is either fuse blown 2 34 Service Manual 5022 xxx 144 xx Motor EP drive assembly bottom cartridge error service check Turn the printer off and remove the rear cover Replace JCART2 cable Go to step 2 Check the connector JCART2 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the EP drive assembly See Problem solved Replace the system card Electrophotographic EP drive assembly See System card removal model C52x only on page 4 48 or removal on page 4 79 Electrophotographic EP drive assembly removal model C53x only on page 4 51 Does the error clear Measure the resistance across fuse F5 and F6 Replace the system card Go to step 3 on the system card See System card removal on page 4 79 lF EFA E Fs Is either fuse blown Diagnostic information 2 35 5022 xxx 145 xx and 906 05 906 08 Motor bump aligner error service check Is the top access door completely closed Open the top access door and slowly close it You should hear the top access door 24 V interlock switch closing when the door almost shuts If you do not check the switch for damage Is the switch damaged Close the top access door Turn printer power on and check for 24 V dc between JCVR1 pin 1 red wire and ground Note The ground lead of th
179. nd connectors 5 11 5022 xxx System card non network models C52x o ipl Bre m JC o moir n oOo JLVPS1 JFUSER1 X gt OG i STRANS2 Dies JUSB1 JCART2 NDUPLX f QQ Jp oo J ysJJTRAY2 JTRAY1 STRANS1 yorr1 ALE 5 12 Service Manual 5022 xxx Connector listing models C52x see System card network models C52x on page 5 11 or System card non network models C52x on page 5 12 Connector JBIN1 V_BF 5 SW S_BIN_FB Ground VS_BUMP_LED S BUMP_ENC Ground V_BUMP_M V_BUMP_M V_JC1 1 V_JC2 3 Ground JBUMP1 JCART1 V_JC1 2 V_JC1 4 5V SW V_C2_U V_C2_W V_JC2 2 V_JC2 4 _5V_SW V_C2_U V_C2_W lt O V_C2_V CART2_HALL_V CART2_HALL_W Ground JCART2 V_C2_V V_24V_CVR COVER_OPEN_SNS VS_DUPLX 5 V DUPLEX PWM DUPLEX _ENC Ground V_24VD Ground FAN FG Ground 24VC FAN1_ PWM V_FUSER_M VS_FUSER_LED Ground FUSER_EXIT_SNSD FUSER_HR_SNS 10 JCVR1 JDUPLX1 Z O JFAN1 JFUSER1 V_FUSER_M S_FUSER_ENC GND BR_THERM VS_FUSER 5V 10 FUSER_HR_THM_RIN Locations and connector
180. ner box Press W until Continue appears and then press to clear the message and continue processing Any information not previously stored on the hard disk is deleted Delete fonts macros and other data stored on the hard disk Install a larger hard disk If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the message and continue printing Format the disk If the error message remains replace the hard disk If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the message and continue printing Format the disk If the error message remains replace the hard disk If this does not fix the problem replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to clear the message and continue printing Order a replacement fuser When print quality is reduced install the new fuser using the instruction sheet that comes with the replacement fuser lf this does not fix the problem replace the system card See System card removal on page 4 79 Replace the fuser If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to clear the message and
181. ng 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 in addition to all the usual precautions such as turning off power before removing electronic cards e Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part in the printer e Make the fewest possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture e Putthe ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the printer e Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins e If you need to put down the ESD sensitive part for any reason first put it into its special bag e Printer covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded e Prevent ESD sensitive parts from being accidentally touched by other personnel Install printer covers when you are not working on the printer and do not put unprotected ESD sensitive parts ona table e If possible keep all ESD sensitive parts in a grounded
182. ng properly Press Back or Stop to exit the test 3 14 Service Manual 5022 xxx Base Sensor Test Bin Full Test This test is used to determine if the bin full sensor is operating correctly This test is only applicable to network printers To run the Bin Full Test 1 Select BASE SENSOR TEST from DIAGNOSTICS 2 Select Bin Full Test The display shows Bin Ful and the current state of this sensor either Closed or Open Move the bin full sensor flag located on the fuser up and down to toggle the sensor state Sensor Test This test is used to determine if specific sensors are working correctly If you need to know where a sensor is located refer to Sensors on page 5 8 To run the Sensor Test 1 Select BASE SENSOR TEST from DIAGNOSTICS 2 Select Sensor Test The display shows each one of the sensors one line at a time and the current state of the sensor Use the down arrow to locate the sensor in question Use the following table to toggle the sensor Fuser Exit paper Open Closed Open the top access cover Activate the fuser exit flag The exit sensor should change state Inner Door front Open Closed Open the front access door The sensor should change state access door Input Open Closed Remove the paper tray 1 Activate the input sensor flag The sensor should change state Narrow Media Open Closed Test the manual feed slot by pulling out the tray The sensor transparency should change stat
183. ns do not fix the problem replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Ensure proper media is set for the type of paper used Fan media and stack it flat in the tray or MPF Properly set media restraints in the paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Replace the MPF swing arm assembly See Multipurpose feeder MPF swing arm assembly removal models C52x only on page 4 67 If the previous actions do not fix the problem replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 5022 xxx Service error codes and paper jam messages continued frre owen ma 290 05 While feeding from the MPF the input Ensure proper media is set for the type of paper 250 21 sensor is not made MPF motor stalled 9xx service error messages used Fan media and stack it flat in the tray or MPF Properly set media restraints in the paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Models C52x only Replace the MPF swing arm assembly See Multipurpose feeder MPF swing arm assembly removal models C52x only on page 4 67 If the previous actions do not fix the problem replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Ensure proper media is set for the type of paper used Fan med
184. nsor flag broke early Possible causes e Paper jam leaving page over sensor e Defective input sensor e Faulty system card Cartridge motor 1 top or cartridge motor 2 bottom has stalled Possible causes e Faulty cable connector e Faulty cartridge motor e Faulty system card Special case Possible cause e System card code failure A 201 08 jam occurred and was not cleared Possible cause Failure to open and close the top access door Exit sensor is made when printer tries to print from an idle state Possible causes Damaged paper exit sensor or paper exit sensor flag Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system card Exit sensor broke early Possible causes e Damaged paper exit sensor or paper exit sensor flag e Faulty fuser e Faulty system card Exit sensor never broke Possible causes e Damaged paper exit sensor or paper exit sensor flag e Faulty fuser e Faulty system card e Faulty output bin flag Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to 143 xx Motor EP drive assembly top cartridge error service check on page 2 34 and then 144 xx Motor EP drive assembly bott
185. nstall the new transfer belt using the instruction sheet that comes with the replacement transfer belt If the problem persists replace the system card See System card removal on page 4 79 Replace the transfer belt using the instruction sheet that comes with the replacement transfer belt See Transfer belt removal on page 4 91 lf the problem persists replace the system card See System card removal on page 4 79 Press w until Ignore appears and then press to clear the message and continue printing Order the specified photoconductor unit When print quality is reduced install the new specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit If the problem persists replace the system card See System card removal on page 4 79 Replace the specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit If the problem persists replace the system card See System card removal on page 4 79 5022 xxx User status and attendance messages continued 84 lt color gt PC Unit e Scroll down the operator panel to see if the printer is showing that all four of the PC units missing are missing If so check the HVPS cable between the system card and the HVPS Ensure that the cable is not plugged in backwards on the HVPS Disconnect and reconnect the cable to make sure there is good co
186. nstall the rear mounting screws K 9 Slide the spring L and the lever arm M onto the shaft 10 Install the e clip N 4 88 Service Manual 11 12 13 14 5022 xxx Rotate the lever arm O all the way up as if the top access door were open While still holding the lever arm O up flip the right lock P up and install the front mounting screws Q Warning Failure to place the camshaft assembly in the open position prevents the front access door from closing and may cause damage to the door Continue to hold the lever arm O up Flip the right lock P down and rotate the camshafts R up This is the open position Lower the lever arm O and make sure the left lock S and right lock P are positioned correctly in their respective channels T Repair information 4 89 5022 xxx Note If the left side of the camshaft assembly becomes disassembled use the following illustration 4 90 Service Manual 5022 xxx Transfer belt removal See Transfer belt assembly C52x on page 7 15 or Transfer belt assembly C53x on page 7 15 for the part number 1 Remove all photoconductor units See Photoconductor unit removal on page 4 70 Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photocondu
187. ntact e Insert or reinstall the specified photoconductor unit and see if problem clears See Photoconductor unit removal on page 4 70 e Remove the top access cover assembly see Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 and confirm that the camshaft follower A on the left side is not out of the groove B If the camshaft follower is out of the groove raise the arm use a screwdriver to ease the camshaft follower back into the groove You need to press down to snap it into position e Check the high voltage contacts path especially the finger on the specified photoconductor unit printer is shown with components removed for clarity High volt TE y OS MARE Nia High voltage S SF contact path e If the contacts are good replace the HVPS See High voltage power supply HVPS removal on page 4 62 e If the problem persists replace the system card See System card removal on page 4 79 Diagnostic information 2 25 5022 xxx User status and attendance messages continued 87 Fuser missing 88 lt color gt Cartridge low 88 Replace lt color gt cartridge 2 26 Service Manual e Install the fuser Replace the fuser if the problem persists e If the problem continues turn the printer off and remove the rear cover Check the JFUSER1 connector for proper connection to the system
