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Lexmark C52 series, Service Manual

The Citizen C52 series user manual is a comprehensive source of Technical Information for our cutting-edge product. This manual offers step-by-step instructions on setup, operation, and maintenance. Download it for free from manualshive.com to enhance your product experience with detailed guidance at your fingertips.

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vi

Service Manual

5022-xxx

  

Factory Defaults   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Energy Conserve   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Auto Align Adj  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Auto Color Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Enforce Color Order  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Color Alignment   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Motor Calibration   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Paper Prompts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Env Prompts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Jobs on Disk  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Duplex Gloss  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Font Sharpening  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Paper Jams   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Error jam locations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Paper jams in the multipurpose feeder or manual feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Loading media in the multipurpose feeder or manual feeder  . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Clearing a paper jam in the multipurpose feeder  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Clearing paper jams in the manual feeder  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Paper path  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Main Components   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
Print media transport   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Mechanical drive   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Paper sensing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Electrophotographic (EP) process   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Main components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Exposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Developing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Transferring   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Cleaning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Electrical interlock   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

5 V interlock switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
24 V interlock switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Repair information

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   

4-1

Removal and cleaning precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensitive parts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handing the photoconductor unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Parts not to be touched   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printhead alignment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Overview   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Printhead mechanical alignment   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 4-3
Skew (black)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Registration (black)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Alignment (cyan, yellow, and magenta)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Printer removal procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Precautions to take before maintenance work   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Cover removals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Exit tray cover removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Front access door cover assembly removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Gearbox shield removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Summary of Contents for C52 series

Page 1: ...Table of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Revision March 30 2007 ...

Page 2: ...ark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you Lexmark Lexmark with diamond design MarkNet and MarkVision are trademarks of Lexmark International Inc registered in the United States and or other countries ImageQuick and PrintCryption are trademarks of Lexmark International Inc PCL is a registered tr...

Page 3: ...ng media 1 7 Selecting preprinted forms and letterhead 1 7 Using media 1 8 Using letterhead 1 8 Using transparencies 1 8 Using envelopes 1 8 Using labels 1 9 Using card stock 1 9 Storing media 1 10 Supported sizes 1 10 Media weight 1 11 Input and output capacities 1 12 Print area 1 12 Serial number and machine type 1 13 Tools required for service 1 13 Acronyms 1 14 Diagnostic information 2 1 Start...

Page 4: ... self test error service check 2 41 920 13 POST power on self test error service check 2 43 920 14 POST power on self test error service check 2 44 920 15 POST power on self test error service check 2 45 920 16 POST power on self test error service check 2 45 920 17 POST power on self test error service check 2 46 920 18 POST power on self test error service check 2 46 920 19 POST power on self te...

Page 5: ...t duplex 3 12 Print Test duplex 3 13 Top Margin duplex 3 14 Motor Test duplex 3 14 Input Tray Tests 3 14 Base Sensor Test 3 15 Bin Full Test 3 15 Sensor Test 3 15 Printer Setup 3 16 Defaults 3 16 Page Counts 3 16 Serial Number 3 16 Engine Setting 1 through 4 3 16 Model Name 3 16 Configuration ID 3 16 EP Setup 3 17 EP Defaults 3 17 Fuser Temperature Fuser Temp 3 17 DC Charge Adjust Dev Bias Adj Tra...

Page 6: ...Print media transport 3 33 Mechanical drive 3 37 Paper sensing 3 42 Electrophotographic EP process 3 44 Main components 3 44 Charging 3 46 Exposing 3 49 Developing 3 50 Transferring 3 51 Fusing 3 52 Cleaning 3 53 Electrical interlock 3 54 5 V interlock switch 3 54 24 V interlock switch 3 55 Repair information 4 1 Removal and cleaning precautions 4 1 Handling ESD sensitive parts 4 1 Handing the pho...

Page 7: ...cable removal 4 59 Fuser removal 4 60 Fuser cable cover removal 4 61 High voltage power supply HVPS removal 4 62 Left bellcrank removal 4 64 Low voltage power supply LVPS removal 4 65 Multipurpose feeder MPF swing arm assembly removal models C52x only 4 67 Paper pick mechanism assembly removal 4 68 Photoconductor unit removal 4 70 Pick roll rubber tires removal and replacement 4 71 Printer pad rem...

Page 8: ...r listing models C53x 5 19 Preventive maintenance 6 1 Scheduled maintenance 6 1 Parts catalog 7 1 How to use this parts catalog 7 1 Assembly 1 Covers 7 2 Assembly 2 Front 7 4 Assembly 3 Right 7 6 Assembly 4 Rear 7 8 Assembly 5 Left 7 10 Assembly 6 Top 7 12 Assembly 7 Customer replaceable units CRUs 7 14 Assembly 8 Contact springs 7 16 Assembly 9 Cable parts packet 7 18 Assembly 10 Miscellaneous 7 ...

Page 9: ...serprodukte der Klasse I gelten als unschädlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Länge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daß im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laser...

Page 10: ...áser de Clase I 1 Los productos láser de Clase I no se consideran peligrosos La impresora contiene en su interior un láser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nive...

Page 11: ...inelt er en 5 milliwatt galliumarsenid laser som arbejder på bølgelængdeområdet 770 795 nanometer Lasersystemet og printeren er udformet således at mennesker aldrig udsættes for en laserstråling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapt...

Page 12: ...som farlige Skriveren inneholder internt en klasse IIIb 3b laser som består av en gallium arsenlaserenhet som avgir stråling i bølgelengdeområdet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I nivå under vanlig bruk vedlikehold som utføres av brukeren eller foreskrevne serviceoperasjoner Avís sobre el Làser Segons ha esta...

Page 13: ...Laser notices xiii 5022 xxx Japanese Laser Notice ...

Page 14: ...xiv Service Manual 5022 xxx Korean Laser Notice ...

Page 15: ...ignes d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travail...

Page 16: ...re el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con la que e...

Page 17: ...producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu treballant...

Page 18: ...g FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Conventions Note A note provides additional information Warning A warning identifies something that migh...

Page 19: ... 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 models C524dn C524dtn C530dn C532dn and C534dn dtn factory installed Integrat...

Page 20: ...configuration Performance factors Performance speed depends on Interface to the host USB serial parallel network Host system and application Page complexity and content of the page Printer options installed or selected Available memory in the printer Media size and type Resolution Memory type Models C520n C522n C524 C524n C524dn C530dn C532n C532dn C534n C534dn dtn Standard DRAM MB 128 128 64 128 ...

Page 21: ...o 63 Hz nominal 90 to 110 V ac extreme Notes Using a 220 to 110 power converter with the 110 V printer is not recommended Using an inverter 12 V dc to 120 V ac for example to power the printer is not recommended Printing states Lexmark C524 C524n C524dn C524dtn Lexmark C520n C522n Lexmark C534n C534dn C534dtn Lexmark C530dn C532n C532dn Idle average power Power Saver on 18 W 16 W 18 W 17 W Power S...

Page 22: ...40 C to 40 C 104 Fahrenheit Printer with Cartridges 40 C to 40 C 104 Fahrenheit Printer without 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 In some cases performance specifications such as paper OCF EP cartridge usage are specified to be measured at an ambient ...

Page 23: ... duplex unit 500 sheet assembly C524dtn 24 in 610mm 17 3 in 440 mm 22 in 558 mm 64 8 lb 29 4 kg Printer duplex unit 550 sheet assembly C534dtn 24 in 610mm 17 3 in 440 mm 22 in 558 mm 64 0 lb 29 0 kg Optional 500 sheet assembly only C52x models 5 in 127 mm 16 5 in 420 mm 20 4 in 518 mm 7 25 lb 3 29 kg Optional 550 sheet assembly only C53x models 5 in 16 5 in 420 mm 20 4 in 7 0 lb 3 2 kg MPF configu...

Page 24: ... 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 change...

Page 25: ... jams and poor print quality Always use new undamaged media Before loading media know the recommended print side of the media This information is usually indicated on the media package Do not use media that has been cut or trimmed by hand Do not mix media sizes types or weights in the same source mixing results in jams Do not use coated media unless they are specifically designed for electrophotog...

Page 26: ...r letter size and Lexmark part number 12A8241 for A4 size transparencies Using envelopes Print samples on the envelopes being considered for use before buying large quantities When printing on envelopes 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 ...

