Lexmark C520 Series Service Manual
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Lexmark C520 Series Service Manual

Lexmark C520 Series Service Manual

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Lexmark
C520, C522, and C524
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 and/or other countries.

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Summary of Contents for Lexmark C520 Series

  • Page 1 C520, C522, and C524 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 and/or other countries.
  • Page 2 Improvements or changes in the products or the programs 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 ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    5022-xxx Table of contents Laser notices ............ix Safety information .
  • Page 4 5022-xxx Start ................2-1 Symptom tables .
  • Page 5 5022-xxx Input sensor service check ............2-63 Exit sensor service check .
  • Page 6 5022-xxx Display Log ..............3-16 Print Log .
  • Page 7 5022-xxx Top cover camshaft assembly removal ..........4-61 Top cover camshaft assembly installation .
  • Page 8 5022-xxx viii Service Manual...

  • Page 9: Laser Notices

    5022-xxx Laser notices Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 10 5022-xxx Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1.
  • Page 11 5022-xxx Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer.
  • Page 12 5022-xxx Laser-notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på...
  • Page 13 5022-xxx Japanese Laser Notice xiii Laser notices...
  • Page 14 5022-xxx Korean Laser Notice Service Manual...

  • Page 15: Safety Information

    5022-xxx Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 16 5022-xxx Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 17 5022-xxx Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 18: Preface

    5022-xxx Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 19: General Information

    5022-xxx 1. General information The Lexmark C52X color laser printers deliver superior text and brilliant graphics. The following models are available. Model name Configuration Machine type Lexmark C520n Network 5022-010 Lexmark C522n Network 5022-210 Lexmark C524 Non-network 5022-400 Lexmark C524n...

  • Page 20: Specifications

    5022-xxx Specifications Resolution • 1200 x 1200 dpi • 4800 Image Quality Data streams • PostScript 3 emulation • PCL 5e and 6 emulation • PDF v1.5 emulation Print speed and performance print speed Performance Performance speed depends on: • Interface to the host (USB, serial, parallel, network) •...

  • Page 21: Dimensions

    5022-xxx Dimensions Description Height Width Depth Weight C520, C522n, C524, C524n, C524dn 19 in. 17.3 in. 16.1 in. 57.5 lb (basic printer) (484 mm) (440 mm) (408 mm) (26.1 kg) C520, C522n, C524, C524n, C524dn 19 in. 17.3 in. 20.2 in. 57.5 lb (output bin installed) (484 mm)

  • Page 22: Electrical Specifications

    5022-xxx Electrical specifications Low voltage model • 100 to 127 V ac at 47 to 63 Hz nominal • 99 to 137 V ac, extreme High voltage model • 220 to 240 V ac at 47 to 63 Hz nominal (not available in all countries) •...

  • Page 23: Acoustics

    5022-xxx Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296. 1-Meter Average Declared Sound Printer Operating mode Bystander Sound Power Level @4800 Pressure @4800 CQ Printing 51 dBA C520n, C522n, C524n Idle 34 dBA Printing (Simplex) 51 dBA C524dn, C524dtn...

  • Page 24: Media Specifications

    For more details about the types of paper and specialty media your printer supports, see the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com. We recommend that you try a limited sample of any paper or specialty media you are considering using with the printer before purchasing large quantities.
  • Page 25 5022-xxx Media Sizes (Continued) ✓ ✓ DL Envelope 110 x 220 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 Lower feed reliability might be encountered when using non-standard media sizes.
  • Page 26 5022-xxx Media Weight Subsystem Size Type Weight Primary Tray Letter, Legal, A4 Xerographic Long Grain 16 to 47 lb(60 to 177 g/m & and Bonds 500 Sheet Optional Feeder Short Grain 24 to 58 lb(90 to 218 g/m Recycled Long Grain 20 to 47lb (75 to 177 g/m Short Grain 28 to 58 lb (105 to 218g/m...
  • Page 27 5022-xxx Media Weight (Continued) Subsystem Size Type Weight Transparency Thickness: 0.12 to 0.13 mm Weight: 161 to 179 g/m A5, B5, JIS-B5, Xerographic Long Grain 20 to 47 lb (75 to 177 g/m Exec., and Bonds Statement, Folio Short Grain 24 to 58 lb (90 to 218 g/m Envelope Monarch, 7 ¾, #9, #10, DL, B5,...

  • Page 28: Input And Output Capacities

    Preprinted forms and letterheads must be able to withstand a fusing temperature of 170 degrees C (338 degrees F) and should be selected using guidelines found in the User's Guide. The chemical process used in preprinting may render some papers unsuitable for use with the Lexmark C52x printers. •...