188. od of time See Handing the photoconductor unit on page 4 2 for additional information C52x C53x 5 Remove the system card support shield See System card support shield removal on page 4 81 6 Remove the fuser cable cover See Fuser cable cover removal on page 4 61 4 74 Service Manual 5022 xxx T Remove the three mounting screws C from the front of the printhead Warning Secure the printhead when removing the printhead alignment screw Failure to do this allows the printhead to fall out of the printer potentially damaging the printhead 8 Close the top access cover and remove the printhead alignment screw D and remove the printhead Repair information 4 75 5022 xxx Installation notes Do not install the printhead mounting screws in the rear of the printer When reinstalling the printhead it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer This allows the pages to be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw Once the black skew is adjusted the mounting screws will be fully tightened 1 When installing the printhead do a rough alignment by visually centering the hole in the frame C with the slot on the bottom of the printhead Do not fully tighten printhead mounting screws until skew has been adju
189. om cartridge error service check on page 2 35 if necessary POR the printer Replace the system card if the error message persists See System card removal on page 4 79 If replacing system card does not fix the problem contact your next level of support This error is generated as a protection for possible paper wrap in the fuser Open the top access door and check for a paper jam Close the top access door If the jam is cleared and the error does not go away go to Exit sensor service check on page 2 52 e Check for anything in the paper path that might cause the paper to jam e The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 e Check output bin flag on fuser for proper operation Ensure that paper is not hanging on the flag e The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 Service error codes and paper jam messages continued 5022 xxx frre owen ma 202 17 202 21 203 09 203 14 203 15 230 03 Exit sensor is made when the printer powers up or covers are closed Possible causes e Damaged paper exit sensor or paper exit sensor flag e Damaged fuser autoconnect e Faulty fuser DC cable connection e Faulty fuser Faulty system card Fuser motor stalled Possible
190. on page 4 68 If the problem still exists replace the system card See System card removal on page 4 79 Load the appropriate media in the selected source Press w until Continue appears and then press to clear the message and print the job using a different paper source POR the printer to recalibrate transparency sensor Ensure the transparency sensor is mounted correctly in the paper pick mechanism If not snap it into place Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 If the problem still exists replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to disable Resource Save and continue printing To enable Resource Save after receiving this message Make sure the link buffers are set to Auto then exit the menus to activate the link buffer changes When Ready is displayed enable Resource Save Install additional memory If this does not fix the problem replace the system card See System card removal on page 4 79 Press w until Continue appears and then press to print the portion of the job already stored and begin collating the rest of the job Cancel the current job If this does not fix the problem replace the system card See System card removal on page 4 79 Press W until Continue appears and then press to stop the defragment operation and continue pr
191. onnector JMIRR1 for proper Printhead removal on connection to the system card the printhead page 4 74 cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the printhead See Printhead Problem solved Replace the system card removal on page 4 74 See System card Does the error clear removal on page 4 79 Is the front access door completely closed Go to step 2 Properly close the door Turn the printer off and remove the rear cover Replace the front access Go to step 3 Check the connector JINT1 5 V interlock door 5 V interlock switch switch cable for proper connection to the See Front access door system card the cable for pinch points andthe 5 V interlock switch cable or connector for any other damage removal on page 4 54 Is the cable damaged Turn the printer power on and check for 5 V dc Replace the front access Go to step 4 between JINT1 pin red wire and ground door 5 V interlock switch See Front access door Is voltage present 5 V interlock switch removal on page 4 54 Replace the printhead See Printhead Problem solved Replace the system card removal on page 4 74 See System card Does the error clear removal on page 4 79 Diagnostic information 2 27 5022 xxx 120 01 120 02 120 08 120 10 120 13 120 15 Fuser error service check Check the input voltage switch on the back of Go to step 2 Set the
192. or cover assembly duplex C530dn C532dn C534dn 7 3 Top access cover assembly network C530dn C532n C534n 7 3 Duplex top access assembly network C532dn C534dn_ 7 3 l 8 Service Manual 40X3607 40X3608 40X3609 40X3610 40X3611 40X3612 40X3613 40X3614 40X3615 40X4199 40X4217 40X4218 40X4219 40X4237 40X4238 40X4239 7377018 7377200 5022 xxx PIKANT TOI fat tse a rs ae a Se ae la tte eta Sais ee tae Sah eee e a 7 15 Bezo OSIO ee ele 7 3 FOWer COlO Japall 2 lt Sees et eat ee ae Here a Se ee See ae Seis Se See eee 7 15 Power cord Taiwan e e eee eeee ee eee 7 15 Power cord Brazil eee 7 15 Paper tray dust cover with spring C53x 7 7 3 Top cover camshaft assembly rrr rrr rrr E a a a 7 13 Bump aligner roller and spring 7 5 Dalec aSSemDIy Cook mar eerde dete Sees Sees eae eS eee Sees ae Sai Se Siete Sere ee 7 5 PrintCryption card C524 C524n C524dn rrr rr rrr rrr rr rrr E ee ee 7 20 Dy cle Cold Re se a Serre oe ee Bes eee See lar eae se oe ee ee ee ee Scere 7 9 System card network C524n C524dn 5 rr rere rere errr ree eee 7 9 System card network C520n C522n s Se sa strdk
193. or damaged in any way Have windows holes perforations cutouts or embossing Have metal clasps string ties or folding bars Have an interlocking design Have postage stamps attached Have any exposed adhesive when the flap is in the sealed or closed position Have bent corners Have rough cockle or laid finishes e Adjust the width guide to fit the width of the envelopes Note A combination of high humidity over 60 and the high printing temperature may wrinkle or seal envelopes Using labels Print samples on the labels being considered for use before buying large quantities For detailed information on label printing characteristics and design see the Card Stock amp Label Guide available on the Lexmark Web site at www lexmark com publications Note Vinyl labels are not supported on this product Use only paper labels When printing on labels e From the printer software MarkVision Professional or the control panel set the Paper Type to Labels e Use only letter A4 and legal size label sheets e Use labels designed specifically for laser printers Check with the manufacturer or vendor to verify that label adhesives face sheet printable stock and topcoats can withstand temperatures up to 180 C 356 F and pressure up to 30 psi without delaminating oozing around the edges or releasing hazardous fumes Do not use vinyl labels e Do not use labels with slick backing material e Use full lab
194. ormal duplex mode feeds two sheets simultaneously while duplex gloss feeds only one sheet Selections include Off default and On Diagnostic aids 3 25 5022 xxx Font Sharpening Lets a user set a text point size value below the setting of the high frequency screens used when printing font data This menu item only affects the PostScript PCL 5 PCL XL and PDF emulators Settings are in the range of 0 150 24 is the default For example if the value is set to 24 then all fonts sized 24 points or less use the high frequency screens To increase value by 1 press the right arrow to decrease the value by 1 press the left arrow Exit Config Menu Press Select to exit the CONFIG MENU The printer performs a power on reset and returns to normal mode 3 26 Service Manual Paper Jams Error jam locations 5022 xxx The following illustration shows the location and error codes generated for specific paper jams and the corresponding locations of these jams A 203 Paper Jam exit sensor retract when duplexing 230 Paper Jam exit sensor to input sensor when duplexing f igh EARO gt 242 Paper Jam tray 2 i a iz 242 Paper Jam tray 1 Tooo 200 Paper Jam input sensor area 230 Paper Jam exit sensor to input sensor when duplexing 250 Paper Jam MPF feeder Diagnostic aids 3 27 5022 xxx Paper jams in t
195. ossible causes Incorrect media setting Incorrect paper loading Incorrect media restraint setting Paper tray failure Paper pick mechanism failure While feeding from tray 1 the input sensor is made while the previous page is still in aligner Possible causes Incorrect media setting Incorrect paper loading Incorrect media restraint setting Paper tray failure Paper pick mechanism e If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Check for anything in the duplex paper path that might cause the paper to jam This includes the paper guides in tray 1 If clearing the paper jam does not fix the problem and the paper is fan folded replace the front access assembly See Front door assembly removal on page 4 55 If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 52 Check for anything in the duplex paper path that might cause the paper to jam This includes the paper guides in tray 1 If clearing a paper jam does not fix the problem go to 146 xx Motor duplex error service check on page 2 36 Ensure proper media is set for the type of paper used Fan media and stack it flat in the tray or MPF Properly set media restraints in paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Replace the paper pick mechanism See Paper pick mechanism assembly removal on
196. ot followed the printer will be rendered inoperable Warning Be careful not to damage the printhead cable when removing the system card 1 Remove the rear cover See Rear cover removal on page 4 25 2 Disconnect all the connectors from the system card Warning Do not use tools to remove the printhead ribbon cable A It can be damaged and should be removed gently by hand When installing carefully line up the cable and press straight into the connector Repair information 4 79 5022 xxx 3 Remove the screw B from the USB connector 4 For models C52x only If a non network system card is installed also remove the two screws C from the parallel connector Network system card Non network system card ji wik kH IFFT l j l fi d l t h 1 5 VE fei bes es sa E T SSeS oe i a P r 6 Remove the system card 4 80 Service Manual 5022 xxx System card support shield removal See System card support shield C52x on page 7 9 or System card support shield C53x on page 7 9 for the part number Aa ed a OND Remove the right cover See Right cover removal on page 4 26 Remove the left cover See Left cover removal on page 4 20 Remove the LVPS See Low voltage power supply LVPS removal on page 4 65 Remove the system card See System card removal on page 4 79 Remove the five mounting screws A from the outer left si
