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Lexmark C520 Series, Service Manual

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Table of contents

v

5022-

xxx

Input sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-63
Exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-63
Dead printer service check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-64
Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-65

One or more operator panel buttons fail  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-65
Operator panel display   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-66

Print quality service check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-67

Print quality—background  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-68
Print quality—blank page   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-69
Print quality—blurred or fuzzy print  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Print quality—half-color page   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-70
Print quality—horizontal banding   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Print quality—horizontal line  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-71
Print quality—insufficient fusing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-71
Print quality—missing image at edge  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-71
Print quality—mottle (2 - 5mm speckles)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-71
Print quality—narrow vertical line  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-71
Print quality—random marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Print quality—residual image   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-72
Print quality—solid color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-72
Print quality—vertical banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-73

Diagnostic aids

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

3-1

Accessing service menus

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Diagnostic mode

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

Diagnostics menu structure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2
Available tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2
Registration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-5

Quick Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-6

Alignment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-7
Motor tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-7

General motor test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-7
Mirror motor test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8
Servo laser test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8
Motor calibration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8

Print tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-9

Input source tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-9
Print quality pages (Prt Quality Pgs)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-9

Duplex tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10

Quick Test (duplex)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
Print Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
Top Margin (duplex)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
Motor Test (duplex)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11

Base sensor test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12

Bin Full Test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12

Printer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13

Defaults  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Page Counts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Serial Number  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Engine Setting 1 through 4  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Model Name  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Configuration ID   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14
Edge to Edge   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14

EP setup  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14

EP Defaults  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14
Fuser Temperature (Fuser Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15
DC Charge Adjust, Dev Bias Adj, Transfer Adjust   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15

Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16

Summary of Contents for C520 Series

Page 1: ...524 5022 xxx 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...

Page 2: ...ams described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTr...

Page 3: ...delines 1 6 Supported print media 1 6 Input and output capacities 1 10 Additional guidelines 1 10 Paper 1 10 Envelopes 1 11 Transparencies 1 11 Labels 1 11 Avoiding jams 1 11 Print area 1 11 Tools req...

Page 4: ...service check 2 37 146 xx Motor duplex error service check 2 38 147 xx 149 xx Motor 500 sheet option tray2 motor error service check 2 39 148 xx MPF motor error service check 2 40 910 01 Engine error...

Page 5: ...l image 2 72 Print quality solid color page 2 72 Print quality vertical banding 2 73 Diagnostic aids 3 1 Accessing service menus 3 1 Diagnostic mode 3 2 Diagnostics menu structure 3 2 Available tests...

Page 6: ...anel inner bezel removal 4 21 Operator panel assembly removal 4 22 Top access cover assembly removal 4 23 Front removals 4 26 Fuser cable cover removal 4 27 printer pad removal 4 27 Multipurpose feede...

Page 7: ...system card 5 5 Parallel system card 5 6 Wiring diagrams 5 7 Preventive maintenance 6 1 Parts catalog 7 1 How to use this parts catalog 7 1 Assembly 1 CRUs 7 2 Assembly 2 Covers 7 4 Assembly 3 Front...

Page 8: ...viii Service Manual 5022 xxx...

Page 9: ...Laserprodukte der Klasse I gelten als unsch dlich 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 L...

Page 10: ...l ser de Clase I 1 Los productos l ser de Clase I no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivat...

Page 11: ...der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p b lgel ngdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstr ling...

Page 12: ...m farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet...

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

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

Page 15: ...signes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le...

Page 16: ...sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la...

Page 17: ...roducte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d a...

Page 18: ...mation provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer...

Page 19: ...ailable in every country Contact your point of purchase for options available in your country Memory options of 128MB 256MB and 512 SDRAM Flash memory options of 32MB and 64MB Hard disk 20GB with adap...

Page 20: ...e to the host USB serial parallel network Host system and application Page complexity and content Printer options installed or selected Available printer memory Media size and type Resolution Memory c...

Page 21: ...5 lb 3 29 kg Basic printer with 500 sheet assembly 24 in 610mm 17 3 in 440 mm 22 in 558 mm 64 75 lb 29 37 kg MPF configuration printer with multipurpose feeder extended and output bin installed 19 in...

Page 22: ...ifications Operating Air Temperature Product Operating 15 6 to 32 200 C 60 to 90 00 F Air Temperature Product Power Off 10 0 to 43 300 C 50 to 110 00 F Air Relative Humidity Relative Humidity 8 to 80...

Page 23: ...ordance with ISO 7779 and conform with ISO 9296 Printer Operating mode 1 Meter Average Bystander Sound Pressure 4800 CQ Declared Sound Power Level 4800 CQ C520n C522n C524n Printing 51 dBA Idle 34 dBA...

Page 24: ...d sample of any paper or specialty media you are considering using with the printer before purchasing large quantities Supported print media The following tables provide information on standard and op...

Page 25: ...mm C5 Envelope 162 x 229 mm B5 Envelope 176 x 250 mm Other Envelope 60 5 to 215 9 mm 97 4 to 215 9 mm 1 Lower feed reliability might be encountered when using non standard media sizes Media Sizes Con...

Page 26: ...63 g m2 Transparency 0 12 to 0 14 mm 4 8 to 5 4 mil Weight 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 2...

Page 27: ...in 24 to 58 lb 90 to 218 g m2 Envelope Monarch 7 9 10 DL B5 C5 C6 C5 C6 B6 16 to 28 lb 60 to 105 g m2 Duplexer A5 B5 Executive Statement Folio Letter A4 and Legal Xerographic and Bonds Long Grain 20 t...

Page 28: ...Guide The chemical process used in preprinting may render some papers unsuitable for use with the Lexmark C52x printers Unsuitable papers include multi part forms and documents chemically treated pape...

Page 29: ...r before purchasing large quantities By selecting the appropriate print media and loading it properly you can avoid most jams The following hints can help you avoid jams Use only recommended print med...

Page 30: ...ers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 Serial number TLI and machine type The serial nu...