Page 27: ...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 Do not use labels with slick backing material Use full label 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 vo...

Page 28: ... Store media in cartons when possible on a pallet or shelf rather than on the floor Store individual packages of media on a flat surface 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 Media Sizes 250 Tray MPF Duplex 500 Tray Manual Feed Slot A4 210 x 297 mm ...

Page 29: ... g m2 163 g m2 Transparency 0 12 to 0 14 mm 4 8 to 5 4 mil 161 to 179 g m2 A5 B5 JIS B5 Exec Statement Folio Xerographic and Bonds Long Grain 20 to 47 lb 75 to 177 g m2 Short Grain 24 to 58 lb 90 to 218 g m2 Multipurpose feeder and manual feed slot Letter Legal A4 Xerographic and Bonds Long Grain 20 to 47 lb 75 to 177 g m2 Short Grain 24 to 58 lb 90 to 218 g m2 Recycled Long Grain 20 to 47 lb 75 t...

Page 30: ... to 120 g m2 Recycled Long Grain 20 to 32 lb 75 to 120 g m2 Short Grain 28 to 32 lb 105 to 120 g m2 Source Media Maximum height Approximate reference capacity Input Standard 250 sheet tray2 Plain paper 1 54 mm 250 sheets 75 g m2 Optional 500 sheet tray C52x or Optional 550 sheet tray C53x 2 Plain paper 1 57 6 mm 500 sheets 80 g m2 550 sheets 75 g m2 Multipurpose feeder2 Plain paper 10 mm 100 sheet...

Page 31: ...nfiguration IDs machine type and model information Tools required for service Flat blade screwdriver 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 Con...

Page 32: ...imulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply M Magenta MPF Multipurpose Feeder MS Microswitch NVRAM Nonvolatile Random Access Memory OPT Optical Sensor PC Photoconductor pel Picture element POR Power On Reset POST Power On Self Test PWM Pulse Width Modulation RIP Raster Imaging Processor SDRAM Synchronous Dual Random Access Memory...

Page 33: ...its are shown Paper jam messages 2xx 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 User status messages provide the user with information on the current status of the printer User attendance mess...

Page 34: ...sage 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 from the operator panel 3 Navigation arrow buttons Press these buttons to scroll up or down through menus m...

Page 35: ...nus These menus are only available when the printer is in the Ready state 7 Back 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 flash drive to send data to the printer 9 Numeric keypad Model C534 only Consists of the numbers 0 9 a backspace button and a pound button Button or light Funct...

Page 36: ...nu Black Cartridge Paper Texture Wireless x Setup Page PDF Menu Cyan PC Unit Paper Weight Profiles List PostScript Menu Magenta PC Unit Paper Loading NetWare Setup Page PCL Emul Menu Yellow PC Unit Custom Types Print Fonts HTML Menu Black PC Unit Universal Setup Print Demo Image Menu Waste Toner Box Fuser Transfer Belt Security Network Ports Help Max Invalid PIN TCP IP Color Quality Job Expiration...

Page 37: ...l displays system information For example 9 The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start 10 The operator panel LED starts blinking 11 A clock face appears on the display The following errors or messages may appear Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge is missing Any cartridge errors such as De...

Page 38: ...nd on page 2 55 Blank page Go to Print quality blank page on page 2 56 Blurred or fuzzy print Go to Print quality blurred or fuzzy print on page 2 59 Half color page Go to Print quality half color page on page 2 59 Horizontal banding Go to Print quality horizontal banding on page 2 59 Horizontal line Go to Print quality horizontal line on page 2 59 Insufficient fusing Go to Print quality insuffici...

Page 39: ...rror has occurred in the fuser Remove and reseat the fuser POR the printer If the error message persists see 120 03 Fuser error service check on page 2 30 120 04 120 07 Fuser Error An error has occurred in the fuser 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 30 120 08 1...

Page 40: ...ge 2 52 200 11 Input sensor does not break Possible causes Incorrect media setting Incorrect paper loading Incorrect media restraint setting Paper tray failure Paper pick mechanism 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 Replace the paper tray...

Page 41: ...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 52 201 07 Exit sensor is made early Possible causes 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 ca...

Page 42: ... top access door 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 52 202 02 Exit sensor is made when printer tries to print from an idle state Possible causes Damaged paper exit sensor or paper exit s...

Page 43: ... 2 52 203 14 During duplex printing retract the exit sensor broke early Possible causes Damaged paper exit sensor or paper exit sensor flag Faulty fuser Faulty system card The fuser exit sensor may not be functioning properly See Exit sensor service check on page 2 52 203 15 During duplex printing the exit sensor never broke Possible causes Damaged paper exit sensor or paper exit sensor flag Obstr...

Page 44: ...aring a paper jam does not fix the problem go to 146 xx Motor duplex error service check on page 2 36 241 03 While feeding from tray 1 the input sensor does not break Possible causes Incorrect media setting Incorrect paper loading Incorrect media restraint setting Paper tray failure Paper pick mechanism failure Ensure proper media is set for the type of paper used Fan media and stack it flat in th...

Page 45: ...actions do not fix the problem go to 148 xx MPF motor error service check on page 2 37 242 03 While feeding from tray 2 the input sensor does not break Possible causes Incorrect media setting Incorrect paper loading Incorrect media restraint setting 500 sheet assembly failure Paper pick mechanism Ensure proper media is set for the type of paper used Fan media and stack flat in 500 sheet tray tray ...

Page 46: ...ray 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 68 250 04 While...

Page 47: ...02 01 902 99 Engine Software Error Unrecoverable system software errors POR the printer If the error message persists replace the system card See System card removal on page 4 92 903 01 903 05 Engine Software Error Unrecoverable system software errors POR the printer If the error message persists replace the system card See System card removal on page 4 92 904 01 904 04 Interface Violation by RIP ...

Page 48: ...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 connected See 920 14 POST power on self test error service check on page 2 44 920 15 POST Error Bad transfer belt NVRAM dat...

Page 49: ...ists 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 ...

Page 50: ... replace the system card See System card removal on page 4 92 958 01 958 99 Memory Failure Processor failure POR the printer If the error message persists replace the system card See System card removal on page 4 92 960 01 960 99 Memory Error Memory failure RAM soldered on card is bad Replace the system card See System card removal on page 4 92 961 01 961 99 Memory Failure Memory failure POR the p...

Page 51: ...s replace the system card See System card removal on page 4 92 32 Unsupported Cartridge Check to see if the toner cartridge is a supported 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 t...

Page 52: ...2 35 Insufficient memory to support Resource Save feature Press 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 pro...

Page 53: ...If this does not fix the problem replace the system card See System card removal on page 4 92 52 Not enough free space in flash memory for resources Press 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 fl...

Page 54: ...l Buffer menu item is not set to Disabled If this does not fix the problem replace the PCI card 56 Standard USB port disabled Press 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 ...

Page 55: ... fuser When print quality is reduced install the new fuser using the instruction sheet that comes with the replacement fuser If this does not fix the problem replace the system card See System card removal on page 4 92 80 Replace fuser Replace the fuser If this does not fix the problem replace the system card See System card removal on page 4 92 82 Waste toner box nearly full Press until Continue ...

Page 56: ...TRANS2 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 4 103 If the problem persists replace the system card See System card removal on page 4 92 83 Transfer belt life warning Press until Continue appears and then press to clear the message and continue printing Order a rep...

Page 57: ... 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 Check the high voltage contacts path especially the finger on the sp...

Page 58: ...ace the specified toner cartridge Press 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 91 If the problem persists replace the system card See System card removal on page 4 92 88 Replace color cartridge Replace the specified toner cartridge Press until C...

Page 59: ...uestions actions Yes No 1 Is the front access door completely closed Go to step 2 Properly close the door 2 Turn the printer off and remove the rear cover Check the connector JINT1 5 V interlock switch 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 front access door 5 V interlock switch See ...

Page 60: ... Go to step 3 Press the camshaft follower into the groove 3 Turn the printer off and remove the rear cover 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 Replace the fuser cable Go to step 4 4 Check the connector JLVPS1 for proper connection to the system card the cable for pinch p...

Page 61: ... Is continuity present Go to step 8 Replace the AC fuser cable 8 Replace the fuser See Fuser removal on page 4 60 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 2 3 4 6 8 5 7 9 10 pin 1 pin 6 pin 10 pin 8 Pin configuration pin 8 DC autoconnect JFUSER1 DC autoconnect JFUSER1 Pin 9 Pin 9 Pin 10 Pin 10 pin 5 pin 1 AC au...