197. ower supply C53x on page 7 11 for the part number 1 Remove the left cover See Operator panel outer bezel removal on page 4 21 2 Remove the six mounting screws A 4 62 Service Manual 5022 xxx 4 Disconnect the five connectors C from the HVPS C Installation notes Be sure to replace the spring when replacing the HVPS See the illustration for proper orientation Wy YYYYYY Repair information 4 63 5022 xxx Left bellcrank removal See Left bellcrank assembly on page 7 5 for the part number 1 Remove the left cover See Left cover removal on page 4 20 2 Remove the C clip A g t A A 3 Remove the left bellcrank 4 64 Service Manual 5022 xxx Low voltage power supply LVPS removal See Low voltage power supply 115 230 V on page 7 7 for the part number 1 Remove the right side cover See Right cover removal on page 4 26 2 Remove the rear cover See Rear cover removal on page 4 25 3 Unplug the JLVPS1 connector A from the system card 4 Remove the five LVPS mounting screws B 5 Disconnect the cable from the LVPS C JF ia 6 Remove the cable from the cable guide and remove the LVPS Repair information 4 65 5022 xxx Installation note When installing the new LVPS make sure the voltage switch D is set for the proper value 115 V or 230 V depending on the country 4 66 Service
198. p access door 2 Open the front access door 3 Remove the three mounting screws A 4 Remove the swing arm assembly from the frame Installation note Refer to the following illustration if the swing arm crank comes loose from the swing arm assembly Make sure the end of the spring B is under the retaining tab C on the swing arm crank after installation Note Spring end B is shown disengaged from swing arm crank ss cuit _ z gt gt A A _ _ _ E Repair information 4 67 5022 xxx Paper pick mechanism assembly removal See Paper pick mechanism assembly C52x on page 7 5 or Paper pick mechanism assembly C53x on page 7 5 for the part number 1 Remove the rear cover See Rear cover removal on page 4 25 2 Disconnect the JTRAY1 A and JTRAY2 B connectors from the system card Lr A N A B 3 Remove all toner cartridges 4 For models C52x only If installed remove the MPF swing arm assembly See Multipurpose feeder MPF swing arm assembly removal models C52x only on page 4 67 4 68 Service Manual 5022 xxx 5 Remove the three mounting screws C 6 Release the front locking tabs D 7 Slide the paper pick mechanism forward until the rear locking tabs E release 8 Lower the paper pick mechanism and remove through the front of the printer Note Make sure t
199. p aligner drive 3 38 duplex drive 3 41 fuser drive 3 40 paper pick mechanism drive 3 37 ophotoconductor unit toner cartridge drive 3 39 transfer belt drive 3 40 media input and output capacities 1 12 selecting preprinted forms and letterhead 1 7 storing 1 10 supported media size 1 10 Supported media weight 1 11 using card stock 1 9 envelopes 1 8 labels 1 9 5022 xxx letterhead 1 8 transparencies 1 8 media specifications input and output capacities 1 12 print area 1 12 selecting media 1 6 supported sizes 1 10 using media 1 8 weight 1 12 memory 1 2 menus accessing service menus 3 1 user menus 2 4 Mirror Motor Test 3 8 Model Name 3 16 models 1 1 7 1 Motor Calibration 3 24 Motor Calibration Test 3 9 motors locations 5 9 MPF swing arm assembly C52x parts catalog 7 4 removal 4 67 multipurpose feeder MPF swing arm assembly C52x 4 67 O operator panel description 2 2 indicator light 2 2 locations 5 1 parts catalog 7 2 service check 2 53 display all diamonds 5 beeps 2 54 display all diamonds no beeps 2 54 display blank 5 beeps LED off 2 53 display blank 5 beeps LED on 2 54 one or more buttons fail 2 53 options and features description 1 1 parts catalog 7 20 P Panel Menus 3 22 Panel Test 3 11 paper selecting preprinted forms and letterhead 1 7 storing 1 10 supported media weight 1 10 1 11 using card stock 1 9 envelopes 1 8 labels 1 9 letterhead 1 8 paper jams error locations 3 27 manual feede
200. page 4 26 Open the top access door Open the front access door Remove all the toner cartridges Remove the six inner screws A oS a A A 6 Disconnect JCART1 B JCART2 C and JTRANS2 D connectors from the drive assembly 0 j j F k i _ 3 lt a E i r F i k 5 4 i j j r ja f f 1 j amp ka a x Repair information 4 51 5022 xxx 7 Remove the nine outer screws E Note Access the top two screws through the top cover 8 Remove the EP drive assembly from the printer 4 52 Service Manual 5022 xxx Installation note Ensure that the top access door is open and the EP drive is retracted when installing the new EP drive assembly Note When retracted upper F and lower retraction plates G will be fully forward If not slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers Repair information 4 53 5022 xxx Front access door 5 V interlock switch removal See Front door 5 V interlock switch on page 7 7 for the part number 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 65 2 Disconnect the JINT1 connector A from the system card 3 Open the top access door 4 Remove the gearbox shield See Gearbox shield removal on page 4 19 5 Remove the interlock switch mounting screw B from the right side of the printer B 6 Remove the cable from cable guide
201. page 4 68 Ensure the proper media is set for the type of paper used Fan media and stack it flat in the tray or MPF Properly set media restraints in paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 5022 xxx Service error codes and paper jam messages continued frre owen ma 241 05 While feeding from tray 1 the input Ensure proper media is set for the type of paper sensor is never made used Possible causes Fan media and stack it flat in the tray or MPF Incorrect media setting Properly set media restraints in paper tray Incorrect paper loading Check the pick arm rolls tires and replace if Incorrect media restraint setting oe Replace the paper tray Paper tray failure l l l l If the previous actions do not fix the problem go Paper pick mechanism failure to 140 xx Autocomp tray 1 motor error e System card service check on page 2 32 241 20 While feeding from tray 1 the Replace the paper tray transparency sensor is blocked If the previous action does not fix the problem Possible causes go to 910 01 Transparency sensor error service check on page 2 38 Transparency sensor Paper tray failure Paper pick mechanism failure System card 241 21 Tray 1 motor stalled Ensure proper media is set for the type of paper used Possible causes Fan media and
202. propery Go to step 3 Reseat the connector connected to the system card Place a voltmeter between JTRAY1 pin 2 and Replace the system card Replace the paper pick ground Initially the meter should indicate See System card mechanism See Paper 5 V dc Activate the input sensor flag removal on page 4 79 pick mechanism assembly removal on page 4 68 Does the voltage drop to 0 V dc 2 52 Service Manual 5022 xxx Operator panel service check Warning When replacing any one of the following components e Operator panel assembly e System card e Printhead assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer One or more operator panel buttons fail Run the Button Test See Button Test on Replace the operator panel Go to step 2 page 3 11 in Diagnostics mode assembly See Operator l anel assembly removal Did any of the buttons fail the test i page 4 23 y Disconnect the operator panel assembly cable Replace the operator panel Replace the system card from JOPP1 on the system card and measure assembly
203. r C52x 4 21 7 parts catalog 7 2 removal 4 21 bin full sensor Bin Full Test 3 15 parts catalog 7 12 removal C52x 4 37 removal C53x 4 38 Bin Full Test 3 15 Black Only Mode 3 21 bump aligner gear parts catalog 7 4 removal 4 39 bump aligner motor locations 5 3 parts catalog 7 6 removal 4 40 Button Test 3 11 buttons description 2 2 parts catalog operator panel 7 2 2 2 5022 xxx C cables parts catalog 7 18 CACHE Test 3 12 card stock 1 9 Color Alignment 3 24 Color Lock Out 3 21 Color Trapping 3 21 configuration ID 3 16 configuration menu accessing 3 1 Auto Align Adj 3 23 Auto Color Adj 3 23 available tests 3 20 Color Alignment 3 24 Color Lock Out 3 21 Color Trapping 3 21 Demo Mode 3 22 Disk Encryption 3 25 Download Emuls 3 22 Duplex Gloss 3 25 Energy Conserve 3 23 Enforce Color Order 3 24 Env Prompts 3 25 Event Log 3 23 exit Config Menu 3 26 Factory Defaults 3 22 Font Sharpening 3 26 Jobs on Disk 3 25 Motor Calibration 3 24 Panel Menus 3 22 Paper Prompts 3 24 PPDS Emulation 3 22 Prt Quality Pages 3 21 Reset Fuser Cnt 3 21 Size Sensing 3 22 connectors 5 11 network system card 5 11 parallel system card 5 12 system card models C52x network 5 11 system card models C52x non network 5 12 system card models C53x network 5 18 contact springs parts catalog 7 16 removal 4 44 covers identification 4 14 locations 5 1 parts catalog 7 2 D dead printer service check 2 51 defaults 3 16 E
204. r 3 28 multipurpose feeder 3 28 Index l 3 5022 xxx paper path diagram 3 30 3 31 main components 3 32 mechanical drive 3 37 paper sensing 3 42 print media transport 3 33 paper pick mechanism parts catalog 7 4 removal 4 68 Paper Prompts 3 24 paper sensing paper exit duplex entry sensor and bin full flag 3 43 paper pick sensor 3 42 parts catalog cable parts packet 7 18 contact springs 7 16 CRUs 7 14 front 7 4 left 7 10 miscellaneous 7 20 rear 7 8 right 7 6 top 7 12 Perm Page Count 3 16 ohotoconductor unit 4 2 handling 4 2 installation 4 70 locations 5 7 parts not to be touched 4 2 removal 4 70 transportation storage 4 2 Pick roll tires replacement 4 71 power cords 7 15 power on self test POST sequence 2 5 PPDS Emulation 3 22 print area 1 12 print quality background 2 55 blank page 2 56 blurred or fuzzy print 2 58 half color page 2 58 horizontal banding 2 58 horizontal line 2 58 insufficient fusing 2 58 missing image at edge 2 58 mottle 2 5mm speckles 2 58 narrow vertical line 2 58 random marks 2 59 residual image 2 59 solid color page 2 60 vertical banding 2 61 printer pads parts catalog 7 4 removal 4 73 printhead locations 5 4 parts catalog 7 8 removal 4 74 printhead alignment 4 3 l 4 Service Manual Prt Color Pg Count 3 16 Prt Mono Pg Count 3 16 Prt Quality Pgs configuration menu 3 21 diagnostic menu 3 10 Q Quick Test duplex 3 12 R removal and cleaning precautions 4 1 removals