Page 31: ...by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Volt Power Supply M Magenta MPF Multipurpose Feeder MROM Masked Read Only Memory MS Microswitch NVRAM N...

Page 32: ...1 14 Service Manual 5022 xxx Printer theory of operation Paper path 6 VWHP FDUG 7UDQVIHU EHOW XVHU XSOH GULYH 03 SLFN 3DSHU SLFN PHFKDQLVP XPS DOLJQ UROOHU 3DSHU H LW IODJ QSXW IODJ...

Page 33: ...General information 1 15 5022 xxx...

Page 34: ...ut of the paper trays or MPF Transfer belt The function of the transfer belt unit is two fold 1 the transfer rolls located inside the transfer belt unit are an integral part of the EP process and 2 th...

Page 35: ...etected by a sensor located in the paper pick mechanism It does not matter where the media comes from Tray 1 Tray 2 or the MPF it will enter the EP process at the bump aligner drive The bump aligner m...

Page 36: ...Once the print media exits the transfer belt it enters the fuser where heat and pressure are applied to bond the toner permanently to the media The fuser rollers continue to turn and pull the print m...

Page 37: ...the output bin If the page is to be duplexed the fuser output drive roll continues to pull the media until it clears the paper exit flag and then reverses the rotation of the roller in order to pull...

Page 38: ...g 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...

Page 39: ...aragraphs 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...

Page 40: ...ive The power to turn the bump aligner roll is supplied from the bump aligner motor The motor drives a set of bump aligner gears which causes the bump aligner roll to turn XPS DOLJQHU UROO DFNXS DOLJQ...

Page 41: ...on the EP drive assembly provides drive to the top two photodeveloper units and toner cartridges yellow and cyan Likewise the bottom cartridge motor 2 drives the two bottom photodeveloper units and t...

Page 42: ...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...

Page 43: ...er flags one at the bottom of the machine paper pick to detect input paper including duplex second side from all sources and one at the top paper exit to detect paper movement beyond the fuser The fla...

Page 44: ...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 i...

Page 45: ...codes generated for specific paper jams and the corresponding locations of these jams 3DSHU DP 7UD 3DSHU DP 7UD 3DSHU DP 03 HHGHU 3DSHU DP QSXW VHQVRU DUHD 3DSHU DP QSXW 6HQVRU WR XVHU 3DSHU DP XVHU...

Page 46: ...ring 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 wit...

Page 47: ...ges 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 fr...

Page 48: ...high voltage current to flow from the HVPS to the charge roll contact on the photoconductor unit It is essential that the contact springs are properly touching to provide a good flow If not print qual...

Page 49: ...s high voltage current to flow from the HVPS to the photoconductor drum contact on the photoconductor unit It is essential that the contact springs are properly touching to provide a good flow If not...

Page 50: ...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 n...

Page 51: ...ransfer belt receives its high voltage charge through spring contacts located on the transfer contact assembly as shown in the following illustration For simplicity sake only one of the roller s high...

Page 52: ...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 T...

Page 53: ...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 uni...

Page 54: ...lt 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...

Page 55: ...red 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...

Page 56: ...The transfer belt surface is cleaned as it rotates past a cleaning blade and shaft located inside the transfer belt assembly Any waste toner that is scraped off of the belt is collected in the waste t...

Page 57: ...General information 1 39 5022 xxx Electrical interlock 5V interlock switch An interlock switch triggered by the front access door disables the 5 V output to the printhead which turns off the laser...

Page 58: ...is closed with the front access door also closed the drive retraction lockout trips the switch arm which closes the 24V interlock switch When the 24V switch opens the normally open side of the switch...

Page 59: ...o Symptom tables on page 2 5 Locate your symptom and take the appropriate action Service errors 1xx xx s 9xx xx s If a service error code appears while you are working on the printer go to Service err...

Page 60: ...the indicator light on the operator panel gives information about the status of the printer using the colors red and green Indicator light status Indicates Off Printer power is off Blinking green Prin...

Page 61: ...list or a different setting for a menu item Press these buttons to scroll items that wrap off of the screen For menu items with numeric values such as Copies press and hold this button to scroll throu...

Page 62: ...For example 8 The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start 9 The operator panel LED starts blinking 10 A clock face appears on the display The followi...

Page 63: ...uality blank page on page 2 69 Blurred or fuzzy print Go to Print quality blurred or fuzzy print on page 2 70 Half color page Go to Print quality half color page on page 2 70 Horizontal banding Go to...

Page 64: ...er Remove and reseat the fuser POR the printer Go to 120 03 Fuser error service check on page 2 32 if the error message still appears 120 04 07 Fuser Error An error has occurred in the fuser Remove an...

Page 65: ...R the printer If error persists replace the system card Go to System card removal on page 4 47 904 xx Interface Violation by RIP These errors indicate an unrecoverable system software error POR the pr...

Page 66: ...nected Go to 920 17 POST power on self test error service check on page 2 51 920 18 POST Error Tray 2 has failed Go to 920 18 POST power on self test error service check on page 2 51 920 19 POST Error...

Page 67: ...printer Go to 945 03 946 03 947 04 Transfer roll black error service check on page 2 59 if the message reappears 950 00 29 NVRAM Mismatch Mismatch between operator panel assembly NVRAM and smart chip...

Page 68: ...51 If problem still exists replace system card Go to System card removal on page 4 47 32 xx Unsupported Print Car tridge Check to see if cartridge is a supported cartridge If so reseat specified toner...

Page 69: ...sufficient 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...

Page 70: ...ntinue 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 flas...

Page 71: ...Make sure the USB Buffer menu item is not set to Disabled If this does not fix the problem replace system card Go to System card removal on page 4 47 58 xx Too many flash options installed Turn off a...

Page 72: ...lem persists open front access door and check bump aligner shaft for binding Clear binding if possible If not possible contact next level of service 82 Replace waste toner box Replace the waste toner...

Page 73: ...using the instruction sheet that comes with the replacement transfer belt If problem persists replace system card Go to System card removal on page 4 47 83 Replace transfer belt Replace the transfer...