Page 62: ...s the cable damaged Replace the LVPS See Low voltage power supply LVPS removal on page 4 65 Go to step 4 4 Replace the fuser See Fuser removal on page 4 60 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Check the input voltage switch on the back of the low voltage power supply LVPS Is the voltage level 115 230 proper...

Page 63: ...user cable 6 Reinstall the fuser See Fuser removal on page 4 60 Does the error clear Problem solved Go to step 7 7 Replace the fuser See Fuser removal on page 4 60 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 2 3 4 6 8 5 7 9 10 pin 1 pin 6 pin 10 pin 8 Pin configuration pin 8 DC autoconnect JFUSER1 DC autoconnect J...

Page 64: ...ectors on page 5 11 for the location of connectors Is the cable damaged Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Go to step 2 2 Measure the resistance across fuse F2 on the system card Is the fuse blown Replace the system card See System card removal on page 4 92 Go to step 3 3 Replace the paper pick mechanism See Paper pick mechanism assembly removal...

Page 65: ...tor 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 Replace the fuser cable Go to step 4 4 Turn the printer 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 t...

Page 66: ...amage Is the cable damaged Replace the JCART1 cable Go to step 2 2 Measure the resistance across fuse F4 and F5 on the system card Is either fuse blown Replace the system card See System card removal on page 4 92 Go to step 3 3 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 onl...

Page 67: ... other damage Is the cable damaged Replace JCART2 cable Go to step 2 2 Measure the resistance across fuse F5 and F6 on the system card Is either fuse blown Replace the system card See System card removal on page 4 92 Go to step 3 3 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...

Page 68: ...4 Replace the bump aligner motor See Bump aligner motor removal on page 4 40 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Is the top access door completely closed Go to step 2 Close the top access door 2 Turn the printer off and remove the rear cover Check the connector JDUPLX1 for proper connection to the system c...

Page 69: ...e the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Turn the printer off and remove the rear cover Check the connector JTRAY2 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 paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Go to step 2 2...

Page 70: ...hanism See Paper pick mechanism assembly removal on page 4 68 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Replace the bump aligner motor See Bump aligner motor removal on page 4 40 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Repla...

Page 71: ...Are the connectors damaged Replace the DC autoconnect cable Go to step 3 3 Check for the following continuity between the DC autoconnect and FUSER1 Is continuity present Go to step 4 Replace the DC fuser cable 4 Replace the fuser See Fuser removal on page 4 60 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Replace th...

Page 72: ... the transparency sensor for correct mounting Is the transparency sensor properly mounted in the paper pick mechanism Go to step 3 Remove the paper pick mechanism properly install the transparency sensor and reinstall the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 3 Replace the paper pick mechanism See Paper pick mechanism assembly removal on page 4 68 Does the err...

Page 73: ...er assembly removal model C53x only on page 4 32 Go to step 2 2 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 Replace the damaged sensor See Toner level sensor removal on page 4 9...

Page 74: ...e 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 Replace the toner level sensor that has 5 V dc on pin 1 See Toner level sensor removal on page 4 96 Go to step 5 Is there approximately 5 V dc on any of the pins 5 Replace the HVPS See High voltage power supply HVPS removal on page 4 62 Does the error clear Problem solved Repl...

Page 75: ...Go to step 2 2 Remove the right cover Check for the following continuity between JCART1 and top cartridge connector 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 Is continuity present 3 Replace the EP drive assembly See Electrophotographic EP drive assembly removal model C52x only on page 4 48 or Electr...

Page 76: ...tep 2 2 Remove the right cover Check for the following continuity between JCART2 and bottom cartridge connector Go to step 3 Replace the JCART2 cable The cable parts packet contains one cartridge motor cable that works for either of the cartridge motors Is continuity present 3 Replace the EP drive assembly See Electrophotographic EP drive assembly removal model C52x only on page 4 48 or Electropho...

Page 77: ... 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 front door assembly See Front door assembly removal on page 4 55 Go to step 2 2 Replace the transfer belt assembly See Transfer belt removal on page 4 10...

Page 78: ...moval model C52x only on page 4 28 or Top access cover assembly removal model C53x only on page 4 32 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Turn the printer off and remove the rear cover Check the connector JOPT1 for proper connection to the system card the cable for pinch points and the cable or connector fo...

Page 79: ...place the JTRANS1 cable Go to step 2 2 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 Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Replace the top access cover assembly See Top...

Page 80: ... removal model C53x only on page 4 32 Go to step 2 2 Disconnect JHVPS1 from system card and HVPS Check for the following continuity 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 Is continuity present Pin 24 Pin 23 Pin 1 Pin 2 Pin 2 Pin 1 Pin 23 Pin 24 Error code...

Page 81: ...black2 on the transfer contact assembly Go to step 4 Replace the transfer contact assembly See Transfer contact assembly removal on page 4 104 Is continuity present 4 Replace the HVPS See High voltage power supply HVPS removal on page 4 62 Does the error clear Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No yellow2 cyan2 magenta2 black2 yel...

Page 82: ... 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 ...

Page 83: ...ent on page 4 74 Replace the system card with a new and not previously installed system card See System card removal on page 4 92 Step Questions actions Yes No 1 Check the AC line voltage Is the line voltage correct Go to step 2 Inform the customer 2 Is the AC line cord damaged Replace the line cord Go to step 3 3 Check the system card for 5 V dc between JLVPS1 pin 1 and ground Is the voltage corr...

Page 84: ...xit sensor flag damaged Replace the fuser See Fuser removal on page 4 60 Go to step 3 3 Is the JFUSER1 properly connected to the system card Go to step 4 Reseat the connector 4 Place a voltmeter between the JFUSER1 pin 7 and ground Initially the meter should indicate 5 V dc Activate the exit sensor flag Does the voltage drop to 0 V dc Replace the system card See System card removal on page 4 92 Re...

Page 85: ...s fail the test Replace the operator panel assembly See Operator panel assembly removal on page 4 23 Go to step 2 2 Disconnect the operator panel assembly cable from JOPP1 on the system card and measure the voltage on pin 6 and ground Does the voltage measure approximately 3 3 V dc Replace the operator panel assembly See Operator panel assembly removal on page 4 23 If this does not fix the problem...

Page 86: ...e the system card See System card removal on page 4 92 Step Questions actions Yes No 1 Check the operator panel assembly cable Is the cable damaged 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 2 Measure the voltage between JOPP1 pin 2 and ground on the system c...

Page 87: ...letter A4 and print the Print Quality pages to see if the problem remains 6 Use Tray 1 to test print quality problems 7 Print the Print Quality Pages and looked for variations in the print from what is expected 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 connecto...

Page 88: ... Problem solved Go to step 5 5 Replace the HVPS See High voltage power supply HVPS removal on page 4 62 Does this fix the problem Problem solved Go to step 6 6 Clean the printhead Does this fix the problem Problem solved Replace the printhead See Printhead removal installation and adjustment on page 4 74 Step Questions actions Yes No 1 Is all the packing material for the photoconductor unit in que...

Page 89: ...tage 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 HVPS spring that runs through the left printer frame See Transfer contact assembly removal on page 4 104 to view the proper mounting and for removal procedures Are the spring s defective Replace the transfer contact ass...

Page 90: ...oval on page 4 62 Did this fix the problem Problem solved Go to step 8 8 Replace the printhead See Printhead removal installation and adjustment on page 4 74 Did this fix the problem Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No ...

Page 91: ... Print quality insufficient fusing 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 Step Questions actions Yes No 1 Measure the distance between repeating bands Is the distance between bands e...

Page 92: ... print cartridge Step Questions actions Yes No 1 Is there any loose or foreign material on the photoconductor unit Replace the photoconductor unit See Photoconductor unit removal on page 4 70 Go to step 2 2 Is there any loose or foreign material on the cartridge roll Replace the print cartridge Go to step 3 3 Is there any loose or foreign material on the transfer belt Replace the transfer belt See...

Page 93: ... Go to step 2 2 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 4 104 to view the proper mounting and for removal procedures Are the spring s defectiv...