205. r belt locations 5 7 parts catalog 7 14 removal 4 91 transfer contact assembly locations 5 5 parts catalog 7 10 removal 4 92 Transfer Motor Test 3 8 transparencies using 1 8 W waste toner assembly locations 5 7 removal 4 93 l 6 Service Manual 5022 xxx Part number index P N 40X0274 40X0275 40X0276 40X0278 40X0279 40X0280 40X0282 40X0286 40X0287 40X0288 40X0290 40X0291 40X0296 40X0297 40X1375 40X1376 40X1377 40X1378 40X1401 40X1404 40X1405 40X1409 40X1410 40X1411 40X1412 40X1413 40X1414 40X1415 40X1416 40X1417 40X1418 40X1419 40X1420 40X1422 40X1423 40X1424 40X1425 40X1426 40X1427 40X1428 40X1429 40X1430 40X1430 40X1431 40X1432 40X1433 40X1434 40X1435 Description Page Power cord Switzerland e e ee 7 15 Power cord lIsrael escent e cree 7 15 Power cord south Africa 5 05 485 ees en eters eee teeter hoes ees 7 15 Power cord Austria Belgium Catalan Czechoslovakia Finland France Germany Greece Hungary Ireland Italy Netherlands Norway Paraguay Poland Portugal Russia Spain Sweden Turkey United Kingdom 7 15 Power cord Denmark Finland Norway Sweden 7 15 OWE COMO hGled Sees eS oes eee tee tee Spek ee ee eee eee See ee ae SS 7 15 Power cord China e
206. r the image has been transferred onto the print media it is ready for fusing The print media is transported into the fuser where the hot roll and backup roll use a combination of high heat and pressure to melt and press the toner to the media Backup roll ek EFE eh A LALA L P kaS 5 F N B j _____ 3 52 Service Manual 5022 xxx Cleaning The transfer belt and photoconductor drum are cleaned at the end of the electrophotographic process cycle The transfer belt surface is cleaned as it rotates past a cleaning blade and shaft located inside the transfer belt assembly Any waste toner that is scraped off of the belt is collected in the waste toner container located next to the belt inside the transfer belt unit The photoconductor drum is cleaned by the cleaning blade Photoconductor drum cleaning blade 71 Transfer belt cleaning blade Transfer belt waste toner container Transfer belt cleaning shaft Diagnostic aids 3 53 5022 xxx Electrical interlock 5 V interlock switch An interlock switch triggered by the front access door disables the 5 V output to the printhead which turns off the laser ip a 7 Gearbox shield removed 5V interlock switch 3 54 Service Manual 5022 xxx 24 V interlock switch The 24 V dc interlock switch is mounted to the right side of the top cover camshaft assembly Opening the top door rotates the drive retraction loc
207. re eee eee ee eee 7 15 Power cord Austria Belgium Catalan Czechoslovakia Finland France Germany Greece Hong Kong Hungary Ireland Italy Netherlands Norway Paraguay Poland Portugal Russia Singapore Spain Sweden Turkey United Kingdom 7 15 Power cord Chile Uruguay 7 15 Power cord Argentina 7 15 Serial interface card adapter C524 C524n C524dn C534n C534dn 7 20 Parallel 1284 B interface card adapter C524 C524n C524dn C534n C534dn 7 20 Power cord Ausiralia New Zealand 8 003 e re re ee rn te ee eee 7 15 Power cord USA Canada Bolivia Peru 7 15 MarkNet N8000 fast ethernet print server C524 C524dn 7 20 MarkNet N8020 gigabit ethernet print server C524 C524dn C534n C534dn 7 20 MarkNet N8030 fiber ethernet print server C524 C524dn C534 C534dn 7 20 MarkNet N8050 802 11g wireless print server US Americas C524 C524dn C534n C534dn 7 20 Transfer belt assembly C52x 2 eee eect r re etree eee eeee 6 1 7 15 MPF paper tray assembly 250 sheet C524 C524n C524dn 7 15 Paper pick mechanism assembly 052x
208. registration makes sure the black printing is properly aligned on the page This is one of the steps in aligning a new printhead See Printhead alignment on page 4 3 It is also the first step in aligning the duplex registration See Quick Test duplex on page 3 12 The settings available are Top Margin Bottom Margin Left Margin Right Margin Skew Quick Test To set print registration 1 Select REGISTRATION from the DIAGNOSTICS menu 2 Select Quick Test and press Q To print the Quick Test page a Press W until the y appears next to Quick Test b Press Q The message Quick Test Printing appears on the display Retain this page to determine the changes you need to make to the margin settings 3 Use wor A to select the margin setting you need to change and press D 4 Use lt q to decrease or gt to increase the offset values and press y to confirm the value The message Submitting selection displays and the original REGISTRATION screen appears with the y beside the previously selected margin setting The print registration range is Description Bottom margin Top margin Left margin Right margin Skew 3 4 Service Manual 20 to 20 Each increment causes approximately 0 55 mm shift in the bottom margin 25 to 25 Each increment corresponds to 8 scans at a 600 dpi scan rate 0 0133 inches or 0 339 mm 25 to 25 Each increment corresponds to 4 pels at 600 dpi 0 00
209. rs if a hard disk is installed It appears even if no buffered jobs exist on the hard disk Selections include Do Not Delete and Delete Disk Encryption Controls whether the printer encrypts the information that it writes to the hard disk Warning When the value for Disk Encryption the printer completely formats the hard disk which means that all information on the disk is deleted Note If an encrypted disk is removed from the printer and another disk is installed the Disk Corrupted Reformat message appears The newly installed disk must either be formatted or removed from the printer Selections include Disable default and Enable When Disk Encryption is selected Yes or No appears for you to confirm Select either Yes or No and press Select to continue To cancel select No The Disk Encryption menu item only appears when e A non defective disk is installed in the printer e The values of bits 3 2 of digit 4 in the Configuration ID 2 are either 01 for Supported or 10 for Supported with an internal network adapter INA A graphic appears showing e The message Encrypting Diskor Formatting Disk e A percentage scale e The message DO NOT POWER OFF The process is complete when the percentage scale displays 100 Duplex Gloss Generates higher quality duplex copies than when using the normal duplex mode The major difference between normal duplex and duplex gloss mode is the number of sheets in the duplex print media path N
210. rt running the width of the media For 60 to 90 g m 16 to 24 Ib bond media use grain long fibers Fiber content Most high quality xerographic media is made from 100 chemically treated pulped wood This content provides the media with a high degree of stability resulting in fewer media feeding problems and better print quality Media containing fibers such as cotton possesses characteristics that can negatively affect media handling 1 6 Service Manual 5022 xxx Unacceptable media The following media types are not recommended for use with the printer e Chemically treated media used to make copies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon required NCR paper e Preprinted media with chemicals that may contaminate the printer e Preprinted media that can be affected by the temperature in the printer fuser e Preprinted media that requires a registration the precise print location on the page greater than 2 3 mm 0 09 in such as optical character recognition OCR forms In some cases registration can be adjusted with a program to successfully print on these forms e Coated media erasable bond synthetic media thermal media e Rough edged rough or heavily textured surface media or curled media e Recycled media containing more than 25 post consumer waste that does not meet DIN19 309 e Media weighing less than 60 g m 16 Ib e Multiple part forms or documents Selec
211. rt shield removal on page 4 81 6 Remove the fuser cable cover See Fuser cable cover removal on page 4 61 4 74 Service Manual 5022 xxx T Remove the three mounting screws C from the front of the printhead Warning Secure the printhead when removing the printhead alignment screw Failure to do this allows the printhead to fall out of the printer potentially damaging the printhead 8 Close the top access cover and remove the printhead alignment screw D and remove the printhead Repair information 4 75 5022 xxx Installation notes Do not install the printhead mounting screws in the rear of the printer When reinstalling the printhead it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer This allows the pages to be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw Once the black skew is adjusted the mounting screws will be fully tightened 1 When installing the printhead do a rough alignment by visually centering the hole in the frame C with the slot on the bottom of the printhead Do not fully tighten printhead mounting screws until skew has been adjusted 2 Align the printhead See Printhead alignment on page 4 3 4 76 Service Manual 5022 xxx Right bellcrank removal See Right bellcrank assembly on pag
212. s C For model C534 remove cables C and the USB cable D Models C52x Models C53x Model C534 shown B Repair information 4 23 5022 xxx Paper tray dust cover removal See Paper tray dust cover with dust cover spring C53x on page 7 3 for the part number Unplug the power cord from the printer Remove the exit tray See Exit tray cover removal on page 4 15 Remove the paper tray Place the printer on its back eee YT Remove the paper tray dust cover assembly i 6 na 7 ee T A B C D 8 Set the dust cover bracket aside to reuse with the new FRU 4 24 Service Manual Remove the four screws A The upper right screw can be accessed through a hole in the frame B 5022 xxx Rear cover removal See Rear cover on page 7 3 for the part number 1 Loosen the eight screws A Note Do not remove the screws 2 Lift up on the rear cover and slide to the right to remove from the back of the printer Repair information 4 25 5022 xxx Right cover removal See Right cover on page 7 3 for the part number Make sure the power cord is removed Place the printer on the table with the right side edge hanging over slightly Open the top access door Open the front access door Remove the three screws A Se B 6 Lift the bottom of the cover out and slide the right cover down to remove the cover 4 26 Service Manual 5022 xxx
213. s 5 13 5022 xxx Connector listing models C52x see System card network models C52x on page 5 11 or System card non network models C52x on page 5 12 continued Connector JHVPS1 Ground C DEVPWM Y DEVPWM Ground HV_EMPTY_C HV_EMPTY_Y HV _CHRG_PWM HV_XFER_PWM_C HV_XFER_PWM_M HV _XFER_PWM_Y CORE_CURR_SNSD HV_XFER_PWM_K VS_JINT 1 5V_SW Ground VS_INT 5V_PH 5 Vdc 5 Vdc LVPS ZERO_XING 24 V dc Ground Ground Ground LVPS_BRON MM_REF MM_LOCK MM_START Ground 24 V dc VS_JOPT 1 5V_SW S_OPT_ENC Ground 24VC OPT_PLEV V_24VD M DEVPWM K DEVPWM 5V_ SW HV_EMPTY_M HV_EMPTY_K TONER_CHK XFER_SERVO_C XFER_SERVO_M XFER_SERVO_Y HVPS_ID XFER_SERVO K 10 12 14 16 18 20 22 24 11 13 15 17 19 21 3 N JINT1 JLVPS1 5 V dc 5 V dc 24 V dc 24 V dc Ground Ground Ground LVPS_HRON 10 12 14 16 1 13 15 JMIRR1 JOPT1 2 OPTION PWM OPT_TYPE Ground OPT_PSIZE OPT_PCTL pD 10 5 14 Service Manual 5022 xxx Connector listing models C52x see System card network models C52x on page 5 11 or System card non network models C52x on page 5 12 continued Connector JOPP1 1 JPH1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2 28 29 3 I2C_DATA5 OP V_PANEL 5V lI2C_CLK_OP Ground I2CIRQ5_R 3 3 V dc Ground Ground D_VDO_M D_VDO_M Ground D_VDO_C D VDO C Ground PH_EMS1_SNS R