Page 74: ...specified photoconductor unit and see if problem clears Go to Photoconductor unit removal on page 4 14 Check high volt contacts especially the finger on the specified photoconductor unit If contacts...

Page 75: ...lace fuser cable If problem persists after replacing cable replace system card Go to System card removal on page 4 47 88 color Cartridge low Replace specified toner cartridge Press until Continue appe...

Page 76: ...aints in paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Replace the paper pick mechanism Go to Paper pick mechanism assembly removal on page 4 30 200 16 Input sen...

Page 77: ...t sensor service check on page 2 63 201 08 Exit sensor is never made when leading edge of paper has moved far enough to engage exit sensor flag Paper wrapped in fuser Damaged paper exit sensor or pape...

Page 78: ...Faulty system card Faulty output bin flag Check output bin flag on fuser for proper operation Ensure that paper is not hanging on the flag The fuser exit sensor may not be functioning properly Go to...

Page 79: ...fuser exit sensor may not be functioning properly Go to Exit sensor service check on page 2 63 230 03 Input sensor is never made during the duplex print Obstructed duplex path Defective input sensor F...

Page 80: ...or MPF Properly set media restaints in paper tray Check the pick arm rolls tires and replace if worn Replace the paper tray Replace the paper pick mechanism Go to Paper pick mechanism assembly removal...

Page 81: ...made while previous page is still in aligner Incorrect media setting Incorrect paper loading Incorrect media restraint setting 500 sheet assembly failure Paper pick mechanism Ensure proper media is se...

Page 82: ...paper tray Replace the MPF swing arm assembly Multipurpose feeder MPF swing arm assembly removal on page 4 28 If the previous actions do not fix the problem replace the paper pick mechanism Go to Pap...

Page 83: ...ct media setting Incorrect paper loading Incorrect media restraint setting Paper tray failure Paper pick mechanism failure System card Ensure proper media is set for the type of paper used Fan media a...

Page 84: ...other damage Is cable properly connected and damage free Go to step 2 If connector is damaged on system card replace system card Go to System card removal on page 4 47 If JINT1 cable or connector is d...

Page 85: ...per connection to system card cable for pinch points and cable or connector for any other damage Is cable properly connected and damage free Go to step 3 If connector is damaged on system card replace...

Page 86: ...ace system card Go to System card removal on page 4 47 If printhead cable is damaged replace printhead Go to Printhead removal on page 4 52 3 Turn printer power on and check for 5 V dc between JINT1 p...

Page 87: ...replace system card Go to System card removal on page 4 47 If printhead cable is damaged replace printhead Go to Printhead removal on page 4 52 3 Turn printer power on and check for 5 V dc between JIN...

Page 88: ...1 for proper connection to system card cable for pinch points and cable or connector for any other damage Is cable properly connected and damage free Go step 4 If connector is damaged on system card r...

Page 89: ...or AC auto connect pin 1 pin 5 pin 2 pin 4 pin 3 pin 1 Go to step 7 Replace AC fuser cable 7 Reinstall fuser Go to Fuser removal on page 4 13 Does error clear Problem solved Go to step 8 8 Replace fus...

Page 90: ...em card removal on page 4 47 If LVPS cable is damaged replace LVPS Go to Low volt power supply LVPS removal on page 4 38 4 Replace fuser Go to Fuser removal on page 4 13 Does error clear Problem solve...

Page 91: ...tor that connects to the LVPS Is continuity present LVPS connector AC auto connect pin 1 pin 5 pin 2 pin 4 pin 3 pin 1 Go to step 6 Replace AC fuser cable 6 Reinstall fuser Go to Fuser removal on page...

Page 92: ...ck mechanism Go to Paper pick mechanism assembly removal on page 4 30 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No 1 Turn th...

Page 93: ...ear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No 1 Turn the printer off and remove the rear cover Check connector JCART1 for proper connectio...

Page 94: ...3 3 Replace EP drive assembly Go to Electrophotographic Process EP drive assembly removal on page 4 40 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step...

Page 95: ...e 5 6 for fuse location on the network system card Replace system card Go to System card removal on page 4 47 Go to step 3 3 Replace EP drive assembly Go to Electrophotographic Process EP drive assemb...

Page 96: ...Yes No 1 Turn the printer off and remove the rear cover Check connector JDUPLX1 for proper connection to system card cable for pinch points and cable or connector for any other damage Is cable properl...

Page 97: ...System card removal on page 4 47 If JOPT1 cable is damaged replace option cable 2 Remove 500 sheet assembly Check auto connects on both the assembly and the printer for damage Are connectors free of d...

Page 98: ...er pick mechanism Go to Paper pick mechanism assembly removal on page 4 30 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No 1 Tu...

Page 99: ...bump aligner motor Go to Bump aligner motor removal on page 4 45 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No 1 Turn the pr...

Page 100: ...embly Go to Electrophotographic Process EP drive assembly removal on page 4 40 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No...

Page 101: ...al on page 4 47 Step Questions actions Yes No 1 Turn the printer off and remove the rear cover Check connector JPH1 large printhead cable for proper connection to system card cable for pinch points an...

Page 102: ...rd removal on page 4 47 Step Questions actions Yes No 1 Turn the printer off and remove the rear cover Check connector JTRAY1 for proper connection to system card cable for pinch points and cable or c...

Page 103: ...moval on page 4 13 Check DC auto connects on both the fuser and the printer for damage Are connectors free of damage Go to step 3 If connector is damaged on fuser replace fuser If the cable connectors...

Page 104: ...nnect toner level sensor cable if not properly connected If sensor cable or connector is damaged replace sensor Go to Toner level sensor removal on page 4 58 If connector is damaged on HVPS replace HV...

Page 105: ...5 Replace HVPS Go to High volt power supply HVPS removal on page 4 55 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No 3LQ W SL...

Page 106: ...cable parts packet contains 1 cartridge motor cable that works for either of the cartridge motors 2 Remove right cover Check for the following continuity between JCART1 and top cartridge connector Is...

Page 107: ...cable The cable parts packet contains one cartridge motor cable that works for either of the cartridge motors 2 Remove right cover Check for the following continuity between JCART2 and bottom cartridg...