  • Page 29: Envelopes

    5022-xxx Envelopes • All envelopes should be new, unused, and without package damage. • Envelopes with excessive curl or twist exceeding 6 mm, those stuck together, those with bent corners or nicked edges, or those that interlock should not be used. •...

  • Page 30: Tools Required For Service

    5022-xxx 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 Serial number, TLI and machine type The serial number is located on the label on the rear of the right cover and on the service tag located on the...

  • Page 31: Acronyms

    5022-xxx Acronyms BLDC Brushless DC Motor Black Only Retract Cyan Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT High-Capacity Input Tray HCOF High-Capacity Output Finisher HVPS...

  • Page 32: Printer Theory Of Operation

    5022-xxx Printer theory of operation Paper path 1-14 Service Manual...
  • Page 33 5022-xxx 1-15 General information...

  • Page 34: Main Components

    5022-xxx Main Components System card The system card provides the intelligence of the printer. Command and control signals originate in the system card that make print media travel possible. The system card controls the timing of the print media during the printing so the media arrives at certain positions in the print process at certain times.

  • Page 35: Print Media Transport

    5022-xxx Print media transport The print media is picked from the input source and fed to the bump aligner roll. The media movement is detected by a sensor located in the paper pick mechanism. It does not matter where the media comes from (Tray 1, Tray 2, or, the MPF), it will enter the EP process at the bump aligner drive.
  • Page 36 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. 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.
  • Page 37 5022-xxx 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. If the page is to be duplexed, the fuser output drive roll continues to pull the media until it clears the paper exit flag and then reverses the rotation of the roller in order to pull the media back into the printer duplex assembly.
  • Page 38 5022-xxx The media is then routed down through the duplex path until it reaches the bump aligner roll. Once in this position, it enters the EP path for the second time. 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.

  • Page 39: Mechanical Drive

    5022-xxx Mechanical drive In order for the print media to move through the paper path, there are several drive motors that supply the mechanical power to the rollers discussed previously. The drives for these components are illustrated and discussed in the following paragraphs. Paper pick mechanism drive When printing from Tray 1 or Tray 2, the paper pick motor drives the paper pick gears which causes the pick roller to turn.
  • Page 40 5022-xxx Bump aligner drive The power to turn the bump aligner roll is supplied from the bump aligner motor. The motor drives a set of bump aligner gears which causes the bump aligner roll to turn. 1-22 Service Manual...
  • Page 41 5022-xxx Photodeveloper unit/developer (toner) cartridge drive The photodeveloper units (four) and toner cartridges (four) receive drive power from the EP drive assembly motors. The top cartridge motor 1 on the EP drive assembly provides drive to the top two photodeveloper units and toner cartridges (yellow and cyan).
  • Page 42 5022-xxx Transfer belt drive The transfer belt unit receives drive from a motor located on the EP drive assembly. When the top access door is open, the coupler for the transfer belt disengages. Fuser drive The fuser drive (motor) is built into the fuser assembly and drives the fuser rollers to turn. 1-24 Service Manual...

  • Page 43: Paper Sensing

    5022-xxx Duplex drive The duplex motor is mounted on the front door assembly. Drive is provided to three drive shafts in the duplexer by a belt that is driven by the motor. The drive shafts move the print media through the duplex unit during printing.
  • Page 44 5022-xxx Paper pick sensor Paper exit/duplex entry sensor and bin full flag The top sensor detects movement in two directions: as the paper exits the fuser and as it is retracted from the exit tray back into the duplex path. Each sheet must be driven past the fuser exit flag and allowed to fall before being turned around and starting the duplex path.

  • Page 45: Paper Jams

    5022-xxx Paper Jams The following illustration shows the location and error codes generated for specific paper jams and the corresponding locations of these jams. 1-27 General information...

  • Page 46: Electrophotographic (Ep) Process

    5022-xxx Electrophotographic (EP) process Main components System card The system card is the brains 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 47: Charging

    5022-xxx HVPS Provides a high volt charge to: • The charge roll located in the photoconductor unit • The photoconductor drum located in the photoconductor unit • The toner adder roller (TAR) located in the toner cartridge • The developer roll located in the toner cartridge •...
  • Page 48 5022-xxx Photoconductor unit (charge roll) The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the charge roll contact on the photoconductor unit. It is essential that the contact springs are properly touching to provide a good flow.
  • Page 49 5022-xxx Photoconductor unit (photoconductor drum) The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the photoconductor drum contact on the photoconductor unit. It is essential that the contact springs are properly touching to provide a good flow.
  • Page 50 5022-xxx Toner cartridge The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the toner cartridge. The toner cartridge contains three parts that are provided high voltage from the HVPS. These three parts are: the doctor blade, the developer roll, and the toner adder roll (TAR). It is essential that the contact springs are properly touching to provide a good flow.
  • Page 51 5022-xxx Transfer belt The transfer belt houses four transfer rollers that provide image transfer from the photoconductor drum to the print media. The transfer belt receives its high voltage charge through spring contacts located on the transfer contact assembly as shown in the following illustration. For simplicity sake, only one of the roller's high voltage paths is shown.