214. s continuity present Replace the fuser See Fuser removal on Problem solved Replace the system card page 4 60 See System card removal on page 4 79 Does the error clear 7 Check for continuity between the following pins Go to step 8 Replace the AC fuser cable of the AC autoconnect and the pins of the i connector that connects to the LVPS vl pin 1 ad LVPS connector AC autoconnect Is continuity present Diagnostic information 2 29 5022 xxx 120 03 Fuser error service check Check the input voltage switch on the back of Go to step 2 Set the switch for proper the the low voltage power supply LVPS country voltage Is the voltage level 115 230 properly set Turn the printer off and remove the rear cover Replace the fuser cable Go to step 3 Check the connector JFUSER1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Check the connector JLVPS1 for proper Replace the LVPS See Go to step 4 connection to the system card the cable for Low voltage power pinch points and the cable or connector for supply LVPS removal any other damage on page 4 65 Is the cable damaged Replace the fuser See Fuser removal on Problem solved Replace the system card page 4 60 See System card Does the error clear removal on page 4 79 Check the input voltage switch on the back of
215. sed to help correct print quality problems To restore EP Defaults 1 Select EP Defaults from EP SETUP 2 Select Restore to reset the values to the factory settings and select Do Not Restore to exit without changing the settings Fuser Temperature Fuser Temp This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media The fuser temperature can be adjusted to Low Normal High The default is Normal DC Charge Adjust Dev Bias Adj Transfer Adjust Each of these three settings enables you to adjust the high voltage levels controlling the electrophotographic process You will use these settings to compensate for unusual operating circumstances such as high humidity The printer uses the value of these settings together with other settings to calculate printing speed and media selection Diagnostic aids 3 17 5022 xxx Event Log Display Log The event log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered so there may be repetitions All 2xx and 9xx error messages are stored in the event log To view the event log 1 S
216. sembly Paper pick mechanism assembly C52x Paper pick mechanism assembly C53x Bump aligner roller and spring Parts catalog 7 5 5022 xxx Assembly 3 Right 7 6 Service Manual 5022 xxx Assembly 3 Right Units Units Description mach FRU p 40X1409 EP drive assembly C52x 40X3578 EP drive assembly C53x 40X3574 Low voltage power supply 115 230 V 40X1433 Bump aligner motor 40X1436 Front door 5 V interlock switch 40X1445 Ground contact plate C52x only Parts catalog 7 7 5022 xxx Assembly 4 Rear 7 8 Service Manual 5022 xxx Assembly 4 Rear Units Units nasenption mach FRU p 40X1417 Printhead assembly C52x 40X3589 40X4218 40X4219 40X4217 40X3575 40X3576 40X3577 40X1429 40X3597 40X1410 Printhead assembly C53x System card network C524n C524dn System card network C520n C522n System card C524 System card network C530dn C532n C532dn System card network C534n System card network C534dn System card support shield C52x System card support shield C53x ee ee a a ee ae 4 ee ee a a a ee 4 i 2 2 2 2 2 2 3 3 4 Smart chip card C52x only Parts catalog 7 9 5022 xxx Assembly 5 Left i i t p i i A g rl NN x a Z ai se J wP E rig t 3 t A n 3 a F s m see it rth pa a er a d A _ sh a a F Ae h sra a i a a Hb aai k ha e 4 t W ka Pw L x Sm i
217. ser straight up and away from the printer B Installation note If you install a new fuser be sure to reset the fuser counter in the Configuration Menu To reset the counter 1 2 3 4 Enter the Configuration Menu Turn off the printer press and hold and p turn on the printer and release the buttons when the clock graphic displays Press Y for the Reset value Resetting Fuser Count Value appears Press to select Motor Calibration from the CONFIG MENU Calibrating displays and the printer prints several blank pages and then returns to the CONFIG MENU Select Exit Config Menu See Page Counts on page 3 16 4 60 Service Manual 5022 xxx Fuser cable cover removal See Fuser cable cover included in parts packet P N 40X1430 C52x on page 7 5 or Fuser cable cover included in parts packet P N 40X3598 C53x on page 7 5 for the part number a Open the top access door Open the front access door Remove the yellow and cyan toner cartridges Pull the locking tab A down on the left side of the cable cover B slide the cable to left lower and remove Repair information 4 61 5022 xxx High voltage power supply HVPS removal See High voltage power supply C52x on page 7 11 or High voltage power supply C53x on page 7 11 for the part number 1 Remove the left cover See Operator panel outer bezel removal on page 4 21 2 Remove the six mounting screws A
218. sh drive to send data to the printer Numeric keypad Model C534 only Consists of the numbers 0 9 a backspace button and a pound button O O 0o00 Diagnostic information 2 3 5022 xxx Menus Note Some menu items may not be available based on the printer model or the options installed Supplies Menu Replace Supply Cyan Cartridge Magenta Cartridge Yellow Cartridge Black Cartridge Cyan PC Unit Magenta PC Unit Yellow PC Unit Black PC Unit Waste Toner Box Fuser Transfer Belt Security Max Invalid PIN Job Expiration 2 4 Service Manual Paper Menu Default Source Paper Size Type Configure MP Substitute Size Paper Texture Paper Weight Paper Loading Custom Types Universal Setup Network Ports TCP IP IPv6 Wireless Standard Network Network lt x gt Standard USB USB lt x gt NetWare Apple Talk LexLink IICD Mirant Reports Menu Settings Page Device Statistics Network Setup Page Network lt x gt Setup Page Wireless lt x gt Setup Page Profiles List NetWare Setup Page Print Fonts Print Demo Help Color Quality Print Quality Printing Guide Supplies Guide Media Guide Print Defects Menu Map Information Guide Connection Guide Moving Guide Settings Setup Menu Finishing Menu Quality Menu Utilities Menu PDF Menu PostScript Menu PCL Emul Menu HTML Menu Image Menu 5022 xxx Power on self test POST sequence When you turn the printer on it performs a
219. solved Replace the system card supply HVPS removal on page 4 62 See System card removal on page 4 79 Does the error clear Diagnostic information 2 49 5022 xxx 950 00 950 29 EPROM mismatch failure Warning When replacing any one of the following components e Operator panel assembly e System card e Printhead assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer This error code indicates a mismatch between the operator panel assembly and the system card Has the operator panel assembly been Replace the operator panel Replace the system card recently replaced assembly with a new and with a new and not not previously installed previously installed system operator panel assembly card See System card See Operator panel removal on page 4 79 assembly removal on page 4 23 950 30 950 60 EPROM mismatch failure Warning When replacing any one of the following components e Operator panel assembly e System card e Printhead assembly Only replace one component at a time Replace the required co
220. sted 2 Align the printhead See Printhead alignment on page 4 3 4 76 Service Manual 5022 xxx Right bellcrank removal See Right bellcrank assembly on page 7 5 for the part number 1 Open the front access cover 2 Remove the gearbox switch shield See Gearbox shield removal on page 4 19 3 Remove the C clip A 4 Remove the right bellcrank Repair information 4 77 5022 xxx Smart chip card removal models C52x only See Smart chip card C52x only on page 7 9 for the part number Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the system card support shield See System card support shield removal on page 4 81 2 From the outside right of the printer disconnect the five connectors A 3 Remove the two mounting screws B and remove the smart chip card Pe e da ry ed 4 78 Service Manual 5022 xxx System card removal See the system card part number for the model you need on page 7 9 Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or print
221. stions actions Read the current status of the photoconductor Reset the value To reset Go to step 2 unit from the customer menus this value To view the status of the photoconductor units In Ready mode press 1 ln Ready mode press e 2 Select Reports and press 3 Select Device Statistics and press Select Supplies Menu and press l i Select Replace Supply Ask the customer if the photoconductor unit and press has been recently replaced It is possible the photoconductor value was not reset and the photoconductor unit is past end of life If the E onanger ang PC unit was recently replaced reset the value If the PC unit was not replaced replace the PC a Yes and press unit Select the PC color unit If this does not fix the Has the photoconductor unit been recently problem go to step 2 replaced Diagnostic information 2 55 5022 xxx Replace the PC unit See Photoconductor Problem solved Go to step 3 unit removal on page 4 70 Does this fix the problem Check the high voltage contact from the HVPS Replace the spring or the Go to step 4 to the transfer belt assembly transfer contact assembly See Transfer contact Transfer belt high voltage assembly removal on path typical 4X page 4 92 l Is a problem found Reseat the JHVPS connector Problem solved Go to step 5 Does this fix the problem Replace the HVPS See High voltage power Problem sol
222. switch for proper the low voltage power supply LVPS country voltage Is the voltage level 115 230 properly set Remove the fuser and check the camshaft Go to step 3 Press the camshaft follower follower on the right side If the camshaft into the groove follower A is above the crescent shaped groove it needs to be pressed down into the proper location Is the camshaft follower on the right side properly placed in the groove Turn the printer off and remove the rear cover Replace the fuser cable Go to step 4 Check the connector JFUSER1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Check the connector JLVPS1 for proper Replace the LVPS cable Go to step 5 connection to the system card the cable for See Low voltage power pinch points and the cable or connector for supply LVPS removal any other damage on page 4 65 Is the cable damaged Remove the fuser See Fuser removal on Replace the appropriate Go to step 6 page 4 60 Check the AC and DC cable autoconnects on both the fuser and the printer for damage Are the connectors damaged 2 28 Service Manual 5022 xxx Check for the following continuity between the Go to step 7 Replace the DC fuser cable DC autoconnect and FUSER1 I mal 3 517 9 rag 2 141618 10 configuration DC autoconnect JFUSER1 DC autoconnect JFUSER1 I