Page 108: ...nt door assembly removal on page 4 34 for a duplex printer 2 Replace transfer belt assembly Go to Transfer belt removal on page 4 15 Does error clear Problem solved Replace system card Go to System ca...

Page 109: ...ff and remove the rear cover Check connector JOPT1 for proper connection to system card cable for pinch points and cable or connector for any other damage Is cable properly connected and damage free G...

Page 110: ...sembly Go to Electrophotographic Process EP drive assembly removal on page 4 40 Does error clear Problem solved Replace system card Go to System card removal on page 4 47 Step Questions actions Yes No...

Page 111: ...2 If connector is damaged on system card replace system card Go to System card removal on page 4 47 If HVPS1 cable is damaged replace top access cover assembly Go to Top access cover assembly removal...

Page 112: ...assembly Go to Transfer contact assembly removal on page 4 57 4 Replace transfer contact assembly Go to Transfer contact assembly removal on page 4 57 Does error clear Problem solved Go to step 5 5 Re...

Page 113: ...If connector is damaged on system card replace system card Go to System card removal on page 4 47 If HVPS1 cable is damaged replace top access cover assembly Go to Top access cover assembly removal o...

Page 114: ...sembly Go to Transfer contact assembly removal on page 4 57 4 Replace transfer contact assembly Go to Transfer contact assembly removal on page 4 57 Does error clear Problem solved Go to step 5 5 Repl...

Page 115: ...2 If connector is damaged on system card replace system card Go to System card removal on page 4 47 If HVPS1 cable is damaged replace top access cover assembly Go to Top access cover assembly removal...

Page 116: ...assembly Go to Transfer contact assembly removal on page 4 57 4 Replace transfer contact assembly Go to Transfer contact assembly removal on page 4 57 Does error clear Problem solved Go to step 5 5 R...

Page 117: ...If connector is damaged on system card replace system card Go to System card removal on page 4 47 If HVPS1 cable is damaged replace top access cover assembly Go to Top access cover assembly removal o...

Page 118: ...ssembly Go to Transfer contact assembly removal on page 4 57 4 Replace transfer contact assembly Go to Transfer contact assembly removal on page 4 57 Does error clear Problem solved Go to step 5 5 Rep...

Page 119: ...recently replaced go to step 3 If the card has not been replaced go to step 2 2 Operator panel assembly If the operator panel assembly has been recently replaced go to step 4 If the operator panel as...

Page 120: ...f the smart chip card has been recently replaced go to step 3 If the smart chip card has not been recently replaced contact the next level of support 2 System card If the system card has been recently...

Page 121: ...ick mechanism Go to Paper pick mechanism assembly removal on page 4 30 3 System card If input sensor is free of damage and operates correctly replace system card Go to System card removal on page 4 47...

Page 122: ...card Check for approximately 5 V dc between JLVPS1 pin 1 and ground If the voltage is correct replace the system card Go to System card removal on page 4 47 If the voltage is incorrect go to step 4 4...

Page 123: ...l assembly If any button fails the Button Test replace the operator panel assembly Go to Operator panel assembly removal on page 4 22 If a 950 00 through 950 29 error code is displayed after replacing...

Page 124: ...replace the operator panel assembly Go to Operator panel assembly removal on page 4 22 3 Operator panel display blank 5 beeps LED on Check for ground between JOPP1 pin 4 and ground If correct replace...

Page 125: ...OFF RGB Brightness RGB Contrast RGB Saturation Set to 0 Color Balance Select Reset Defaults to zero out all colors Check the paper type texture and weight settings against what is loaded in the print...

Page 126: ...nt Potential cause Action 1 Transfer belt assembly HVPS contacts Check the high voltage contact from the HVPS to the transfer belt assembly If a problem is found replace the spring or the transfer con...

Page 127: ...t on page 3 7 If the motor fails to turn replace the EP drive assembly Go to Electrophotographic Process EP drive assembly removal on page 4 40 4 Photoconductor unit charge roll HVPS contact path Chec...

Page 128: ...ck the continuity of the HVPS cable If incorrect replace the cable assembly 6 HVPS Replace the HVPS Go to High volt power supply HVPS removal on page 4 55 7 Printhead Replace the printhead Go to Print...

Page 129: ...t power supply LVPS removal on page 4 38 Potential cause Action 1 Developer cartridge Reseat developer cartidge Potential cause Action 1 Developer cartridge Keep running prints through and the problem...

Page 130: ...r assembly for toner contamination The hot roll espe cially might cause toner to be retained and deposited on the page Potential cause Action 1 Photoconductor unit Replace the photoconductor unit for...

Page 131: ...replace the cable assembly 4 HVPS Replace the HVPS Go to High volt power supply HVPS removal on page 4 55 5 System card Replace the system card Go to System card removal on page 4 47 Potential cause A...

Page 132: ...2 74 Service Manual 5022 xxx...

Page 133: ...on the printer 4 Release the buttons when the clock graphic displays The Diagnostics Mode group contains the settings and operations used while manufacturing and servicing the printer Go to Diagnostic...

Page 134: ...nment settings Can be used in place of each individual color alignment pages MOTOR TESTS Align Motor Test Tests the bump aligner motor Go to General motor test on page 3 7 Bottom Cartridge Tests the b...

Page 135: ...3 3 5022 xxx PRINT TESTS Tray 1 Go to Input source tests on page 3 9 Tray 2 if installed Manual Feeder MP Feeder Prt Quality Pgs Go to Print quality pages Prt Quality Pgs on page 3 9 Diagnostics mode...

Page 136: ...SETUP Defaults Go to Defaults on page 3 13 Page Counts This menu contains three submenus Color Page Count Mono Page Count and Perm Page Count Go to Page Counts on page 3 13 Serial Number Go to Serial...

Page 137: ...s page to determine the changes you need to make to the margins settings 3 Use or to select the margin setting you need to change and press EP SETUP EP Defaults Go to EP Defaults on page 3 14 Fuser Te...