Page 94: ...y of the HVPS cable Go to step 4 Replace the cable assembly Is there continuity 4 Replace the HVPS See High voltage power supply HVPS removal on page 4 62 Did this solve the problem Problem solved Replace the system card See System card removal on page 4 92 Step Questions actions Yes No Pin 24 Pin 23 Pin 1 Pin 2 Pin 2 Pin 1 Pin 23 Pin 24 ...

Page 95: ...n on the printer 4 Release the buttons when the clock graphic displays The Diagnostics menu group contains the settings and operations used while manufacturing and servicing the printer See Diagnostics menu on page 3 2 for more information Configuration menu 1 Turn off the printer 2 Press and hold and 3 Turn on the printer 4 Release the buttons when the clock graphic displays The Configuration men...

Page 96: ... MOTOR TESTS order differs depending upon model Align Motor Test Tests the bump aligner motor See General motor tests on page 3 8 Fuser 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 General 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...

Page 97: ...ensor 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 Configu...

Page 98: ...t xxxx CalSet x xx x xx x xx x xx x xx Engine ID xx FSpeed xxx Printer Revision Levels Loader xx xx xxxx x Kernel xxx xx xxxx x Base xx xx xxxx x Network xxx xx xxxxx x Network Drvr xx xx xxxx x Engine xx xx xxxx x Font x xxxxx xx x Margin Settings Top Margin x Bottom Margin x Left Margin x Right Margin x Skew x Cyan Top Margin x Cyan Left Margin xx Cyan Right Margin x Cyan Skew x Cyan Bow x Yello...

Page 99: ...ew Each increment corresponds to 1 1200 of an inch 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 Top margin 25 to 25 Each increment corresponds to 8 scans at a 600 dpi scan rate 0 0133 inches or 0 339 mm A positive change moves the image down the page and increases the...

Page 100: ...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 until the 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...

Page 101: ...k Test in the same color menu Press Select two pages print 3 On the pages make sure all the Current Values are set to zero If not go back two steps and repeat 4 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 5 On the operator panel use and to locate Top Margi...

Page 102: ...irror Motor Test After the test completes the panel displays either Pass or Fail To stop the test press Stop Motor test Setup requirements Notes Top access cover Front access door Align Motor Test Closed Closed Select Forward or Reverse Fuser Closed Closed Select Forward or Reverse Tray 1 Not applicable Not applicable Remove all paper from the input source tray to avoid paper jams while performing...

Page 103: ...st 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 p...

Page 104: ...uality 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 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...

Page 105: ... 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 P represents the number of times the memory test has passed and finished successfully Initially 000000 d...

Page 106: ...of times the CACHE test has failed finished with errors Initially 000000 is displayed The maximum fall count is 999 999 2 To exit the test turn the printer off Duplex Tests Quick Test duplex Note Before you set the duplex top margin be sure to set the skew and alignment See Printhead alignment on page 4 3 This test prints a duplex version of the Quick Test that can be used to verify the correct pl...

Page 107: ... 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...

Page 108: ...ault value is 0 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 Select 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 T...

Page 109: ... access door The sensor should change state Input Open Closed Remove the paper tray 1 Activate the input sensor flag The sensor should change state Narrow Media transparency Open Closed Test the manual feed slot by pulling out the tray The sensor should change state 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 fron...

Page 110: ...turn 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 or...

Page 111: ...rs and a check 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 used 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 e...

Page 112: ...re stored in the event log To view the event log 1 Select EVENT LOG from DIAGNOSTICS 2 Select Display Log Up to three error codes display at a time Press or 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...

Page 113: ...n 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 to return to EVENT LOG EXIT DIAGNOSTICS Press Select to exit DIAGNOSTICS The printer performs a power on reset and returns to normal mo...

Page 114: ...ctory Defaults See Factory Defaults on page 3 22 Energy Conserve See Energy Conserve on page 3 23 EVENT LOG See Event Log on page 3 23 Auto Align Adj See Auto Align Adj on page 3 23 Auto Color Adj See Auto Color Adj on page 3 23 Enforce Color Order See Enforce Color Order on page 3 24 Color Alignment See Color Alignment on page 3 24 Motor Calibration See Motor Calibration on page 3 24 Paper Prompt...

Page 115: ...ges 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 setting...

Page 116: ...ownload 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 sele...

Page 117: ...lect to begin printing the log Auto Align Adj Controls whether the printer executes the automatic alignment calibration after an initiating event 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 appropriat...

Page 118: ... 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 Select to select Motor Calibration from the CON...

Page 119: ... 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 ...

Page 120: ...s 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 to decrease the value by 1 press Exit Config Menu Press Select to exit the CONFIG MENU The printer performs a power on reset and returns to normal mode ...

Page 121: ...Diagnostic aids 3 27 5022 xxx Paper Jams Error jam locations The following illustration shows the location and error codes generated for specific paper jams and the corresponding locations of these jams ...

Page 122: ...n the display load a single sheet of paper flush with the right side of the slot and then press Select Load an envelope with the flap side up 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 2...

Page 123: ...o 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 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 unt...

Page 124: ...3 30 Service Manual 5022 xxx Theory of operation Paper path Paper exit flag Duplex MPF pick Paper pick mechanism Input flag Bump roller align System card Transfer belt Fuser ...

Page 125: ...Diagnostic aids 3 31 5022 xxx ...

Page 126: ...a 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 ...

Page 127: ...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 500 sheet assembly pick tire Bump aligner roll MPF pick tire Pick tire Backup aligner roll ...

Page 128: ...rvice Manual 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 ...

Page 129: ...l 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 drive roll Fuser exit drive roll Paper exit flag Fuser backup roll Fuser exit idler ro...

Page 130: ... it reaches the bump aligner roll Once in this position it enters the EP path for the second time The paper exit flag serves two purposes When it 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 ...

Page 131: ...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 ...

Page 132: ...bump aligner motor The motor drives a set of bump aligner gears which causes the bump aligner roll to turn Note If this motor is stalling or causing waste toner box full messages the vertical auger mechanism might be causing the problem Bump aligner roll Bump aligner gears Bump aligner gears Bump aligner motor ...

Page 133: ...sembly 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 ...

Page 134: ...es drive from a motor located on the EP drive assembly When the top access door is open the coupler for the transfer belt disengages Fuser drive The fuser drive motor is built into the fuser assembly and drives the fuser rollers to turn Inside Outside Transfer belt motor Coupler ...

Page 135: ...nted 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 unit during printing Duplex motor Drive shafts Belt Bottom view of motor and gear ...

Page 136: ... 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 senso...

Page 137: ...aper 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...

Page 138: ...rd 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 ...

Page 139: ...ic 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 ima...

Page 140: ...o 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 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 essenti...

Page 141: ...arts 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 Toner add roll high voltage contact path Developer roll high voltage contact path High voltage power supply Cleaner blade high voltage c...

Page 142: ...um 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 ...

Page 143: ...th 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 ...

Page 144: ...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...

Page 145: ...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 Photoc...

Page 146: ... 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 Hot roll ...

Page 147: ...t 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 Transfer belt cleaning blade Photoconductor drum cleaning blade Transfer belt cleaning shaft Transfer belt waste toner containe...

Page 148: ...al 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 Gearbox shield removed 5V interlock switch ...

Page 149: ...s closed with the front access door also closed the drive retraction lockout trips the switch arm which closes the 24 V dc interlock 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 consider...

Page 150: ...3 56 Service Manual 5022 xxx ...

Page 151: ...to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing electronic cards 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 Make the fewest possible movements with your body to prevent an increase of static electricity from clothing fi...

Page 152: ...e 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 Use care not to contaminate the surface of the optical photoconductor roller with an oil based solvent fingerprints and other foreign matter Do not scratch the surface of th...

Page 153: ...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 and skew is adjusted The first step in aligning the printhead is to loosen the printhead mounting screws and to set the skew for black Note If you ne...

Page 154: ...tor 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 f Remove all of the toner cartridges A B A B C52x C...

Page 155: ...able cover D slide the cable to left lower and remove h Loosen the printhead mounting screws E in the following order top middle lower left and lower right 2 Reinstall the transfer belt assembly and the photoconductor units 3 Connect the transfer belt cable 4 Replace the toner cartridges ...

Page 156: ... Speed xxxMHz Serial Number xxxxxxx CalStat xxxx CalSet x xx x xx x xx x xx x xx Engine ID xx FSpeed xxx Print er Revisi on Levels Loader xx xx xxxx x Kernel xxx xx xxxx x Base xx xx xxxx x Network xxx xx xxxxx x Network Drvr xx xx xxxx x Engine xx xx xxxx x Font x xxxxx xx x Margin Settings Top Margin x Bottom Margin x Left Margin x Right Margin x Skew x Cyan Top Margin x Cyan Left Margin xx Cyan...