  • Page 52: Exposing

    5022-xxx Exposing The main components in the exposure process are the system card, the printhead and the photoconductor unit. The following illustration depicts a typical data path for a single color exposure. Data is received from a computer into a port on the system card. The system card's RIP function converts this data into raster information which is fed to the printhead along with other control data.

  • Page 53: Developing

    5022-xxx Developing The two primary components of the developing process are the photoconductor unit and the toner cartridge. The toner cartridge contains a toner adder roll, developer roll and toner. Toner is advanced toward the toner adder roll by three paddle assemblies. The advanced toner clings to the electrically charged toner adder roll. The toner on the toner adder roll is then electrically attracted to the developer roll because of the difference in electrical charge between the toner adder roll and the developer roll.

  • Page 54: Transferring

    5022-xxx Transferring After the toner is attracted to the photoconductor drum, the image is ready for transfer onto the print media. The print media is advanced in the paper path onto the transfer belt and is carried along the belt underneath each photoconductor unit.

  • Page 55: Fusing

    5022-xxx Fusing After the image has been transferred onto the print media, it is ready for fusing. The print media is transported into the fuser where the hot roll and backup roll use a combination of high heat and pressure to melt and press the toner to the media.

  • Page 56: Cleaning

    5022-xxx Cleaning The transfer belt and photoconductor drum are cleaned at the end of the EP process cycle. The transfer belt surface is cleaned as it rotates past a cleaning blade and shaft located inside the transfer belt assembly. Any waste toner that is scraped off of the belt is collected in the waste toner container located next to the belt inside the transfer belt unit.

  • Page 57: Electrical Interlock

    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. 1-39 General information...

  • Page 58: V Interlock Switch

    5022-xxx 24V interlock switch The 24 volt interlock switch is mounted to the right side of the top cover camshaft assembly. Opening the top door rotates the drive retraction lockout which opens the 24V interlock switch. When the top door is closed with the front access door also closed, the drive retraction lockout trips the switch arm which closes the 24V interlock switch.

  • Page 59: Diagnostic Information

    5022-xxx 2. Diagnostic information Start CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.

  • Page 60: Understanding The Operator Panel

    5022-xxx Understanding the operator panel The operator panel consists of these items: • 160 x 64 pixel liquid crystal display (LCD) • Eight buttons • An indicator light Indicator light The two-toned light emitting diode called the indicator light on the operator panel gives information about the status of the printer using the colors red and green.

  • Page 61: Buttons

    5022-xxx Buttons Button Function Press to return to the previous screen. Note: It has a curved arrow icon. Note: This button is only active if appears on the top left of the screen. Press to open the administration menus. These menus are only available when the printer is in the Ready state.

  • Page 62: Power-On Self Test (Post) Sequence

    5022-xxx Power-on self test (POST) sequence When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: The LED turns on. The operator panel turns on. A partial row of pixels appears.

  • Page 63: Symptom Tables

    5022-xxx Symptom tables Printer symptom table Symptom Action Dead printer Go to “Dead printer service check” on page 2-64. Operator panel—one or more buttons do Go to “One or more operator panel buttons fail” on not work. page 2-65. Operator panel—display is blank. Printer Go to “Operator panel display”...

  • Page 64: Service Error Codes

    5022-xxx Service error codes Error code Display Text Description Action code Mirror Motor A mirror motor error has POR the printer. Go to “110.xx—Mirror occurred. motor service check” on page 2-26 if the message still appears. Printhead Error An error has occurred in POR the printer.
  • Page 65 5022-xxx Error code Display Text Description Action code 12-14 Motor Error EP Drive assembly POR the printer. Go to “144.12-14/16— cartridge 2 (bottom) Motor (EP drive asm bottom cartridge) motor has failed. error service check” on page 2-37 if the message reappears.
  • Page 66 5022-xxx Error code Display Text Description Action code POST Error Printhead motor not Go to “920.05—POST (power on self test) connected error service check” on page 2-43. POST Error Input sensor not Go to “920.06—POST (power on self test) connected error service check”...
  • Page 67 5022-xxx Error code Display Text Description Action code Transfer Roll Cyan transfer roll has POR the printer. Go to “945.01, 946.01, failed. 947.02—Transfer roll (cyan) error service check” on page 2-55 if the message reappears. Transfer Roll Magenta transfer roll has POR the printer.