Page 138: ...nting the Registration screen displays again Description Value Direction of change Bottom margin 20 to 20 Each increment causes approximately 0 55 mm shift in the bottom margin A positive offset moves...

Page 139: ...from Quick Test Step 1 Reprint the Quick Test to ensure the settings are correct Make additional adjustments as required 9 Press Back to return to ALIGNMENT Motor tests The motor tests are run primar...

Page 140: ...Stop Servo laser test 1 Select Motor Tests from DIAGNOSTICS Scroll until you reach Servo Laser Test 2 Press Select to run the test The panel displays Servo Laser Test After the test completes the pane...

Page 141: ...of a broad range of the device s settings and to test the device s ability to generate acceptable printed output After a user selects this option the printer begins generating 5 pages in English The d...

Page 142: ...es until you press Stop Print Test duplex This test provides service personnel with a way to verify the fuctioning of the printer s duplex hardware After the user selects this test the device automati...

Page 143: ...and widens the top margin A decrease moves the top margin upward and narrows the top margin 4 Press 5 Print the Quick Test duplex again to verify the adjustment Repeat if necessary Motor Test duplex T...

Page 144: ...f the sensors one line at a time and the current state of the sensor Use the down arrow to locate the sensor in question Use the following table to toggle the sensor 3 Press Back or Stop to exit the t...

Page 145: ...e any of the values The page count can only be viewed and cannot be changed To view the color page count mono page count or the permanent page count 1 Select Page Counts from PRINTER SETUP 2 Scroll to...

Page 146: ...by the value for Configuration ID 1 3 Enter the Configuration ID 1 To select a digit or character to change press or until the digit or character is underlined To change a digit or character press to...

Page 147: ...ure can be adjusted to Low Normal High The default is Normal DC Charge Adjust Dev Bias Adj Transfer Adjust Each of these three settings enables you to adjust the high voltage levels controlling the EP...

Page 148: ...the EVENT LOG menu Print Log Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather than CONFIG MENU The Event Log printed from DIAGNOSTICS includes Detail...

Page 149: ...llow and photoconductor units from excessive wear In addition to setting the values the cyan magenta and yellow toner cartridges and their matching photoconductor units must be removed from the printe...

Page 150: ...size sensing Auto is the same as On Panel Menus Lets the system support person enable or disable the operator panel menus The advantage of disabling the menus is so users cannot change values for the...

Page 151: ...ts the values that are displayed in the Power Saver menu item On Off Select Off to cause Power Saver to only display Disabled If Disabled is selected in Power Saver the printer deactivates the Power S...

Page 152: ...slot for instance the Magenta toner cartridge must be in the Magenta slot Then if the user tries to place a cartridge in an incorrect slot the printer message 31 Defective or Missing color Cartridge...

Page 153: ...essage are disabled for Paper or Env prompts that are set to Manual Manual Paper or Manual Env Jobs on Disk Lets the user select whether or not the printer deletes all buffered jobs on the hard disk D...

Page 154: ...ng font data This menu item only affects the PostScript PCL 5 PCL XL and PDF emulators 0 150 24 For example if the value is set to 24 then all fonts sized 24 points or less use the high frequency scre...

Page 155: ...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 shipp...

Page 156: ...hotoconductor 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 rem...

Page 157: ...proper skew H PDUN 4XLFN 7HVW 3ULQWHU QIRUPDWLRQ 3DJH RXQW 36 QVWDOOHG 0HPRU 0 3URFHVVRU 6SHHG 0 6HULDO 1XPEHU DO6WDW DO6HW QJLQH 6SHHG 3ULQWHU 5HYLVLRQ HYHOV RDGHU HUQHO DVH 1HWZRUN 1HWZRUN UYU QJLQH...

Page 158: ...rinthead alignment screw equals approximately 5 millimeter movement of the top edge print alignment marks H PDUN 4XLFN 7HVW 3ULQWHU QIRUPDWLRQ 3DJH RXQW 36 QVWDOOHG 0HPRU 0 3URFHVVRU 6SHHG 0 6HULDO 1X...

Page 159: ...WH LW FRXQWHUFORFNZLVH WR PRYH WKHP XS 3ULQWKHDG DOLJQPHQW VFUHZ H PDUN 4XLFN 7HVW 3ULQWHU QIRUPDWLRQ 3DJH RXQW 36 QVWDOOHG 0HPRU 0 3URFHVVRU 6SHHG 0 6HULDO 1XPEHU DO6WDW DO6HW 0DUJLQ 6HWWLQJV 7RS 0DU...

Page 160: ...ft In some cases the top right mark may be off the page You will have to repeat print the Quick Test page to see your printhead adjustment Continue adjusting the printhead alignment screw and reprinti...

Page 161: ...d move the left alignment marks to the right Press Select to accept the value and scroll to Right Margin Press Select and adjust the right margin by pressing the left arrow to decrease the value and m...

Page 162: ...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 14 On the pages...

Page 163: ...the current cyan Z value to obtain the new skew Z value 7 SLFDO FRXUVH DQG ILQH DGMXVWPHQW 7RS 7 LQH GMXVWPHQW 7RS 7 RXUVH GMXVWPHQW LUVW ORFDWH WKH OLQH RI WKH FRORU WKDW RX DUH DOLJQLQJ WKDW OLQHV...

Page 164: ...ecessary before proceeding on to Quick Test step two page 19 Obtain left L right R and Bow P value using the same method as obtaining T from Quick Test Step 1 Reprint the Quick Test to ensure the sett...

Page 165: ...e 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 Confi...

Page 166: ...ems that will need to be removed prior to some of the removal procedures The removal procedure will specify when the part must be removed XVHU 7RS DFFHVV GRRU URQW DFFHVV GRRU 3KRWRFRQGXFWRU XQLWV 7RQ...

Page 167: ...oval Warning Fuser can be extremely hot Use care when handling to avoid burns 1 Turn off printer 2 Open top access door 3 Rotate fuser thumbscrew A counterclockwise until loosened 4 Grasp handles B li...

Page 168: ...hotoconductor units by their handle and place the photoconductor units on a clean surface 1 Open top access and front access doors 2 Lift right end handle A of photoconductor unit releasing from mount...