Page 157: ...xx x Engine xx xx xxxx x Font x xxxxx xx x Margin Settings Top Margin x Bottom Margin x Left Margin x Right Margin x Skew x Cyan Top Margin x Cyan Left Margin xx Cyan Right Margin x Cyan Skew x Cyan Bow x Yellow Top Margin x Yellow Left Margin x Yellow Right Margin x Yellow Skew x Yellow Bow x Magenta Top Margin x Magenta Left Margin x Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Mar...

Page 158: ...embly and the photoconductor units 7 Connect the transfer belt cable 8 Reinstall the toner cartridges 9 Reinstall the exit tray cover Registration black Top Margin 1 Reconnect the power cord to the electrical outlet but do not turn on the printer yet 2 Enter Diagnostic mode press and hold and turn on the printer and release the buttons when the clock graphic displays 3 Select Quick Test REGISTRATI...

Page 159: ...he page Decreasing the value moves the bottom alignment 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 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 Increasing the value moves the left side alignment ma...

Page 160: ... cyan yellow and magenta 1 Press Back on the operator panel until you reach the top menu select ALIGNMENT MENU and press Select 2 Select Cyan 3 Select Top Margin and use or to select zero Press Select to save the setting 4 Select Left Margin Right Margin Bottom Margin Skew and Bow In each menu use or to select zero and press Select to save the value It is important to set all the values to zero be...

Page 161: ...7 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 8 Enter the New Cyan T value on the operator panel using or and press Select to save the value 9 Reprint the Quick Test and evaluate whether you are at zero changes ...

Page 162: ...wn below 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 12 Repeat steps 2 through 11 for yellow and magenta Note Start each color group by setting the Top Margin Left Margin Right Margin Bottom Margin Skew and Bow to zero ...

Page 163: ...he power cable from the outlet prior to starting removals or checks 2 Prior to starting any repairs read and understand the warnings in this manual High temperature High voltage Laser radiation 3 Confirm the direction of all parts and screw lengths during removal replacement 4 Utilize the proper cleaning procedures solvents during maintenance 5 Confirm that all parts and covers are properly instal...

Page 164: ...4 14 Service Manual 5022 xxx Cover removals ...

Page 165: ...Repair information 4 15 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 ...

Page 166: ... 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...

Page 167: ...ooking 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 6 Close the front access door C E D ...

Page 168: ...4 18 Service Manual 5022 xxx 7 Remove the four screws F that attach the pivot pin to the front access door cover 8 Remove the front access cover assembly ...

Page 169: ...per 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 A B ...

Page 170: ...dge hanging over slightly 2 Remove the waste toner assembly See Waste toner assembly removal on page 4 105 3 Open the top access door 4 Open the front access door 5 Remove the three screws A 6 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 C B ...

Page 171: ...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 the outer beze...

Page 172: ... 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 A B ...

Page 173: ...ard 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 3 Disengage the upper locking tabs B 4 Disconnect the cab...

Page 174: ...ove the exit tray See Exit tray cover removal on page 4 15 3 Remove the paper tray 4 Place the printer on its back 5 Remove the four screws A The upper right screw can be accessed through a hole in the frame B 6 Remove the paper tray dust cover assembly 7 Lift the dust cover bracket C and disconnect the dust cover spring D 8 Set the dust cover bracket aside to reuse with the new FRU A B D C ...

Page 175: ... 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 A ...

Page 176: ...umber 1 Make sure the power cord is removed 2 Place the printer on the table with the right side edge hanging over slightly 3 Open the top access door 4 Open the front access door 5 Remove the three screws A 6 Lift the bottom of the cover out and slide the right cover down to remove the cover ...

Page 177: ...Repair information 4 27 5022 xxx Installation note Be sure the tab B is fully engaged B ...

Page 178: ... 3 for the part number 1 Remove the rear cover See Rear cover removal on page 4 25 2 Remove the left cover See Operator panel outer bezel removal on page 4 21 3 Remove the fuser See Fuser removal on page 4 60 4 Remove the four screws A exposed after removing the fuser 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 179: ...xit 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 B ...

Page 180: ...4 30 Service Manual 5022 xxx 9 Remove the linkage screw C C ...

Page 181: ...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 supply HVPS 13 Lift and remove the top access cover assembly D Rear Left side ...

Page 182: ... the right cover See Right cover removal on page 4 26 2 Remove the left cover See Operator panel outer bezel removal on page 4 21 3 Remove the rear cover See Rear cover removal on page 4 25 4 Remove the fuser See Fuser removal on page 4 60 5 Remove the four screws A exposed after removing the fuser 6 Remove the operator panel See Operator panel assembly removal on page 4 23 7 Remove the exit tray ...

Page 183: ... 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 B ...

Page 184: ...4 34 Service Manual 5022 xxx 10 Remove the linkage screw C C ...

Page 185: ... 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 12 Unplug the connector I from CN1 on the high voltage power supply HVPS I Rear Left side ...

Page 186: ...4 36 Service Manual 5022 xxx 13 Disconnect the ground cable J 14 Lift and remove the top access cover assembly J ...

Page 187: ...or the part number 1 Open the top access door 2 Remove the fuser See Fuser removal on page 4 60 3 Disconnect the spring A 4 Remove the seven screws B securing the inner access cover 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 7 Remove the sensor and cable ...

Page 188: ...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 3 Turn the cable cover over and press the side of the bin full sensor B to snap it loose from the cable cover 4 Remove the bin full sensor and cable ...

Page 189: ... on page 4 68 2 Close the front access door for better access to the gears 3 Remove the three e clips and washers A 4 Remove the gears Installation notes When reinstalling the gears apply a light coat of the packaged grease 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 t...

Page 190: ...ligner 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 A ...

Page 191: ...Repair information 4 41 5022 xxx 4 Disconnect the JBUMP1 connector B from the system card 5 Remove the bump aligner motor from the printer B ...

Page 192: ...mp aligner rollers and springs removal models C53x See Deflector assembly C53x on page 7 5 for the part number 1 Remove the paper tray 2 Push up and back to release the bump aligner spring 3 Lower the bump aligner spring to remove it ...

Page 193: ...Repair information 4 43 5022 xxx 4 Remove the bump aligner roller Installation note Make sure to support the bump aligner roller in the arms of the bump aligner spring ...

Page 194: ...s 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 3 Press the lower half C D of the springs and remove the springs B A D C ...

Page 195: ... 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 I G F E H D I ...

Page 196: ... 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 3 Place a flathead screwdriver between the deflector assembly and the right side frame and lever the deflector away from the frame 4 Pivot the deflector out and remove ...

Page 197: ... 5022 xxx Installation notes 1 Align the two studs A to the two alignment holes B in the left side frame 2 Align the stud C with the alignment hole D on the right frame 3 Snap into place 4 Replace the screw on the right side ...

Page 198: ... C53x on page 7 7 for the part number 1 Remove the low voltage power supply See Low voltage power supply LVPS removal on page 4 65 2 Open the top access door 3 Open the front access door 4 Remove all the toner cartridges 5 Disconnect the JTRANS2 connector A from the system card 6 Disconnect JCART1 B and JCART2 C connectors from the drive assembly B C ...

Page 199: ...epair information 4 49 5022 xxx 7 Remove the six inner screws 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 E E E ...

Page 200: ...oor 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 ...

Page 201: ...assembly C53x on page 7 7 for the part number 1 Remove the right cover See Right cover removal on page 4 26 2 Open the top access door 3 Open the front access door 4 Remove all the toner cartridges 5 Remove the six inner screws A 6 Disconnect JCART1 B JCART2 C and JTRANS2 D connectors from the drive assembly ...

Page 202: ...4 52 Service Manual 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 E E E ...

Page 203: ... 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 ...

Page 204: ...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 6 Remove the cable from cable guide and remove the 5 V interlock switch A B ...

Page 205: ...ont 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 JDUPLX1 cable B from the system card B A ...

Page 206: ... the frame Be careful not to lose the grounding clip D 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 8 Open the front door assembly D C E ...

Page 207: ...Repair information 4 57 5022 xxx 9 Unwrap and remove the cable from the left and right pulleys F 10 Remove the mounting screw G and the cap H G H ...