223. t R Fine Adjustment 54 Coarse 300 0 300 240 42 30 0 T New Cyan R value Note Start each color group by setting the Top Margin Left Margin Right Margin Bottom Margin Skew and Bow to zero 4 12 Service Manual 5022 xxx Printer removal procedures Precautions to take before maintenance work Do not implement any operation removal or modification and so on which is not presented in this manual 1 Turn the printer power off and unplug the power cable from the outlet prior to starting AN removals or checks 2 Prior to starting any repairs read and understand the warnings in this manual e High temperature e High voltage e Laser radiation Confirm the direction of all parts and screw lengths during removal replacement Utilize the proper cleaning procedures solvents during maintenance Confirm that all parts and covers are properly installed and assembled prior to starting the print test ae Repair information 4 13 5022 xxx Cover removals Outer bezel C52X Bezel C53X Inner bezel C52X Operator Panel C52X Exit tray cover Rear cover Top access cover assembly Front access cover Paper tray dust cover with spring 4 14 Service Manual 5022 xxx Exit tray cover removal See Exit tray cover C52x on page 7 3 for the part number Grasp the exit tray and lift away from printer Repair information 4 15 5022 xxx
224. t Cartridges 40 C to 40 C 104 Fahrenheit Air Relative Humidity Relative Humidity 8 to 80 Altitude 10 300 meters 34 000 feet Web Bulb Temperature Product Power Off 26 7 C 80 1 F Maximum T In some cases performance specifications such as paper OCF EP cartridge usage are specified to be measured at an ambient condition Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296 1 Meter Average Declared Sound Operating mode Bystander Sound Power Level 4800 Pressure 4800 CQ CQ C524dn C524dtn 52 dBA mwe o fea C520n C522n C524n C532n C534n Color printing 51 dBA Color printing 51 dBA C530dn C534dn C534dtn Duplex printing 53 dBA 1 4 Service Manual 5022 xxx Dimensions Basic printer with no C520 C522n C524 C524n 19 in 17 3 in 16 1 in 57 5 Ib extensions C524dn 484 mm 440 mm 408 mm 26 1 kg C532n C534n 19 in 17 3 in 16 1 in 57 0 Ib 484 mm 440 mm 408 mm 25 9 kg C530dn C532dn C534dn 19 in 17 3 in 16 1 in 58 8 Ib 484 mm 440 mm 408 mm 26 7 kg Printer with exit tray C520 C522n C524 C524n 19 in 17 3 in 20 2 in 57 5 Ib extended 484 mm 440 mm 512 mm 26 1 kg C532n C534n 19 in 17 3 in 20 2 in 57 0 Ib 484 mm 440 mm 512 mm 25 9 kg C530dn C524dn C534dn 19 in 17 3 in 20 2 in 58 8 Ib 484 mm 440 mm 512 mm 26 7 kg Printer duplex unit C524dtn 24 in 17 3 in 22 in 64 8 Ib 500 sheet assembly
225. t See Quick Test duplex on page 3 12 Print Test See Print Test duplex on page 3 13 Top Margin See Top Margin duplex on page 3 14 Motor Test See Motor Test duplex on page 3 14 INPUT TRAY TESTS if Tray 2 is installed Tray 2 See Input Tray Tests on page 3 14 BASE SENSOR TEST Bin Full Test See Bin Full Test on page 3 15 Sensor Test See Sensor Test on page 3 15 PRINTER SETUP Defaults see Defaults on page 3 16 PAGE COUNTS This menu contains three submenus Prt Color Pg Count Mono Pg Count and Perm Page Count See Page Counts on page 3 16 Serial Number See Serial Number on page 3 16 Engine Setting 1 through 4 See Engine Setting 1 through 4 on page 3 16 Model Name See Model Name on page 3 16 Configuration ID See Configuration ID on page 3 16 EP Defaults See EP Defaults on page 3 17 Fuser Temp See Fuser Temperature Fuser Temp on page 3 17 DC Charge Adjust Dev Bias Adj Transfer Adjust EVENT LOG Display Log See Display Log on page 3 18 See DC Charge Adjust Dev Bias Adj Transfer Adjust on page 3 17 Print Log see Print Log on page 3 18 Clear Log see Clear Log on page 3 19 EXIT DIAGNOSTICS This selection exits Diagnostics mode and Resetting the Printer displays The printer performs a POR and returns to normal mode Diagnostic aids 3 3 5022 xxx Registration Print
226. t during printing Duplex motor Drive shafts Bottom view Belt of motor and gear Diagnostic aids 3 41 5022 xxx Paper sensing Sensors are strategically placed in the printer to ensure that the print media is making it to specific points within a given time in the electrophotographic process There are two paper flags one at the bottom of the machine paper pick to detect input paper including duplex second side from all sources and one at the top paper exit to detect paper movement beyond the fuser The flags are similar in design in that a mechanical arm is moved by the media to interrupt an optical sensor both are normally blocked when no media is present There is also a multifunction transparency sensor that detects if 1 tray 1 is present 2 narrow media is being used and 3 the media is a transparency The sensor works for tray 1 tray 2 500 sheet option and the MPF Paper pick sensor Paper pick mechanism Multifunction transparency sensor Input sensor 3 42 Service Manual 5022 xxx Paper exit duplex entry sensor and bin full flag The top sensor detects movement in two directions as the paper exits the fuser and as it is retracted from the exit tray back into the duplex path Each sheet must be driven past the fuser exit flag and allowed to fall before being turned around and starting the duplex path If the print media activates the paper exit flag for too long or the print media doesn t reach t
227. t is difficult to press both locking tabs at the same time Using a spring hook press the locking tab A and disengage the sensor on that side Press the other locking tab B and remove the sensor 4 84 Service Manual 5022 xxx Top access door 24 V interlock switch removal See Top access door 24 V interlock switch on page 7 13 for the part number 1 Remove the top access cover assembly See Top access cover assembly removal model C52x only on page 4 28 2 Disconnect the JCVR1 connector A from the system card 3 Remove the right cover See Right cover removal on page 4 26 4 Remove the mounting screw B and 24 V interlock switch C Repair information 4 85 5022 xxx Top cover camshaft assembly removal See Top cover camshaft assembly on page 7 13 for the part number 1 90 eo A PD Remove the top access door 24 V interlock switch See Top access door 24 V interlock switch removal on page 4 85 Remove the left cover See Operator panel outer bezel removal on page 4 21 Rotate the lever arm A all the way up as if the top access door were open hold the lever arm A in place and rotate the camshafts B down to the closed position While still holding the lever arm A up remove the left front mounting screw C and flip the right lock D back Continue to hold the lever arm A up and remove the right front mounting screw E release the lever ar
228. t tray cover removal See Exit tray cover C52x on page 7 3 for the part number Grasp the exit tray and lift away from printer Repair information 4 15 5022 xxx Front access door cover assembly removal See Front access door cover assembly for the part number for the models you need on page 7 3 Remove the paper tray Remove the right cover See Right cover removal on page 4 26 Disconnect the transfer belt cable A Press the two tabs B on either side of the transfer belt assembly and lift out the transfer belt assembly Note Leave the photoconductor units on the transport belt when removing m ade a Warning To avoid damaging the photoconductor drum hold the photoconductor units by their handle and place the photoconductor units on a clean surface Never expose the photoconductor units to light for a prolonged period of time See Handing the photoconductor unit on page 4 2 for additional information Model C52x Model C53x 4 16 Service Manual 5022 xxx 5 Looking down at the keyed end of the restraint C twist the end clockwise slide the restraint upward through the slit D and slip the end of the restraint through the keyed hole E Repeat for the other side ol 6 Close the front access door Repair information 4 17 5022 xxx T Remove the four screws F that attach the pivot pin to the front access door cover 8 Remove the front access cover assembly 4 18 Serv
229. t triggers the paper exit sensor it serves as a one way gate for the media when it is exiting the printer to the output bin and also serves as a one way gate when the media is entering back into the printer for a duplex print In other words it diverts the print media s path directing it to either the output bin or the duplex paper path 3 36 Service Manual 5022 xxx Mechanical drive In order for the print media to move through the paper path there are several drive motors that supply the mechanical power to the rollers discussed previously The drives for these components are illustrated and discussed in the following paragraphs Paper pick mechanism drive When printing from Tray 1 or Tray 2 the paper pick motor drives the paper pick gears which causes the pick roller to turn During an MPF print the paper pick motor drives the swing arm assembly for the MPF and causes the MPF paper pick roller to turn MPF paper pick Swing arm bracket C52x MPF swing arm assembly Paper pick mechanism gears Paper pick motor Paper tray and paper pick mechanism shown from rear with components removed for clarity Paper pick mechanism Diagnostic aids 3 37 5022 xxx Bump aligner drive The power to turn the bump aligner roll is supplied from the bump aligner motor The motor drives a set of bump aligner gears which causes the bump aligner roll to turn Bump aligner roll Bump aligner gears Bump aligner gears Bu
230. t was just replaced and then press lt color gt PC Unit Replaced displays Press to select Yes 4 70 Service Manual 5022 xxx Pick roll rubber tires removal and replacement See Pick arm roll on page 7 15 for the part number The autocompensator pick roll tires are located in the base printer There are also tires in all input options If you have additional input options and you are having problems with media picking replace these tires also Always replace the pick tires in pairs The tires come in a package of two Warning Remove only the rubber tires and not the pick tire assembly to avoid losing small parts 1 Remove the paper tray 2 Pull the autocompensator pick arm A down Repair information 4 71 5022 xxx 3 Remove the rubber tire B from the pick roll assembly C Repeat for the other pick roll assembly ome B C B Installation notes Install the new rubber tires with the surface texture D turning in the direction as shown Note Feel the rubber surface to verify it turns properly in the direction shown 4 72 Service Manual 5022 xxx Printer pad removal See Printer pad included in parts packet screws P N 40X1431 on page 7 5 for the part number 1 Slide the corner of the printer containing the damaged pad over the corner of the table 2 Pull the pad A from the bottom of the printer Installation Note When installing the new pad remove the
231. talog 7 6 removal C52x 4 48 removal C53x 4 51 electrophotographic EP process 3 44 charging 3 46 cleaning 3 53 developing 3 50 exposing 3 49 fusing 3 52 main components 3 44 transferring 3 51 Energy Conserve 3 23 Enforce Color Order 3 24 engine setting 3 16 Env Prompts 3 25 envelopes 1 8 error codes and messages 1xx service error codes 2 7 2 8 9xx service error codes 2 15 2 18 error codes and messages2xx paper jams 2 8 2 15 error codes and messages3x 8x attendance messages 2 19 2 26 ESD sensitive parts 4 1 event log configuration menu 3 23 diagnostics mode 3 18 exit sensor service check 2 52 F Factory Defaults 3 22 Font Sharpening 3 26 front door assembly front cable removal 4 59 parts catalog 7 4 removal 4 55 fuser locations 5 7 motor test 3 8 parts catalog 7 14 removal 4 60 Reset Fuser Cnt 3 21 Fuser Motor Test 3 8 H high voltage power supply HVPS locations 5 5 parts catalog 7 10 removal 4 62 how to use this parts catalog 7 1 J jams common messages diagram 3 27 paper jam messages 2 8 paper path 3 30 Jobs on Disk 3 25 L labels 1 9 locations cards 5 10 covers 5 1 CRUs and FRUs 5 7 front 5 2 left 5 5 machine type label 1 13 motors 5 9 printer cards 5 10 rear 5 4 right 5 3 sensors 5 8 serial number label 1 13 top 5 6 low voltage power supply LVPS locations 5 3 parts catalog 7 6 removal 4 65 machine type tag location 1 13 maintenance approach 1 1 mechanical drive bum