Page 169: ...oconductor unit removal on page 4 14 2 Disconnect connector A on top of transfer belt 3 Pull out on transfer belt locking handles B until they release lift belt up and away from printer Waste toner as...

Page 170: ...5022 xxx Cover removals Exit tray cover removal 1 Grasp exit tray and lift away from printer HIW FRYHU 7RS DFFHVV FRYHU DVVHPEO URQW DFFHVV FRYHU 5LJKW FRYHU 5HDU FRYHU LW WUD FRYHU 2XWHU EH HO QQHU E...

Page 171: ...Repair information 4 17 5022 xxx Rear cover removal 1 Loosen eight screws A Do not remove screws 2 Lift up on rear cover and remove from back of printer...

Page 172: ...4 18 Service Manual 5022 xxx Right cover removal 1 Open top access door 2 Open front access door 3 Ensure power cord is removed 4 Remove two screws A 5 Lift cover and remove from right side of printer...

Page 173: ...s you can leave the photoconductor units on the transport belt when removing However follow all warnings in regards to care of the photoconductor units 4 Remove four screws A 5 Remove gearbox shield B...

Page 174: ...hole F Repeat for other side 9 Slide front access cover assembly forward away from printer Left cover removal 1 Remove waste toner assembly See Waste toner assembly removal on page 4 15 2 Open front a...

Page 175: ...bezel Flex top of outer bezel to disengage operator panel 2 Remove outer bezel with inner bezel attached 3 When reinstalling or replacing outer bezel insert bottom of bezel first ensuring that outer b...

Page 176: ...R before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable 1 Remove outer bezel See Operator panel outer bezel removal on page 4 21 2...

Page 177: ...ear cover removal on page 4 17 4 Remove exit tray See Exit tray cover removal on page 4 16 5 If top access door is open close it Warning Ensure that top access door is closed before removing linkage s...

Page 178: ...4 24 Service Manual 5022 xxx 8 Remove four screws B exposed after removing fuser 9 Remove screw C exposed after removing exit tray...

Page 179: ...Disconnnect fan JFAN1 operator panel JOPP1 high volt power supply connector JHVPS1 and bin full sensor JBIN1 network printers only cables from system card 12 Unplug connector E from CN1 on high volt...

Page 180: ...nual 5022 xxx Front removals 0DFKLQH SDG HOOFUDQN DVVHPEO XPS DOLJQHU JHDUV 5HVWUDLQW FDEOH DVVHPEO URQW GRRU DVVHPEO 03 VZLQJ DUP DVVHPEO 3DSHU SLFN PHFKDQLVP DVVHPEO HIOHFWRU DVVHPEO URQW GRRU FDS X...

Page 181: ...eft side of cable cover slide cable to left lower and remove printer pad removal 1 Slide corner of printer containing damaged pad over corner of work area Pull pad from bottom of printer 2 When instal...

Page 182: ...nual 5022 xxx Multipurpose feeder MPF swing arm assembly removal 1 Remove 250 sheet paper tray 2 Open top access door 3 Open front access door 4 Remove three mounting screws A 5 Remove swing arm assem...

Page 183: ...tion if swing arm crank comes lose from swing arm assembly Ensure that end of spring B is attached to swing arm crank as shown in the illustration Spring end should slide under retaining tab D after i...

Page 184: ...ges 4 If installed remove MPF swing arm assembly See Multipurpose feeder MPF swing arm assembly removal on page 4 28 5 Remove three mounting screws A 6 Release front locking tabs B 7 Slide paper pick...

Page 185: ...front access door for better access to gears 3 Remove three e clips and washers A 4 Remove gears 5 When reinstalling gears apply a light coat of the packaged grease Note The following illustration sho...

Page 186: ...over assembly See Front access cover assembly removal on page 4 19 2 Remove rear cover See Rear cover removal on page 4 17 3 Disconnect JTRANS1 cable from system card 4 Disconnect cable A from right s...

Page 187: ...y cable restraint springs C from front door assembly Unwrap cable restraints 7 Remove mounting screw D and cap E 8 Open front door assembly slide to the right and remove 9 See Front door assembly rest...

Page 188: ...power supply LVPS removal on page 4 38 2 Disconnect JDUPLX1 and JTRANS1 cable from system card 3 Disconnect cable A from right side of frame Be careful not to lose grounding clip B 4 Remove front acc...

Page 189: ...restraint springs C from duplex front door assembly Unwrap cable restraints 7 Remove mounting screw D and cap E 8 Open duplex front door assembly slide to the right and remove 9 See Front door assemb...

Page 190: ...front door assembly 3 For right cable remove four screws B and gearbox switch shield C There is a locking tab on the back of the gearbox shield 4 For left and right cables remove end of cable D from...

Page 191: ...Repair information 4 37 5022 xxx Right side removals 3 GULYH DVVHPEO RZ YROW SRZHU VXSSO 936 9 LQWHUORFN VZLWFK XPS DOLJQHU PRWRU...

Page 192: ...e right side cover See Right cover removal on page 4 18 2 Remove rear cover See Rear cover removal on page 4 17 3 Unplug JLVPS1 connector from system card 4 Remove five LVPS mounting screws A 5 Discon...

Page 193: ...Repair information 4 39 5022 xxx 7 When installing new LVPS ensure voltage switch C is set for proper value 115 or 230 V depending on the country...

Page 194: ...embly removal 1 Remove low volt power supply See Low volt power supply LVPS removal on page 4 38 2 Open top access door 3 Open front access door 4 Remove all toner cartridges 5 Disconnect JCART1 JCART...

Page 195: ...Repair information 4 41 5022 xxx 7 Remove nine outer screws B 1RWH FFHVV WRS WZR VFUHZV WKURXJK WRS FRYHU...

Page 196: ...drive is retracted when installing new EP drive assembly 8SSHU UHWUDFWLRQ SODWH 3 GULYH VKRZQ UHWUDFWHG RZHU UHWUDFWLRQ SODWH 1RWH KHQ UHWUDFWHG XSSHU DQG ORZHU UHWUDFWLRQ SODWHV ZLOO EH IXOO IRUZDUG...