  • Page 68: User Attendance Messages

    5022-xxx User attendance messages Error Primary message Action code code Defective Print Cartridge • Reseat specified toner cartridge. • Inspect smart chip card contacts for damage/contamination. If damaged, contact next level of service. • Inspect toner cartridge contacts for damage/contamination. Replace toner cartridge if defective.
  • Page 69 5022-xxx Error Primary message Action code code Short Paper • Press until Continue appears, and then press to clear the message and continue printing. The printer does not automatically reprint the page that prompted the message. • Check tray length and width guides to ensure media is properly fitted. •...
  • Page 70 5022-xxx Error Primary message Action code code Insufficient memory, • The printer was unable to restore some or all of the confidential or held some held jobs were lost jobs on the hard disk. • Press until Continue appears, and then press to clear the message.
  • Page 71 5022-xxx Error Primary message Action code code Unsupported option in • Turn the printer off. slot <x> • Unplug the power cord from the wall outlet. • Remove the unsupported option. • Connect the power cord to a properly grounded outlet. •...
  • Page 72 5022-xxx Error Primary message Action code code Unformatted disk • Press until Continue appears, and then press to clear the message and continue printing. • Format the disk. • If the error message remains, replace the hard disk. • If this does not fix the problem, replace system card. Go to “System card removal”...
  • Page 73 5022-xxx Error Primary message Action code code Transfer belt missing • Insert the transfer belt. • Check connector JTRANS1 for proper connection to system card, cable for pinch points and cable or connector for any other damage. If connector is damaged on system card, replace system card. Go to “System card removal”...
  • Page 74 5022-xxx Error Primary message Action code code <color> PC Unit missing • Scroll down the operator panel to see if the printer is showing that all four of the pc units are missing. If so, check the HVPS cable between the system card and HVPS.
  • Page 75 5022-xxx Error Primary message Action code code Fuser missing • Install fuser. Replace fuser if problem persists. • If problem continues, turn the printer off and remove the rear cover. Check connector JFUSER1 for proper connection to system card, cable for pinch points and cable or connector for any other damage.

  • Page 76: User Attendance Messages-Paper Jams And Paper Handling Errors (2Xx.xx)

    5022-xxx User attendance messages—paper jams and paper handling errors (2xx.xx) When the printer jams, the appropriate jam message will be displayed on the printer operator panel. Error Description Possible causes Action code codes Input sensor flag is • Paper jam leaving page over sensor •...
  • Page 77 5022-xxx Error Description Possible causes Action code codes Input sensor flag is • Improper placement of paper in tray 1 • Fan media and stack flat in made when tray 1 is tray or MPF. • Damaged input sensor flag or input installed.
  • Page 78 5022-xxx Error Description Possible causes Action code codes Special case. • System card code failure • POR the printer. Replace system card if message reappears. Go to “System card removal” on page 4-47. • If replacing system card does not fix the problem, contact the next level of support.
  • Page 79 5022-xxx Error Description Possible causes Action code codes During retract, exit • Damaged paper exit sensor or paper • Check for anything in the sensor is never made exit sensor flag paper path that might cause when leading edge of the paper to jam.
  • Page 80 5022-xxx Error Description Possible causes Action code codes Input sensor flag is not • Incorrect media setting • Ensure proper media is set made when it should be. for the type of paper used. • Incorrect paper loading • Fan media and stack flat in •...
  • Page 81 5022-xxx Error Description Possible causes Action code codes Tray 1 motor stalled. • Incorrect paper loading • Ensure proper media is set for the type of paper used. • Paper pick mechanism failure • Fan media and stack flat in •...
  • Page 82 5022-xxx Error Description Possible causes Action code codes Tray 2 autocomp or • Incorrect paper loading • Fan media and stack flat in redrive motor stalled. 500-sheet tray (tray 2). • 500-sheet assembly failure • If the previous actions do •...
  • Page 83 5022-xxx Error Description Possible causes Action code codes MPF motor stalled. • Incorrect paper loading • Ensure proper media is set for the type of paper used. • Paper pick mechanism failure • Fan media and stack flat in • System card tray or MPF.

  • Page 84: Printer Service Checks

    5022-xxx Printer service checks 110.xx—Mirror motor service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JMIRR1 for proper system card, replace connection to system card, printhead cable system card.
  • Page 85 5022-xxx Step Questions / actions Reconnect JINT1 if disconnected. Ensure Go to step 5. Replace 5V interlock front access door is completely closed. switch.Go to “Front access Check for 5VDC between JINT1 pin 3 (white door 5V interlock switch wire) and ground. Is voltage present? removal”...