Page 208: ...ont 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 ...

Page 209: ...se the cable spring A from the front door assembly 3 Remove the gearbox switch shield B See Gearbox shield removal on page 4 19 4 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 2 Close the top access door 3 Release the cable spring D from the front door assembly Note In order to ac...

Page 210: ... Installation note If you install a new fuser be sure to reset the fuser counter in the Configuration Menu To reset the counter 1 Enter the Configuration Menu Turn off the printer press and hold Select and turn on the printer and release the buttons when the clock graphic displays 2 Press Select for the Reset value Resetting Fuser Count Value appears 3 Press Select to select Motor Calibration from...

Page 211: ...x on page 7 5 or Fuser cable cover included in parts packet P N 40X3598 C53x on page 7 5 for the part number 1 Open the top access door 2 Open the front access door 3 Remove the yellow and cyan toner cartridges 4 Pull the locking tab A down on the left side of the cable cover B slide the cable to left lower and remove A B ...

Page 212: ...ge 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 3 Release the locking tab B from the front lower corner of the HVPS A B ...

Page 213: ...Repair information 4 63 5022 xxx 4 Disconnect the five connectors C from the HVPS Installation notes Be sure to replace the spring when replacing the HVPS See the illustration for proper orientation ...

Page 214: ...ce Manual 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 3 Remove the left bellcrank ...

Page 215: ...t 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 6 Remove the cable from the cable guide and remove the LVPS A B C ...

Page 216: ...4 66 Service Manual 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 D ...

Page 217: ... 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 A ...

Page 218: ...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 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 ...

Page 219: ...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 the JTRAY1 and JTRAY2 connectors do not bind when passing through the frame access hole C E D ...

Page 220: ...ew photoconductor unit is installed reset the life count value in the printer memory If a message appears on the operator panel 1 When 84 color PC Unit Life Warning or 84 Replace color PC Unit appears select Supply Replaced and then press Replace Supply displays 2 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 pr...

Page 221: ...inter 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 A ...

Page 222: ...m the pick roll assembly C Repeat for the other pick roll assembly 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 B C B ...

Page 223: ...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 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 A B ...

Page 224: ...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 Printhead removal 1 Power the printer off 2 Disconnect the power cord from the electrical outlet and from the printer 3 Remove the exit tray cover by lifting away from the ...

Page 225: ...oconductor 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 9 Remove the system card support shield See System card support shield removal on page 4 94 10 Pull the locking tab C down on the l...

Page 226: ...he 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 b Close the top access cover and remove the printhead alignment screw F and remove the printhead ...

Page 227: ...ll be used to align the black plane to the printer frame This also allows the black skew adjustment with the printhead alignment screw Once the black skew is aligned the mounting screws will be fully tightened and the next steps of alignment can be completed 1 When installing the printhead do a rough alignment by visually centering the hole in the frame with the slot on the bottom of the printhead...

Page 228: ... c Route the cables through the access holes on the right side of the printer d Replace the four screws from the inner right side of the support shield e Replace the five mounting screws to the outer left side of the printer f Reattach the printhead ground cable to the second screw from the bottom 3 Replace the system card a Replace the eight screws A in the system card b Replace the screw in the ...

Page 229: ...card Warning Be careful reconnecting the printhead ribbon cable B It can be damaged and should be handled carefully 4 Replace the LVPS a Install the LVPS and make sure the cable is in the cable guides C b Reconnect the cable D to the LVPS c Replace the five LVPS mounting screws E ...

Page 230: ...ector F from the system card 5 Replace the right cover a Place the printer on the table with the right side edge hanging over slightly b Slide the right cover up until it locks into position Note Be sure the tab G is fully engaged 6 Replace the three screws ...

Page 231: ...ough to hold the printhead in the printer 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 after the printhead is installed and black skew is adjusted using the alignment screw Skew black 1 Plug the ele...

Page 232: ...xx xxxxx x Network Drvr xx xx xxxx x Engine xx xx xxxx x Font x xxxxx xx x Margin Settings Top Margin x Bottom Margin x Left Margin x Right Margin x Skew x Cyan Top Margin x Cyan Left Margin xx Cyan Right Margin x Cyan Skew x Cyan Bow x Yellow Top Margin x Yellow Left Margin x Yellow Right Margin x Yellow Skew x Yellow Bow x Magenta Top Margin x Magenta Left Margin x Magenta Right Margin x Magent ...

Page 233: ...xx x Engine xx xx xxxx x Font x xxxxx xx x Margin Settings Top Margin x Bottom Margin x Left Margin x Right Margin x Skew x Cyan Top Margin x Cyan Left Margin xx Cyan Right Margin x Cyan Skew x Cyan Bow x Yellow Top Margin x Yellow Left Margin x Yellow Right Margin x Yellow Skew x Yellow Bow x Magenta Top Margin x Magenta Left Margin x Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Mar...

Page 234: ...lt assembly and the photoconductor units 7 Connect the transfer belt cable 8 Replace the toner cartridges 9 Replace the exit tray Registration black Top Margin 1 Reconnect the power cord to the electrical outlet but do not turn on the printer yet 2 Enter Diagnostic mode press and hold and turn on the printer and release the buttons when the clock graphic displays 3 Select Quick Test REGISTRATION i...

Page 235: ...tom alignment marks up on the page Decreasing the value moves the bottom alignment 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 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 Increasing the value moves...

Page 236: ...rint the Quick Test page and check the results Repeat if necessary 5 When the registration is complete proceed to the color alignments Alignment cyan yellow and magenta 1 Press Back on the operator panel until you reach the top menu select ALIGNMENT MENU and press Select 2 Select Cyan 3 Select Top Margin and use or to select zero Press Select to save the setting 4 Select Left Margin Right Margin B...

Page 237: ... 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 ...

Page 238: ...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 8 Enter the New Cyan T value on the operator panel using or and press Select to save the value 9 Reprint the Quick Test and evaluate whether you are at zero changes ...

Page 239: ...hown below 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 12 Repeat steps 2 through 11 for yellow and magenta Note Start each color group by setting the Top Margin Left Margin Right Margin Bottom Margin Skew and Bow to zero ...

Page 240: ...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 A ...

Page 241: ...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 1 Remove the system card support shield See System card support shield removal on page 4 94 2 From the outside right of the printer disconnect the five connectors A 3 Remov...

Page 242: ...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 ...

Page 243: ...SB connector 4 Remove the two screws C from the parallel connector on non network printers or from the parallel connector shield on network printers 5 Remove the eight screws D from the system card 6 Remove the system card Network system card Non network system card ...

Page 244: ...e system card See System card removal on page 4 92 5 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 6 Remove the four screws C from the inner right side of the support shield 7 Pull the cables through the access holes on the right side of the prin...

Page 245: ... 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 D ...

Page 246: ... the toner sensors 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 4 104 Note Do not remove the springs from the contact assembly as stated in the last step of the procedure Yellow Cyan Magenta Black ...

Page 247: ... 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 A B ...

Page 248: ... 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 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 A C B ...

Page 249: ...pen hold the lever arm A in place and rotate the camshafts B down to the closed position 4 While still holding the lever arm A up remove the left front mounting screw C and flip the right lock D back 5 Continue to hold the lever arm A up and remove the right front mounting screw E release the lever arm 6 Remove the e clip F 7 Slide the lever arm A and the spring G off the shaft Warning When removi...

Page 250: ...ill not work correctly 1 Ensure the EP drive assembly is engaged by sliding the upper retraction plate A fully to the rear 2 Remove the camshaft from the package and place the left and right mounting brackets B on a flat surface 3 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 4 Release ...

Page 251: ...ugh 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 I 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 ...

Page 252: ...ssembly in the open position prevents the front access door from closing and may cause damage to the door 13 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 14 Lower the lever arm O and make sure the left lock S and right lock P are positioned correctly in their respective channels T Note If the left side of the camshaft assemb...

Page 253: ... 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 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 per...

Page 254: ...move all the inside contact springs See Contact springs removal on page 4 44 3 Remove the four screws A and remove the transfer contact assembly 4 Remove the eight springs B for reuse during installation Note The top spring may fall away from the transfer contact assembly during removal Installation note For ease of installation put the transfer contact assembly on before installing the springs B ...

Page 255: ...Repair information 4 105 5022 xxx Waste toner assembly removal Not a FRU 1 Press the release latch A 2 Swing the front of the waste toner away from the printer and remove A ...