Page 197: ...38 2 Disconnect JINT1 connector from system card 3 Open top access door 4 Open front access door Warning When removing gearbox switch shield ensure you do not damage the 5V interlock switch activation...

Page 198: ...4 44 Service Manual 5022 xxx 6 Remove interlock switch mounting screw C 7 Remove cable from cable guide and remove 5V interlock switch 5LJKW VLGH RI SULQWHU...

Page 199: ...otor removal 1 Remove right side cover 2 Remove bump aligner gears See Bump aligner gear removal on page 4 31 3 Remove two bump aligner motor mounting screws A 4 Disconnect JBUMP1 connector from syste...

Page 200: ...4 46 Service Manual 5022 xxx Rear removals 6 VWHP FDUG VXSSRUW VKLHOG 6 VWHP FDUG 6PDUW FKLS FDUG 3ULQWKHDG DVVHPEO...

Page 201: ...replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Be careful not to damage the printhead cable when removing the system card 1 Remove...

Page 202: ...4 48 Service Manual 5022 xxx 5 Remove eight screws C from system card...

Page 203: ...emove five mounting screws A from outer left side of printer Note attachment of printhead ground cable to the second screw from the bottom for later installation 5 Remove four screws B from inner righ...

Page 204: ...g screws D from top and bottom of support shield Note Only the printhead cables come through the access holes in the system card support shield 9 Lower and remove support shield Be careful not to cut...

Page 205: ...nt 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 system...

Page 206: ...See System card support shield removal on page 4 49 5 Remove fuser cable cover See Fuser cable cover removal on page 4 27 6 Remove three mounting screws A from front of printhead 7 Remove printhead a...

Page 207: ...ted that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw Once black skew is adjusted the mounting screws will be fully tig...

Page 208: ...4 54 Service Manual 5022 xxx Left side removals 7RQHU OHYHO VHQVRU 7UDQVIHU FRQWDFW DVVHPEO LJK YROW SRZHU VXSSO...

Page 209: ...olt power supply HVPS removal 1 Remove left cover See Left cover removal on page 4 20 2 Remove six mounting screws A 3 Release locking tab B from front lower corner of HVPS 4 Disconnect five connector...

Page 210: ...ve screw A and spring cap B 3 Press lower half C D of springs and remove springs 4 When installing ensure top half E of spring is under straight spring F This is typical for both types of springs Also...

Page 211: ...side contact springs See Contact springs removal on page 4 56 3 Remove four screws A and remove transfer contact assembly 4 Remove eight springs B for reuse during installation Note For ease of instal...

Page 212: ...pply HVPS removal on page 4 55 2 Depress locking tabs A on sensor remove sensor Cyan and Yellow 3 Remove transfer contact assembly See Transfer contact assembly removal on page 4 57 Do not remove spri...

Page 213: ...Repair information 4 59 5022 xxx Top removals 7RS DFFHVV GRRU 9 LQWHUORFN VZLWFK ZLWK FDEOH 7RS FRYHU FDPVKDIW DVVHPEO...

Page 214: ...switch removal 1 Remove top access cover assembly See Top access cover assembly removal on page 4 23 2 Disconnect JCVR1 connector from system card 3 Remove right cover See Right cover removal on page...

Page 215: ...lever arm A in place and rotate camshafts B down to the closed postion 4 While still holding lever arm A up remove left front mounting screw C and flip right lock D back 5 Continue to hold lever arm...

Page 216: ...by reversing the removal procedures The camshaft assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed or the printer w...

Page 217: ...and right mounting brackets B on a flat surface 3 Rotate lever arm C all the way up as if the top access door were open hold lever arm C in place and rotate camshafts down D to the closed position Re...

Page 218: ...rough opening in waste toner shutter G Ensure cam H engages waste toner shutter G as illustrated Also ensure drive pinion I engages upper retraction plate J as illustrated 7 Install rear mounting scre...

Page 219: ...ng Failure to place the camshaft assembly in the open position will prevent the front access door from closing and may cause damage to the door during closing 12 Continue to hold lever arm O up Flip r...

Page 220: ...4 66 Service Manual 5022 xxx Note Prior to installation if the left side of the camshaft assembly becomes disassembled use the following illustration...

Page 221: ...ctors 5 1 5022 xxx 5 Locations and connectors Locations Sensors LQ IXOO VHQVRU DQG IODJ 3DSHU H LW GXSOH HQWU VHQVRU DQG IODJ 0XOWLIXQFWLRQ WUDQVSDUHQF VHQVRU QSXW VHQVRU XVHU VKRZQ ZLWK DFFHVV FRYHU...

Page 222: ...5 2 Service Manual 5022 xxx 7RQHU SDWFK VHQVRU 736 7RQHU OHYHO VHQVRUV...

Page 223: ...Locations and connectors 5 3 5022 xxx Motors...

Page 224: ...5 4 Service Manual 5022 xxx Printer cards...

Page 225: ...Locations and connectors 5 5 5022 xxx Connectors Network system card Legend Jxx connector Fx fuse...

Page 226: ...5 6 Service Manual 5022 xxx Parallel system card Legend Jxx connector Fx fuse...

Page 227: ...Locations and connectors 5 7 5022 xxx Wiring diagrams See back of manual...

Page 228: ...5 8 Service Manual 5022 xxx...

Page 229: ...Preventive maintenance 6 1 5022 xxx 6 Preventive maintenance There is no preventive maintenance for this printer...

Page 230: ...6 2 Service Manual 5022 xxx...

Page 231: ...f units actually used in the base printer or product Units kit or pkg refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates t...

Page 232: ...7 2 Service Manual 5022 xxx Assembly 1 CRUs 5HDU 9LHZ...

Page 233: ...nada Bolivia Peru NS 40X0288 1 1 Power cord Argentina NS 40X0273 1 1 Power cord Chile Uruguay NS 40X0277 1 1 Power cord Brazil NS 40X0270 1 1 Power cord Japan NS 40X0282 1 1 Power cord China NS 40X028...