  • Page 86: Xx-Printhead Error Service Check

    5022-xxx 113.xx—Printhead error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JINT1 (5V interlock system card, replace switch cable) for proper connection to system card.

  • Page 87: Xx-Printhead Error Service Check

    5022-xxx 114.xx—Printhead error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JINT1 (5V interlock system card, replace switch cable) for proper connection to system card.

  • Page 88: 02/08-10/13-15-Fuser Error Service Check

    5022-xxx 120.01/02/08-10/13-15—Fuser error service check Step Questions / actions Check the input voltage switch on the back of Go to step 2. Set switch for proper the low volt power supply (LVPS). Is the country voltage. voltage level (115/230) properly set? Turn the printer off and remove the rear Go step 3.
  • Page 89 5022-xxx Step Questions / actions Check for continuity between the following Go to step 7. Replace AC fuser cable. pins of the AC auto-connect and the pins of the connector that connects to the LVPS. Is continuity present? LVPS connector AC auto-connect pin 1 pin 5...

  • Page 90: Fuser Error Service Check

    5022-xxx 120.03—Fuser error service check Step Questions / actions Check the input voltage switch on the back of Go to step 2. Set switch for proper the low volt power supply (LVPS). Is the country voltage. voltage level (115/230) properly set? Turn the printer off and remove the rear Go step 3.
  • Page 91 5022-xxx Step Questions / actions Check for the following continuity between Go to step 5. Replace DC fuser cable. DC auto-connect and FUSER1. Is continuity present? DC auto-connect JFUSER1 pin 9 pin 9 pin 10 pin 10 Check for continuity between the following Go to step 6.

  • Page 92: 03-08-Autocomp (Tray 1) Motor Error Service Check

    5022-xxx 140.01/03-08—Autocomp (tray 1) motor error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JTRAY2 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 93: 11/15/17-18/20-25-Motor (Ep Drive Asm Top Cartridge) Error Service Check

    5022-xxx Step Questions / actions Turn printer power on and check for 24 V dc Go to step 3. Disconnect JCVR1 and between JCVR1 pin 1 (red wire) and ground. check for 24 V dc between Is voltage present? pin 1 of system card connector and ground.

  • Page 94: 14/16-Motor (Ep Drive Asm Top Cartridge) Error Service Check

    5022-xxx 143.12-14/16—Motor (EP drive asm top cartridge) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JCART1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 95: 14/16-Motor (Ep Drive Asm Bottom Cartridge) Error Service Check

    5022-xxx 144.12-14/16—Motor (EP drive asm bottom cartridge) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JCART2 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 96: Xx-Motor (Duplex) Error Service Check

    5022-xxx Step Questions / actions Close the front access door. Turn printer Go to step 4. Disconnect JCVR1 and power on and check for 24 V dc between check for 24 V dc between JCVR1 pin 1 (red wire) and ground. Is pin 1 of system card voltage present? connector and ground.

  • Page 97: Xx/149.Xx-Motor (500-Sheet Option Tray2 Motor) Error Service Check

    5022-xxx Step Questions / actions Replace duplex front door assembly. Go to Problem solved. Replace system card. Go to “Duplex front door assembly removal” on “System card removal” on page 4-34. page 4-47. 147.xx/149.xx—Motor (500-sheet option tray2 motor) error service check Step Questions / actions Turn the printer off and remove the rear...

  • Page 98: Xx-Mpf Motor Error Service Check

    5022-xxx 148.xx—MPF motor error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JTRAY2 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 99: Post (Power On Self Test) Error Service Check

    5022-xxx 920.01—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JBUMP1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 100: Post (Power On Self Test) Error Service Check

    5022-xxx 920.03—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JTRANS2 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 101: Post (Power On Self Test) Error Service Check

    5022-xxx Step Questions / actions Check for the following continuity between Go to step 4. Replace DC fuser cable. DC auto-connect and FUSER1. Is continuity present? DC auto-connect JFUSER1 pin 3 pin 3 pin 8 pin 8 pin 9 pin 9 pin 10 pin 10 Reinstall fuser.

  • Page 102: Post (Power On Self Test) Error Service Check

    5022-xxx 920.06—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JTRAY1 for proper system card, replace connection to system card, cable for pinch system card.
  • Page 103 5022-xxx 920.08—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JFUSER1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 104: 12-Post (Power On Self Test) Error Service Check

    5022-xxx 920.09-12—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JHVPS1 for proper system card, replace connection to system card, cable for pinch system card.
  • Page 105 5022-xxx Step Questions / actions Replace HVPS. Go to “High volt power Problem solved. Replace system card. Go to supply (HVPS) removal” on page 4-55. “System card removal” on Does error clear? page 4-47. 2-47 Diagnostic information...