232. ted the printer lets users place each toner cartridge in only its specified slot For instance the Magenta toner cartridge must be in the Magenta slot If the user tries to place a cartridge in an incorrect slot the printer message 31 Defective or Missing color Cartridge or32 Unsupported color Cartridge appears where colo stands for Cyan Magenta Yellow or Black When Off is selected the printer does not issue any message to let the user know that the cartridge is placed in the wrong slot inside the printer Color Alignment Prints the Print Alignment Page and requires that the best line in each set of lines must be selected Press Select to begin printing Consulting the printed page follow the instructions on the operator panel to choose the best appearing line numbered 0 through 20 for the following sets of lines These includes Set A Set B and so forth through Set L For each of the sets listed the sub value is 0 20 10 is the default Motor Calibration Allows for speed calibration after resetting the fuser maintenance counter To calibrate the motors Press to select Motor Calibration from the CONFIG MENU Calibrating displays and the printer prints several blank pages and then returns to the CONFIG MENU Paper Prompts Controls the source the printer selects for a change paper source message The printer displays the change paper source message based on the size of the paper requested and not by the paper type
233. ter If the error message persists see 120 01 120 02 120 08 120 10 120 13 120 15 Fuser error service check on page 2 28 POR the printer If the error message persists see 140 xx Autocomp tray 1 motor error service check on page 2 32 POR the printer If the error message persists see 142 xx and 906 01 906 04 Motor fuser error service check on page 2 33 POR the printer If the error message persists see 143 xx Motor EP drive assembly top cartridge error service check on page 2 34 POR the printer If the error message persists see 144 xx Motor EP drive assembly bottom cartridge error service check on page 2 35 POR the printer If the error message persists see 145 xx and 906 05 906 08 Motor bump aligner error service check on page 2 36 Diagnostic information 2 7 5022 xxx Service error codes and paper jam messages continued moe Omen a 146 01 146 08 Motor Error 147 01 147 08 Motor Error 148 01 148 08 Motor Error 149 01 149 08 Motor Error 2xx paper jam messages 200 01 200 11 200 16 200 21 2 8 Service Manual Duplex motor has failed Tray 2 motor has failed MPF motor has failed Tray 2 motor has failed Input sensor is made when printer tries to print from an idle state Possible causes e Paper jam leaving page over sensor e Defective input sensor e Faulty system card Input sensor do
234. test error service check Turn the printer off and remove the rear cover Replace the damaged Go to step 2 Check the connector JTRANS2 model C52x cable or JTRANS1 model C53x for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Replace the EP drive assembly See Problem solved Replace the system card Electrophotographic EP drive assembly See System card removal model C52x only on page 4 48 removal on page 4 79 Does the error clear 2 38 Service Manual 5022 xxx 920 04 POST power on self test error service check Turn the printer off and remove the rear cover Replace the fuser cable Go to step 2 Check the connector JFUSER1 for proper connection to the system card the cable for pinch points and the cable or connector for any other damage Is the cable damaged Remove the fuser See Fuser removal on Replace the DC Go to step 3 page 4 60 Check the DC autoconnects on autoconnect cable both the fuser and the printer for damage Are the connectors damaged Check for the following continuity between the Go to step 4 Replace the DC fuser cable DC autoconnect and FUSER1 mel 3 5 7 9 rag 2141618 10 configuration DC autoconnect JFUSER1 Is continuity present Replace the fuser See Fuser removal on Problem solved Replace the system card See System card remo
235. the outer bezel insert the bottom of the bezel first ensuring that the outer bezel bottom portion fully seats Repair information 4 21 5022 xxx Operator panel inner bezel removal models C52x only See the part number for the inner bezel for the model you need on page 7 3 1 Remove the outer bezel See Operator panel outer bezel removal on page 4 21 2 Press the top of the inner bezel to release the inner bezel A from the outer bezel 3 Gently twist to free the lower tabs B 4 22 Service Manual 5022 xxx Operator panel assembly removal See Operator panel assembly C52x on page 7 3 for the part number See the same page for the individual part numbers for the C53x models Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the outer bezel See Operator panel outer bezel removal on page 4 21 2 Remove the screw A 5 A 3 Disengage the upper locking tabs B 4 Disconnect the cables C For model C534 remove cables C and the USB cable D Models C52x Models C53x Model C534 shown B Repair information 4 23 5022 xxx Paper tray dust cover remo
236. ther damage Is the cable damaged 3 Disconnect JHVPS1 from the system card and the HVPS Check for the following continuity JHVPS1 cable HVPS end System card end Is continuity present Replace the top access cover assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Go to step 2 Go to step 3 Replace the top access cover assembly See Top access cover assembly removal model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Replace the damaged sensor See Toner level sensor removal on page 4 83 Go to step 4 Diagnostic information 2 41 5022 xxx Reconnect JHVPS1 cable to the system card Replace the toner level Go to step 5 and the HVPS Do not reinstall the left cover sensor that has 5 V dc on but make sure the front access door and the pin 1 See Toner level top cover assembly are closed and that the sensor removal on waste toner assembly is reinstalled Turn the page 4 83 printer on Attach the negative end of the voltmeter to the ground and check the voltage on pin 1 of each toner level sensor cable You will need to check this on the back of the HVPS see the illustration below Pin1 typical Negative lead Waste toner 4X assembly Is there approximately 5 V dc on any of the pins Replace the HVPS Se
237. ting media Using appropriate media prevents jams and helps ensure trouble free printing To help avoid jams and poor print quality e Always use new undamaged media e Before loading media know the recommended print side of the media This information is usually indicated on the media package e Do not use media that has been cut or trimmed by hand e Do not mix media sizes types or weights in the same source mixing results in jams e Do not use coated media unless they are specifically designed for electrophotographic printing Selecting preprinted forms and letterhead Use these guidelines when selecting preprinted forms and letterhead e Use grain long papers for best results for 60 to 90 g m weights e Use only forms and letterhead printed using an offset lithographic or engraved printing process e Avoid papers with rough or heavily textured surfaces Use papers printed with heat resistant inks designed for use in xerographic copiers The ink must be able to withstand temperatures up to 180 C 856 F without melting or releasing hazardous emissions Use inks that are not affected by the resin in toner Inks that are oxidation set or oil based generally meet these requirements latex inks might not When in doubt contact the paper supplier Preprinted papers such as letterhead must be able to withstand temperatures up to 180 C 356 F without melting or releasing hazardous emissions General information 1 7 5022 xxx
238. tings Page Count XX Top Margin x PSAC XX Bottom Margin x Installed Memory xxx MB Left Margin x Processor Speed xxxMHZz Right Margin x Serial Number XXXXXXX Skew x CalStat XXXX Cyan Top Margin x CalSet X XX X XX X XX Cyan Left Margin XX X XX X XX Cyan Right Margin x Engine ID XX Cyan Skew X FSpeed XXX Cyan Bow x Printer Revision Levels Yellow Top Margin x Loader XX XX XXXX X Yellow Left Margin x Kernel XXX XX XXXX X Yellow Right Margin x Base XX XX XXXX X Yellow Skew X Network XXX XX XXXXX X Yellow Bow X Network Drvr XX XX XXXX X Magenta Top Margin Engine XX XX XXXX X o ee Font X XXXXX XX X agenta Rig argin H 1 Magen Skew ae Right margin magenta Bow x Dup Top Margin x alignment Paper Source marks Formatted Size Bottom margin alignment marks Repair information 4 5 5022 xxx 9 Adjust the screw to adjust the skew and straighten the image on the paper If the top right alignment marks are lower than the top left alignment marks rotate the alignment screw counterclockwise a full revolution and print the Quick Test page Repeat adjusting the screw and printing the Quick Test until the top alignment marks are the same distance from the top of the media Note One rotation of the printhead alignment screw equals approximately 0 5 millimeter movement of the top edge print alignment marks Straight Skewed s o ed n 10 When the top right and top left alignment marks are both showing and are even
239. umber for the Front door parts packet for the model you need on page 7 5 Removal procedures are for either the left or the right front door assembly restraint cables Right restraint cable 1 PR Remove the front access cover assembly See Front access door cover assembly removal on page 4 16 Release the cable spring A from the front door assembly Remove the gearbox switch shield B See Gearbox shield removal on page 4 19 Remove the end of the cable C from the frame Left restraint cable 1 Remove the front access cover assembly See Front access door cover assembly removal on page 4 16 Close the top access door Release the cable spring D from the front door assembly Note In order to access the springs make sure the top access cover is closed Remove the end of the cable E from the frame i Installation note The shortest cable installs on the right side of the printer Repair information 4 59 5022 xxx Fuser removal See Fuser assembly 115 V on page 7 15 Fuser assembly 230 V on page 7 15 or Fuser assembly 100 V on page 7 15 for the part number CAUTION The fuser can be extremely hot Use care when handling to avoid burns AN Turn off the printer Open the top access door Rotate the fuser thumbscrews A counterclockwise until loosened Grasp the handles B lift the fu