Page 234: ...7 4 Service Manual 5022 xxx Assembly 2 Covers...

Page 235: ...er assembly duplex front access door C524dn only NS 40X1413 1 1 Cover assembly front access door non duplex 5 40X1426 1 1 Cover left 6 40X1451 1 1 Cover assembly network top access NS 40X1412 1 1 Cove...

Page 236: ...7 6 Service Manual 5022 xxx Assembly 3 Front...

Page 237: ...431 screw parts packet 3 40X1446 1 1 Bellcrank assembly right 4 40X1432 1 1 Parts packet bump aligner gear 5 40X1420 1 1 Parts packet front door 6 40X1419 1 1 Door assembly duplex front NS 40X1418 1 1...

Page 238: ...7 8 Service Manual 5022 xxx Assembly 4 Right...

Page 239: ...Index P N Units mach Units kit or pkg Description 4 1 40X1409 1 1 Drive assembly EP 2 40X1406 1 1 Power supply low volt 115 230 V 3 40X1436 1 1 Switch front door 5V interlock 4 40X1433 1 1 Motor bump...

Page 240: ...7 10 Service Manual 5022 xxx Assembly 5 Rear...

Page 241: ...ex P N Units mach Units kit or pkg Description 5 1 40X1417 1 1 Printhead assembly 2 40X1408 1 1 Card system network C524n C524dn NS 40X1442 1 1 Card system network C520n C522n 3 40X1429 1 1 Shield sys...

Page 242: ...7 12 Service Manual 5022 xxx Assembly 6 Left...

Page 243: ...ts catalog 7 13 5022 xxx Assembly 6 Left Index P N Units mach Units kit or pkg Description 6 1 40X1416 4 1 Sensor toner level 2 40X1428 1 1 Contact assembly transfer 3 40X1411 1 1 Power supply high vo...

Page 244: ...7 14 Service Manual 5022 xxx Assembly 7 Top...

Page 245: ...xx Assembly 7 Top Index P N Units mach Units kit or pkg Description 7 1 40X1421 1 1 Assembly top cover camshaft 2 40X1437 1 1 Switch top access door 24V interlock 3 40X1440 1 1 Sensor bin full with ca...

Page 246: ...7 16 Service Manual 5022 xxx Assembly 8 Contact Springs Packet SODFHV SODFHV SODFHV SODFHV SODFHV SODFHV...

Page 247: ...Units kit or pkg Description 8 40X1434 1 1 Parts packet contact springs 1 N A 4 1 Contact spring torsion PCD 2 N A 4 1 Contact spring torsion CR 3 N A 4 1 Cap contact spring 4 N A 8 1 Contact spring...

Page 248: ...7 18 Service Manual 5022 xxx Assembly 9 Cable Parts Packet...

Page 249: ...pkg Description 9 40X1430 1 1 Parts packet cable 1 N A 1 1 Cable cartridge motor 2 N A 1 1 Cable fuser AC 3 N A 1 1 Cable fuser DC 4 N A 1 1 Cable smart chip 5 N A 1 1 Cable option NS N A 1 1 Cover f...

Page 250: ...1 US 802 11g wireless print adapter NS 1010043 1 1 International 802 11g wireless print adapter NS 14T0030 1 1 N4000e print server US and Americas NS 14T0040 1 1 N4000e print server Western Europe NS...

Page 251: ...paper pick mechanism drive 1 21 photodeveloper unit developer toner cartridge drive 1 23 transfer belt drive 1 24 media specifications avoiding jams 1 11 print area 1 11 menus selecting numerical val...

Page 252: ...checks 110 xx Mirror motor service check 2 26 111 xx Printhead error service check 2 26 112 xx Printhead error service check 2 27 113 xx Printhead error service check 2 28 114 xx Printhead error servi...

Page 253: ...63 input sensor service check 2 63 operator panel service check 2 65 print quality service check 2 67 service error codes 2 6 service tag location 1 12 specifications acoustics 1 5 data streams 1 2 d...

Page 254: ...I 4 Service Manual 5022 xxx...

Page 255: ...er cord 7 3 40X1375 MarkNet N8000 fast ethernet print server 7 20 40X1376 MarkNet N8020 gigabit ethernet print server 7 20 40X1377 MarkNet N8030 fiber ethernet print server 7 20 40X1378 MarkNet N8050...

Page 256: ...mbly 7 7 40X1445 ground contact plate 7 9 40X1446 right bellcrank assembly 7 7 40X1447 left bellcrank assembly 7 7 40X1448 inner bezel C524 7 5 40X1449 inner bezel C522 7 5 40X1450 inner bezel C520 7...

Page 257: ...0 5 9 1 D 0 1 0 7 8 7 8 4 D 1 9 D 9 1 1 5 4 9 5 9 1 4 1 1 3 5 8 9 8 1 1 8 9 1 8 1 0 1 1 5 4 9 1 D 8 9 1 1 C 1 8 D 6 0 5 1 A 5 C 1 8 0 9 1 4 C 8 9 1 D D 1 5 1 5 4 C 1 8 1 0 C 1 8 1 1 C 1 8 1 0 5 9 1 4...

Page 258: ...2 5 2 5 2 5 2 36 3 7 5 2 5 2 1 0 83 43 6 4 19 98598 3746 1 0 37 43 6 37 43 6 37 43 6 438 87 37 43 6 5 2 5 2 114 145 6 686 737 6 5 2 5 2 6 4 498 5 2 5 2 6 4 498 3 145 6 686 5 2 5 2 6 6 4 49 8 37 46 966...

Page 259: ...6 2 1 2 2 4 1 6 A 8 0 9 A D 9 8 0 9 A 9 E 2 1 6 2 9 9 E A 6 2 6 3 9 A B 7 1 D 9 A 9 A B A B 1 2 9 A 0 2 1 2 2 A A 1 2 A A 1 2 2 2 2 5 4 6 2 D 9 9 2 A A D 9 9 2 2 8 0 9 A A D 9 9 2 2 B 9 D 9 9 2 1 2 8...

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