  • Page 106: Post (Power On Self Test) Error Service Check

    5022-xxx 920.13—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JCART1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 107: Post (Power On Self Test) Error Service Check

    5022-xxx 920.14—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JCART2 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 108: Post (Power On Self Test) Error Service Check

    5022-xxx 920.15—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JTRANS1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 109: Post (Power On Self Test) Error Service Check

    5022-xxx 920.17—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JBIN1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 110: Post (Power On Self Test) Error Service Check

    5022-xxx 920.19—POST (power on self test) error service check Step Questions / actions Turn the printer off and remove the rear Go to step 2. If connector is damaged on cover. Check connector JTRANS2 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 111: 946.00, 947.01-Transfer Roll (Yellow) Error Service Check

    5022-xxx 945.00, 946.00, 947.01—Transfer roll (yellow) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JHVPS1 for proper system card, replace connection to system card, cable for pinch system card.

  • Page 112: Replace Hvps. Go To "High Volt Power Problem Solved

    5022-xxx Step Questions / actions Remove HVPS. Go to “High volt power Go to step 4. Replace transfer contact supply (HVPS) removal” on page 4-55. assembly. Go to “Transfer Check for continuity between yellow1 and contact assembly yellow2 on transfer contact assembly. Is removal”...

  • Page 113: 946.01, 947.02-Transfer Roll (Cyan) Error Service Check

    5022-xxx 945.01, 946.01, 947.02—Transfer roll (cyan) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JHVPS1 for proper system card, replace connection to system card, cable for pinch system card.
  • Page 114 5022-xxx Step Questions / actions Remove HVPS. Go to “High volt power Go to step 4. Replace transfer contact supply (HVPS) removal” on page 4-55. assembly. Go to “Transfer Check for continuity between cyan1 and contact assembly cyan2 on transfer contact assembly. Is removal”...

  • Page 115: 946.02, 947.03-Transfer Roll (Magenta) Error Service Check

    5022-xxx 945.02, 946.02, 947.03—Transfer roll (magenta) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JHVPS1 for proper system card, replace connection to system card, cable for pinch system card.
  • Page 116 5022-xxx Step Questions / actions Remove HVPS. Go to “High volt power Go to step 4. Replace transfer contact supply (HVPS) removal” on page 4-55. assembly. Go to “Transfer Check for continuity between magenta1 and contact assembly magenta2 on transfer contact assembly. Is removal”...

  • Page 117: 946.03, 947.04-Transfer Roll (Black) Error Service Check

    5022-xxx 945.03, 946.03, 947.04—Transfer roll (black) error service check Step Questions / actions Turn the printer off and remove the rear Go step 2. If connector is damaged on cover. Check connector JHVPS1 for proper system card, replace connection to system card, cable for pinch system card.
  • Page 118 5022-xxx Step Questions / actions Remove HVPS. Go to “High volt power Go to step 4. Replace transfer contact supply (HVPS) removal” on page 4-55. assembly. Go to “Transfer Check for continuity between black1 and contact assembly black2 on transfer contact assembly. Is removal”...

  • Page 119: Through 950.29 Eprom Mismatch Failure

    5022-xxx 950.00 through 950.29 EPROM mismatch failure Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 120: Through 950.60 Eprom Mismatch Failure

    5022-xxx 950.30 through 950.60 EPROM mismatch failure Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 121: Input Sensor Service Check

    5022-xxx Input sensor service check Action Input sensor flag Check the input sensor flag for damage and proper operation. If a problem is found, replace the paper pick mechanism. Go to “Paper pick mechanism assembly removal” on page 4-30. Input sensor/sensor cable Check connector JTRAY1 for proper connection to system card, cable for pinch points and cable or connector for any other damage.

  • Page 122: Dead Printer Service Check

    5022-xxx Dead printer service check A dead printer is a condition where the display is blank, the LED on the operator panel is off, no fans turn, no motors turn, and the fuser lamp does not come on. If a 500-sheet option assembly is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, replace the 500-sheet option assembly.

  • Page 123: Operator Panel Service Check

    5022-xxx Operator panel service check Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 124: Operator Panel Display

    5022-xxx Operator panel display Service tip: The printer has detected a problem with the system card, the operator panel assembly cable (part of the top cover access assembly), or the operator panel assembly if POST does not complete. The printer emits 5 beeps, and sticks in a continuous pattern until the printer is turned off.