240. umn indicates that the part is procurable but is not pictured in the illustration Model information used in the parts catalog Lexmark C534dn dtn Duplex network 550 sheet tray Parts catalog 7 1 5022 xxx Covers Assembly 1 7 2 Service Manual Assembly 1 Covers 5022 xxx Units Units Description mach FRU p 2 2 2 3 4 4 4 5 6 6 7 8 8 8 8 9 40X1415 40X1448 40X1449 40X1450 40X1414 40X3608 40X3585 40X3586 40X3582 40X3587 40X3588 40X3583 40X1451 40X1412 40X3604 40X3605 40X1422 40X3594 40X1427 40X3612 40X1425 40X1443 40X1413 40X3602 40X3581 40X1426 40X1440 40X3601 ee A A A MA MA A A ee ae ae Se a A A A A M Outer bezel C52x Inner bezel C524 C524n C524dn Inner bezel C522n Inner bezel C520n Operator panel assembly C52x Bezel C530dn Bezel C532n Bezel C532dn Operator panel assembly C530dn C532n C532dn Bezel C534n Bezel C534dn Operator panel assembly C534n C534dn Top access cover assembly network C520n C522n C524n C524dn Top access cover assembly non network C524 Top access cover assembly network C532n C534n Duplex top access assembly network C530dn C532dn C534dn Exit tray cover C52x Exit tray cover C53x Rear cover Paper tray dust cover with dust cover spring C53x Right cover Front access door cover assembly duplex C524dn only Front access door cover assembly
241. use the fine adjustment 6 8 T Enter the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the T value The current value is automatically entered on the sheet At this point it should be zero Current New Cyan Cyan T value T value 8 Enter the New Cyan T value on the operator panel using the right and left arrows and press Select to save the value 9 Reprint the Quick Test and evaluate whether you are at zero changes 4 10 Service Manual 5022 xxx 10 Repeat this process for skew Z Don t forget to add the T value and the current cyan Z value to obtain the new skew Z value An example is shown below Current New Current New Cyan Cyan Cyan Cyan T value T value Z value Z value STEP 1 Adjust the Top T margin and Skew Z then confirm before going to Step 2 Repair information 4 11 5022 xxx 11 Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin T the Skew Z and on the second page of the Quick Test page the Left Margin L Right Margin R and Bow P Left L Fine Adjustment 60 54 Left L Coarse tH 42 36 L 0 Current Cyan L value 12 48 Adjustment Cyan Alignment Step 2 Bow P Coarse Adjustment AERE 80 60 40 20 0 20 40 60 80 Bow P Fine Adjustment 20 N A 0O 0 i mi mi m md Onego LN I New Current Cyan
242. uter bezel with the inner bezel B attached For models C53x Remove the bezel The bezel is one piece for this set of models Installation note When reinstalling or replacing the outer bezel insert the bottom of the bezel first ensuring that the outer bezel bottom portion fully seats Repair information 4 21 5022 xxx Operator panel inner bezel removal models C52x only See the part number for the inner bezel for the model you need on page 7 3 1 Remove the outer bezel See Operator panel outer bezel removal on page 4 21 2 Press the top of the inner bezel to release the inner bezel A from the outer bezel 3 Gently twist to free the lower tabs B 4 22 Service Manual 5022 xxx Operator panel assembly removal See Operator panel assembly C52x on page 7 3 for the part number See the same page for the individual part numbers for the C53x models Warning When replacing any one of the following components e Operator panel assembly e System card e Smart chip card C52x or printhead assembly C53x Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove the outer bezel See Operator panel outer bezel removal on page 4 21 2 Remove the screw A 5 A 3 Disengage the upper locking tabs B 4 Disconnect the cable
243. val See Paper tray dust cover with dust cover spring C53x on page 7 3 for the part number Unplug the power cord from the printer Remove the exit tray See Exit tray cover removal on page 4 15 Remove the paper tray Place the printer on its back eee YT Remove the paper tray dust cover assembly i 6 na 7 ee T A B C D 8 Set the dust cover bracket aside to reuse with the new FRU 4 24 Service Manual Remove the four screws A The upper right screw can be accessed through a hole in the frame B 5022 xxx Rear cover removal See Rear cover on page 7 3 for the part number 1 Loosen the eight screws A Note Do not remove the screws 2 Lift up on the rear cover and slide to the right to remove from the back of the printer Repair information 4 25 5022 xxx Right cover removal See Right cover on page 7 3 for the part number Make sure the power cord is removed Place the printer on the table with the right side edge hanging over slightly Open the top access door Open the front access door Remove the three screws A Se B 6 Lift the bottom of the cover out and slide the right cover down to remove the cover 4 26 Service Manual 5022 xxx Installation note Be sure the tab B is fully engaged Repair information 4 27 5022 xxx Top access cover assembly removal model C52x only See Top access cover
244. val on page 4 79 Does the error clear Replace the printhead card See Printhead Problem solved Replace the system card removal on page 4 74 See System card Does the error clear removal on page 4 79 Diagnostic information 2 39 5022 xxx 920 06 POST power on self test error service check Replace the paper pick mechanism See Problem solved Replace the system card Paper pick mechanism assembly removal See System card on page 4 68 removal on page 4 79 Does the error clear 920 07 POST power on self test error service check Turn the printer off and remove the rear cover Replace the paper pick Go to step 2 Check the connector JTRAY1 for proper mechanism See Paper connection to the system card the cable for pick mechanism assembly pinch points and the cable or connector for removal on page 4 68 any other damage Is the cable damaged Check the transparency sensor for correct Go to step 3 Remove the paper pick mounting mechanism properly install the transparency sensor and reinstall the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Is the transparency sensor properly mounted in the paper pick mechanism Replace the paper pick mechanism See Problem solved Replace the system card Paper pick mechanism assembly removal See System card on page 4 68 removal on page 4 79 Does the error clear Turn th
245. ved Go to step 6 supply HVPS removal on page 4 62 Does this fix the problem Clean the printhead Problem solved Replace the printhead See Printhead removal on Does this fix the problem page 4 74 Print quality blank page Is all the packing material for the Go to step 2 Remove the packing photoconductor unit in question removed material Replace the photoconducior unit for the color Problem solved Go to step 3 in question Does this fix the problem Enter the Diagnostics mode turn off the Go to step 5 Replace the EP drive printer press and hold W and p turn on the assembly See printer and release the buttons when the clock Electrophotographic EP graphic displays and run the appropriate drive assembly removal cartridge drive motor test for the missing color model C52x only on See General motor tests on page 3 8 page 4 48 or Electrophotographic EP drive assembly removal model C53x only on page 4 51 Did the motor run 2 56 Service Manual 5022 xxx Check the high voltage contact from the HVPS Replace the transfer contact Go to step 6 to the photoconductor charge roll Ensure the assembly See Transfer contact springs are properly mounted and that contact assembly the charge roll contact spring is making good removal on page 4 92 contact with the HVPS spring that runs through the left printer frame See Transfer contact assembly removal on pag
246. w voltage power supply LVPS removal on page 4 65 Remove the system card See System card removal on page 4 79 Remove the five mounting screws A from the outer left side of the printer Note Make a note of the attachment of the printhead ground cable B to the second screw from the bottom for later installation Remove the four screws C from the inner right side of the support shield Pull the cables through the access holes on the right side of the printer For network printers Remove the two screws D attaching the parallel connector support plate For non network printers Remove the INA mounting plate screw E and the INA mounting plate f hian 2 7 bas r ag Repair information 4 81 5022 xxx 9 Remove the four mounting screws D from the top and bottom of the support shield Note Only the printhead cables come through the access holes in the system card support shield 10 Lower and remove the support shield Be careful not to damage the cables that route through the top frame of the printer 4 82 Service Manual 5022 xxx Toner level sensor removal See Toner level sensor on page 7 11 for the part number Note the locations of the toner sensors Yellow Cyan Magenta Black 1 Remove the HVPS See High voltage power supply HVPS removal on page 4 62 2 For yellow and cyan only Remove the transfer contact assembly See Transfer contact assembly remova
247. when using non standard media sizes J Manual Feed Slot J Media weight O w o o S Primary tray and 500 sheet optional tray 16 to 47 Ib 60 to 177 g m Letter Legal A4 Xerographic Long Grain Short Grain 24 to 58 Ib 90 to 218 g m Recycled Long Grain 20 to 471b 75 to 177 g m Short Grain 28 to 58 Ib 105 to 218g m Card Stock Cover 50 b 65 Ib long and short 135 g m 176 g m Index 67 b 90 Ib 120 g m 163 g m Tag 74 b 100 Ib 120 g m 163 g m Transparency 0 12 to 0 14 161 to 179 g m mm 4 8 to 5 4 mil A5 B5 JIS B5 Exec Xerographic Long Grain 20 to 47 Ib 75 to 177 g m Foli B Seer ale enone Short Grain 24 to 58 Ib 90 to 218 g m Multipurpose feeder and manual feed slot Letter Legal A4 Xerographic Long Grain 20 to 47 Ib 75 to 177 g m and Bonds 5 Short Grain 24 to 58 Ib 90 to 218 g m Recycled Long Grain 20 to 47 Ib 75 to 177 g m Short Grain 28 to 58 Ib 105 to 218 g m Card Stock Cover 50 Ib 65 Ib long short 135 g m 176 g m Index 67 b 90 Ib 120 g m 163 g m Tag 74 b 100 Ib 120 g m 163 g m Labels max Paper 35 Ib 131 g m Vinyl Not Supported Letter Legal A4 Transparency Thickness 0 12 161 to 179 g m continued to 0 13 mm General information 1 11 SS SNr 5022 xxx Media weight O e o o o Y A5 B5 JIS B5 Exec Xerographic 20 to 47 Ib 75 to 177 g m Envelope 16 to 28 Ib 60 to 105 g m C5 C6
248. y from the transfer contact assembly during removal a ade ea Installation note For ease of installation put the transfer contact assembly on before installing the springs 5 4 92 Service Manual 5022 xxx Waste toner assembly removal Not a FRU 1 Press release latch A 2 Swing front of waste toner away from printer and remove Repair information 4 93 5022 xxx 4 94 Service Manual 5022 xxx 4 Repair information Removal and cleaning precautions AN Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of removal unless otherwise specified Do not operate the printer anytime during removals If it is absolutely necessary to run the printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage parts such as the high voltage power supply After part replacement ensure the wiring harness is not caught or damaged Do not attempt to cut or extend the wiring harness Confirm the wiring harness connector is connected properly Be sure to handle the fuser carefully as it remains hot for a while after the printer stops running Always unplug connectors by holding the connector housing Warning Read the following before handli

Lexmark C52x, C53x (5022-xxx)

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