Page 256: ...4 106 Service Manual 5022 xxx ...

Page 257: ...Locations and connectors 5 1 5022 xxx 5 Locations and connectors Locations Covers ...

Page 258: ...rinter pad Bellcrank assembly Bump aligner gears Right front door assembly restraint cable Front door cap Left front door assembly restraint cable Front door assembly Deflector assembly MPF swing arm assembly models C52X only Paper pick mechanism assembly ...

Page 259: ...Locations and connectors 5 3 5022 xxx Right EP drive assembly Bump aligner motor 5 V interlock switch ...

Page 260: ...5 4 Service Manual 5022 xxx Rear ...

Page 261: ...Locations and connectors 5 5 5022 xxx Left Toner level sensor Transfer contact assembly High voltage power supply ...

Page 262: ...5 6 Service Manual 5022 xxx Top Top cover camshaft assembly Top access door 24V interlock switch with cable ...

Page 263: ...Locations and connectors 5 7 5022 xxx CRU and FRUs ...

Page 264: ...5 8 Service Manual 5022 xxx Sensors Toner level sensor Toner patch sensor TPS ...

Page 265: ...Locations and connectors 5 9 5022 xxx Motors ...

Page 266: ...5 10 Service Manual 5022 xxx Printer cards ...

Page 267: ...Locations and connectors 5 11 5022 xxx Connectors System card network models C52x ...

Page 268: ...5 12 Service Manual 5022 xxx System card non network models C52x ...

Page 269: ... JCART1 1 V_JC1 1 2 V_JC1 2 3 V_JC2 3 4 V_JC1 4 5 Ground 6 5V_SW 7 N C 8 V_C2_U 9 V_C2_V 10 V_C2_W JCART2 1 CART2_HALL_V 2 V_JC2 2 3 CART2_HALL_W 4 V_JC2 4 5 Ground 6 _5V_SW 7 N C 8 V_C2_U 9 V_C2_V 10 V_C2_W JCVR1 1 V_24V_CVR 2 COVER_OPEN_SNS JDUPLX1 1 VS_DUPLX 5 V 2 DUPLEX_PWM 3 DUPLEX_ENC 4 Ground 5 V_24VD 6 Ground JFAN1 1 FAN_FG 2 Ground 3 24VC 4 FAN1_PWM JFUSER1 1 V_FUSER_M 2 V_FUSER_M 3 VS_FU...

Page 270: ...VS_JINT 1 5V_SW 2 Ground 3 VS_INT 5V_PH JLVPS1 1 5 V dc 2 5 V dc 3 5 V dc 4 5 V dc 5 LVPS_ZERO_XING 6 24 V dc 7 24 V dc 8 24 V dc 9 Ground 10 Ground 11 Ground 12 Ground 13 Ground 14 Ground 15 LVPS_BRON 16 LVPS_HRON JMIRR1 1 MM_REF 2 MM_LOCK 3 MM_START 4 Ground 5 24 V dc JOPT1 1 VS_JOPT 1 5V_SW 2 OPTION_PWM 3 S_OPT_ENC 4 OPT_TYPE 5 Ground 6 Ground 7 24VC 8 OPT_PSIZE 9 OPT_PLEV 10 OPT_PCTL Connector...

Page 271: ...ADJ01 12 VDO_HADJ01 13 PH_EMS0 14 VDO_BOOST0 15 VDO_LPOW0 16 VS_ 5VPH_NVX_R 17 PH_EOS_THERM_SNS 18 5V_PH 19 I2C_CLK_PH 20 I2C_DATA_PH 21 VDO_LENA 22 PH_EMS2_SNS_R 23 VDO_BOOST2 24 VDO_LPOW2 25 VDO_LADJ23 26 VDO_HYSNC1 27 PH_EMS3_SNS_R 28 VDO_BOOST3 29 VDO_LPOW3 30 Ground Connector listing models C52x see System card network models C52x on page 5 11 or System card non network models C52x on page 5 ...

Page 272: ...SW 6 TRANS_BELT_SNS 7 TRANS_THERM_SNS 8 VS_5V_TPS 9 VS_JTRANS 9 3 3V 10 TPS_SNS 11 TPS_GAIN_ADJ 12 TPS_SNS_RTN 13 TPS_THERM_SNS 14 N C JTRAN2 1 V_TRANS_PHA 2 V_TRANS_PHA 3 V_TRANS_PHB 4 V_TRANS_PHB JTRAY1 1 VS_TRAY_INPT_LED 5V 2 S_TRAY_INPUT 3 Ground 4 VS_TRAY 5V_NMT 5 TRAY_NMT 3 3v 6 Ground 7 N C Connector listing models C52x see System card network models C52x on page 5 11 or System card non net...

Page 273: ... VS_TRAY_ENC_LED 2 S_TRAY_ENC 3 Ground 4 V_TRAY_PICK_M 5 V_TRAY_PICK_M 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 Pin no Signal Pin no Signal ...

Page 274: ...5 18 Service Manual 5022 xxx System card network models C53x ...

Page 275: ... 2 S_BUMP_ENC 3 Ground 4 V_BUMP_M 5 V_BUMP_M JCART1 1 CART1_HALL_U 2 CART1_HALL_V 3 CART2_HALL_U 4 CART1_FG 5 Ground 6 5V_SW 7 N C 8 V_CART1_WIND_U 9 V_CART1_WIND_V 10 V_CART1_WIND_W JCART2 1 CART2_HALL_U 2 CART2_HALL_V 3 CART2_HALL_W 4 CART2_FG 5 Ground 6 5V_SW 7 N C 8 V_CART2_WIND_U 9 V_CART2_WIND_V 10 V_CART2_WIND_W JCVR1 1 V_24V_CVR 2 COVER_OPEN_SNS JDUPLX1 1 VS_DUPLX 5 V 2 DUPLEX_PWM 3 DUPLEX...

Page 276: ...XFER_PWM_Y 20 XFER_SERV0_Y 21 CORE_CURR_SNSD 22 HVPS_ID 23 HV_XFER_PWM_K 24 XFER_SERV0 K JINT1 1 VS_JINT 1 5V_SW 2 Ground 3 VS_INT 5V_PH JLVPS1 1 5 V dc 2 5 V dc 3 5 V dc 4 5 V dc 5 LVPS_ZERO_XING 6 24 V dc 7 24 V dc 8 24 V dc 9 Ground 10 Ground 11 Ground 12 Ground 13 Ground 14 Ground 15 LVPS_BRON 16 LVPS_HRON JMIRR1 1 MM_REF 2 MM_LOCK 3 MM_START 4 Ground 5 24 V dc JOPT1 1 VS_JOPT 1 5V_SW 2 SERIAL...

Page 277: ...OST1 10 VDO_LPOW1 11 VDO_LADJ01 12 VDO_HADJ01 13 PH_EMS0 14 VDO_BOOST0 15 VDO_LPOW0 16 VS_ 5VPH_NVX_R 17 PH_EOS_THERM_SNS 18 5V_PH 19 I2C_CLK_PH 20 I2C_DATA_PH 21 VDO_LENA 22 PH_EMS2_SNS_R 23 VDO_BOOST2 24 VDO_LPOW2 25 VDO_LADJ23 26 VDO_HYSNC1 27 PH_EMS3_SNS_R 28 VDO_BOOST3 29 VDO_LPOW3 30 Ground Connector listing models C53x see System card network models C53x on page 5 18 continued Connector Pin...

Page 278: ...TRANS2 1 VS_5V_TPS 2 V_JTRANS 9 3 3V 3 TPS_SNS 4 TPS_PWM1 5 TPS_SNS_RTN 6 TPS_THERM_SNS 7 Ground 8 I2C_CLK_TB 9 I2_DATA_TB 10 V_TRANS 1 3 3V 11 Ground 12 N C JTRAY1 1 VS_TRAY_INPT_LED 5V 2 S_TRAY_INPUT 3 Ground 4 VS_TRAY 5V_NMT 5 TRAY_NMT 3 3v 6 Ground 7 N C JTRAY2 1 VS_TRAY_ENC_LED 2 S_TRAY_ENC 3 Ground 4 V_TRAY_PICK_M 5 V_TRAY_PICK_M Connector listing models C53x see System card network models C...

Page 279: ...rs 5 23 5022 xxx 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 ...