  • Page 125: Print Quality Service Check

    5022-xxx Print quality service check Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photoconductor unit. Service tip: Before troubleshooting any print quality problems do the following: Print a menu settings page and check the life status of all supplies.

  • Page 126: Print Quality-Background

    5022-xxx Print quality—background Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.

  • Page 127: Print Quality-Blank Page

    5022-xxx Print quality—blank page Potential cause Action Packing material Remove the packing material for the photoconductor unit in question. Photoconductor unit Replace the photoconductor unit for the color in question. Cartridge drive motor Enter the diagnostic mode. Go to “Accessing service menus” on page 3-1.

  • Page 128: Print Quality-Blurred Or Fuzzy Print

    5022-xxx Potential cause Action HVPS cable Turn the printer off and check the continuity of the HVPS cable. If incorrect, replace the cable assembly. HVPS Replace the HVPS. Go to “High volt power supply (HVPS) removal” on page 4-55. Printhead Replace the printhead.

  • Page 129: Print Quality-Horizontal Line

    5022-xxx Print quality—horizontal line Potential cause Action Photoconductor unit Photoconductor unit is defective. Replace photoconductor unit. Print quality—insufficient fusing Potential cause Action Fuser Ensure fuser has been properly installed. If so, replace fuser. LVPS Replace LVPS. Go to “Low volt power supply (LVPS) removal” on page 4-38.

  • Page 130: Print Quality-Residual Image

    5022-xxx Print quality—residual image Service tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade, and other parts inside the print cartridge. Action Hot roll fuser assembly Check the fuser assembly for toner contamination.

  • Page 131: Print Quality-Vertical Banding

    5022-xxx Potential cause Action HVPS cable Turn the printer off and check the continuity of the HVPS cable. If incorrect, replace the cable assembly. HVPS Replace the HVPS. Go to “High volt power supply (HVPS) removal” on page 4-55. System card Replace the system card.
  • Page 132 5022-xxx 2-74 Service Manual...

  • Page 133: Diagnostic Aids

    5022-xxx 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Mode 1.

  • Page 134: Diagnostic Mode

    5022-xxx Diagnostic mode Note: Tray 2 refers to the 500-sheet tray located in the 500-sheet option assembly. Diagnostics menu structure When the diagnostic menu is entered, each diagnostic main menu item displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays and each individual test displays in the order shown.
  • Page 135 5022-xxx Diagnostics mode tests (Continued) 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. Diagnostic aids...
  • Page 136 5022-xxx Diagnostics mode tests (Continued) DUPLEX TESTS (if installed) Quick Test Go to “Quick Test (duplex)” on page 3-10. Print Test Go to “Print Test (duplex)” on page 3-10. Top Margin Go to “Top Margin (duplex)” on page 3-10. Motor Test Go to “Motor Test (duplex)”...

  • Page 137: Registration

    5022-xxx Diagnostics mode tests (Continued) EP SETUP EP Defaults Go to “EP Defaults” on page 3-14. Fuser Temp Go to “Fuser Temperature (Fuser Temp)” on page 3-15. DC Charge Adjust Go to “DC Charge Adjust, Dev Bias Adj, Transfer Adjust” on page 3-15.

  • Page 138: Quick Test

    5022-xxx to decrease or to increase the offset values, and press to confirm the value. The message Submitting selection displays, and the original REGISTRATION screen appears with beside the previously selected margin setting. The print registration range is: Description Value Direction of change Bottom margin -20 to +20 Each increment causes...

  • Page 139: Alignment

    5022-xxx Alignment Select ALIGNMENT from DIAGNOSTICS. Scroll until you reach the color that you desire to align. Go to each submenu, press Select and use the right and left arrow keys to zero out all settings. Press the Select button after you zero out each setting. Note: It is important to zero out all settings to make the adjustment easier.

  • Page 140: Mirror Motor Test

    5022-xxx Mirror motor test Select Motor Tests from DIAGNOSTICS. Scroll until you reach Mirror Motor. Press Select to run the test. The panel displays “Mirror Motor Test”. After the test completes, the panel displays either “Pass” or “Fail”. To stop the test, press Stop ( Servo laser test Select Motor Tests from DIAGNOSTICS.

  • Page 141: Print Tests

    5022-xxx 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.

  • Page 142: Duplex Tests

    5022-xxx Duplex tests Quick Test (duplex) This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page (Single), or continue printing duplexed pages (Continuous) until Stop ( ) is pressed.

  • Page 143: Motor Test (Duplex)

    5022-xxx to select the margin setting you need to change. • Each increment shifts the duplex top margin by 1/100 of an inch. • The Top Margin (duplex) range is -20 to +20, and the default value is 0. • An increase moves the top margin down and widens the top margin.