Page 280: ...5 24 Service Manual 5022 xxx ...

Page 281: ...anged at this interval to maintain the print quality and reliability of the printer The following maintenance items are available for the customer Maintenance items Description Part number Lexmark C52x models Lexmark C53x models Fuser assembly 115 V 40X1400 40X3569 Fuser assembly 230 V 40X1402 40X3570 Fuser assembly 100 V 40X1403 40X3571 Transfer belt assembly 40X1401 40X3572 Also can be used in m...

Page 282: ...6 2 Service Manual 5022 xxx ...

Page 283: ...gether and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Model information used in the parts catalog Asm Index Part number Units mach Units FRU Description Model name Configuration Machine type Lexmark C520n Network 5022 010 Lexmark C522n Network 5022 210 Lexmark C524 Non network 5022 400 Lexmark C52...

Page 284: ...7 2 Service Manual 5022 xxx Assembly 1 Covers 15 1 2 3 4 9 5 8 10 12 13 14 6 7 11 ...

Page 285: ...1 1 Top access cover assembly non network C524 8 40X3604 1 1 Top access cover assembly network C532n C534n 8 40X3605 1 1 Duplex top access assembly network C530dn C532dn C534dn 9 40X1422 1 1 Exit tray cover C52x 9 40X3594 1 1 Exit tray cover C53x 10 40X1427 1 1 Rear cover 11 40X3612 1 Paper tray dust cover with dust cover spring C53x 12 40X1425 1 1 Right cover 13 40X1443 1 1 Front access door cove...

Page 286: ...7 4 Service Manual 5022 xxx Assembly 2 Front ...

Page 287: ...0X1420 1 1 Front door parts packet C52x including A Right cable assembly 1 B Front door cap 1 C Left cable assembly 1 5 40X3593 1 1 Front door parts packet C53x including A Right cable assembly 1 B Front door cap 1 C Left cable assembly 1 6 40X1419 1 1 Duplex front door assembly C524dn 6 40X1418 1 1 Front door assembly C520n C522n C524n 6 40X3592 1 1 Duplex front door assembly C530dn C532dn C534dn...

Page 288: ...7 6 Service Manual 5022 xxx Assembly 3 Right ...

Page 289: ...its FRU Description 3 1 40X1409 1 1 EP drive assembly C52x 1 40X3578 1 1 EP drive assembly C53x 2 40X3574 1 1 Low voltage power supply 115 230 V 3 40X1433 1 1 Bump aligner motor 4 40X1436 1 1 Front door 5 V interlock switch NS 40X1445 1 1 Ground contact plate C52x only ...

Page 290: ...7 8 Service Manual 5022 xxx Assembly 4 Rear ...

Page 291: ...1 System card network C524n C524dn 2 40X4219 1 1 System card network C520n C522n 2 40X4217 1 1 System card C524 2 40X3616 1 1 System card network C530dn C532n C532dn 2 40X3617 1 1 System card network C534n 2 40X3618 1 1 System card network C534dn 3 40X1429 1 1 System card support shield C52x 3 40X3597 1 1 System card support shield C53x 4 40X1410 1 1 Smart chip card C52x only ...

Page 292: ...7 10 Service Manual 5022 xxx Assembly 5 Left 1 2 3 ...

Page 293: ...xx Assembly 5 Left Index P N Units mach Units FRU Description 5 1 40X1416 4 1 Toner level sensor 2 40X1428 1 1 Transfer contact assembly 3 40X1411 1 1 High voltage power supply C52x 3 40X3579 1 1 High voltage power supply C53x ...

Page 294: ...7 12 Service Manual 5022 xxx Assembly 6 Top 1 2 ...

Page 295: ...Parts catalog 7 13 5022 xxx Assembly 6 Top Index P N Units mach Units FRU Description 6 1 40X3613 1 1 Top cover camshaft assembly 2 40X1437 1 1 Top access door 24 V interlock switch ...

Page 296: ...7 14 Service Manual 5022 xxx Assembly 7 Customer replaceable units CRUs 3 4 1 2 5 6 2 ...

Page 297: ...Paper tray assembly single feeder C520n C522n 5 40X3599 1 1 MPF paper tray assembly 250 sheet C530dn C532dn C534dn 5 40X3596 1 1 Paper tray assembly single feeder C532n C534n 6 40X1401 1 1 Transfer belt assembly C52x 6 40X3572 1 1 Transfer belt assembly C53x NS 40X0297 1 1 Power cord USA Canada Bolivia Peru NS 40X0288 1 1 Power cord Argentina NS 40X0296 1 1 Power cord Australia New Zealand NS 40X0...

Page 298: ...7 16 Service Manual 5022 xxx Assembly 8 Contact springs ...

Page 299: ...N Units mach Units FRU Description 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 HVPS doctor developer contact spring 8 ...

Page 300: ...7 18 Service Manual 5022 xxx Assembly 9 Cable parts packet ...

Page 301: ... 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 Duplex cable 1 2 40X3598 1 1 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 ...

Page 302: ...524n C524dn NS 40X4655 1 1 PrintCryption card C534n C534dn NS 40X2663 1 1 Forms card C524 C524n C524dn NS 40X4654 1 1 Forms card C534n C534dn NS 40X1375 1 1 MarkNet N8000 fast ethernet print server C524 C524dn NS 40X1376 1 1 MarkNet N8020 gigabit ethernet print server C524 C524dn C534n C534dn NS 40X1377 1 1 MarkNet N8030 fiber ethernet print server C524 C524dn C534 C534dn NS 40X1378 1 1 MarkNet N8...

Page 303: ...tons description 2 2 parts catalog operator panel 7 2 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 Emul...

Page 304: ...ION 3 4 Bottom Margin 3 5 Left Margin 3 5 Quick Test 3 6 Right Margin 3 5 Skew 3 4 Top Margin 3 5 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 catalog 7 6...

Page 305: ... media weight 1 11 using card stock 1 9 envelopes 1 8 labels 1 9 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...

Page 306: ...ostic menu 3 10 Q Quick Test duplex 3 12 R removal and cleaning precautions 4 1 removals 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 bez...

Page 307: ...r 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 failure 2 50 dead printer 2 51 exit sensor 2 52 input sensor 2 52 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 4 4 3 s...

Page 308: ...bly installation 4 100 locations 5 6 parts catalog 7 12 removal 4 99 transfer belt locations 5 7 parts catalog 7 14 removal 4 103 transfer contact assembly locations 5 5 parts catalog 7 10 removal 4 104 Transfer Motor Test 3 8 transparencies using 1 8 W waste toner assembly locations 5 7 removal 4 105 ...

Page 309: ...ricas C524 C524dn C534n C534dn 7 20 40X1400 Fuser assembly 115 V C52x 6 1 7 15 40X1401 Transfer belt assembly C52x 6 1 7 15 40X1402 Fuser assembly 230 V C52x 6 1 7 15 40X1403 Fuser assembly 100 V C52x 6 1 7 15 40X1404 MPF paper tray assembly 250 sheet C524 C524n C524dn 7 15 40X1405 Paper pick mechanism assembly C52x 7 5 40X1409 EP drive assembly C52x 7 7 40X1410 Smart chip card C52x only 7 9 40X14...

Page 310: ...ly 115 V C53x 6 1 7 15 40X3570 Fuser assembly 230 V C53x 6 1 7 15 40X3571 Fuser assembly 100 V C53x 6 1 7 15 40X3572 Transfer belt assembly C53x 6 1 7 15 40X3573 Paper pick mechanism assembly C53x 7 5 40X3574 Low voltage power supply 115 230 V 7 7 40X3578 EP drive assembly C53x 7 7 40X3579 High voltage power supply C53x 7 11 40X3581 Front access door cover assembly non duplex C532n C534n 7 3 40X35...

Page 311: ...etwork C530dn C532n C532dn 7 9 40X3617 System card network C534n 7 9 40X3618 System card network C534dn 7 9 40X4217 System card C524 7 9 40X4218 System card network C524n C524dn 7 9 40X4219 System card network C520n C522n 7 9 40X4225 PrintCryption card C524 C524n C524dn 7 20 40X4653 Bar code card C534n C534dn 7 20 40X4654 Forms card C534n C534dn 7 20 40X4655 PrintCryption card C534n C534dn 7 20 73...

Page 312: ...I 10 Service Manual 5022 xxx ...

Page 313: ......

Page 314: ......

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