  • Page 144: Base Sensor Test

    5022-xxx Base sensor test Bin Full Test This test is used to determine if the bin full sensor is operating correctly. This test is only applicable to network printers. To run the Bin Full Test: Select BASE SENSOR TEST from the DIAGNOSTICS menu. Select Bin Full Test.

  • Page 145: Printer Setup

    5022-xxx Printer setup Defaults US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure. Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone. Page Counts All of the submenus under this menu are read only.

  • Page 146: Configuration Id

    5022-xxx Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is manufactured, however the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever you replace the system board.

  • Page 147: Fuser Temperature (Fuser Temp)

    5022-xxx Fuser Temperature (Fuser Temp) This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media. The fuser temperature can be adjusted to: Low, Normal, High. The default is Normal. DC Charge Adjust, Dev Bias Adj, Transfer Adjust Each of these three settings enables you to adjust the high voltage levels controlling the EP process.

  • Page 148: Event Log

    Page counts for most errors • Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the event log: Select Print Log from EVENT LOG.

  • Page 149: Configuration Menu (Config Menu)

    5022-xxx Configuration menu (CONFIG MENU) The Configuration Menu menu items and values are as follows. Factory defaults are identified with an asterisk (*). Once in the CONFIG MENU, press the down arrow to scroll to each menu item. Menu item Purpose Values and descriptions Reset Fuser Cnt Resets the fuser count...
  • Page 150 5022-xxx Menu item Purpose Values and descriptions Color Trapping Uses an algorithm to 1–5 (2)* Values 1 through 5 indicate the compensate for mechanical amount of color remaining beneath mis-registration in the the black content. Each setting i printer. When small black 1/600 of an inch.
  • Page 151 5022-xxx Menu item Purpose Values and descriptions Factory Defaults Sets the majority of printer Restore Base The Restore Network value only values back to their factory appears on printer models that Restore Network default settings. have integrated network support. Note: When factory default This selection cannot be reversed, settings are restored: so this operation should only be...
  • Page 152 5022-xxx Menu item Purpose Values and descriptions Auto Color Adj Sets the suggested number 100–1000 (500*) Increases in increments of 50. of pages which the printer If the printer exceeds the set value should print between while printing a job, it completes the consecutive calibrations.
  • Page 153 5022-xxx Menu item Purpose Values and descriptions Paper Prompts Controls the source the Auto MP Feeder is only available on printer selects for a change some printer models. MP Feeder paper source message. The Note: If the Configure MP setting is printer displays the change Manual Paper changed to Manual, and a...
  • Page 154 5022-xxx Menu item Purpose Values and descriptions Duplex Gloss Generates higher quality Off* The major difference between duplex copies than when normal duplex and duplex gloss using the normal duplex mode is the number of sheets in mode. the duplex print media path. Normal duplex mode feeds two sheets simultaneously, while duplex gloss feeds only one sheet.

  • Page 155: Repair Information

    5022-xxx 4. Repair information Removal and cleaning precautions Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer, reverse the order of removal unless otherwise specified. •...

  • Page 156: Photoconducter Unit

    5022-xxx Photoconducter unit The following precautions must be observed when handling the photoconductor unit. The photoconductor unit is a supply item you will have to remove during some of the repair procedures: During transportation/storage Use the specified carton whenever moving or storing the photoconductor unit. Handling •...

  • Page 157: Printer Adjustments

    5022-xxx Printer adjustments Printhead alignment Overview When reinstalling the printhead, it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer. This allows the pages to be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw.
  • Page 158 5022-xxx During installation of the printhead, the printhead's lower right corner slot (as seen when looking through the rear of the printer) and the hole in the frame should have been visually aligned. Remove the paper exit tray for access to the printhead alignment screw. Enter Diagnostic mode.
  • Page 159 5022-xxx Repair information...
  • Page 160 5022-xxx Note: If the right side of the print is missing, the visual alignment was too far off and the left side of the printhead is too high. Rotate the alignment screw counterclockwise a full revolution and print the Quick Test page. Check right side of print.
  • Page 161 5022-xxx top alignment marks. Repeat adjustment of top margin and printing of Quick Test page until top margin is set. Scroll to Bottom Margin and press Select. Adjust the bottom margin by increasing the value (right arrow) to move the alignment marks up on the page or decreasing the value (left arrow) to move the marks down on the page.
  • Page 162 5022-xxx Scroll to Quick Test in the Cyan menu. 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: On the pages, ensure all the Current Values are set to zero.
  • Page 163 5022-xxx Look at the course and fine adjustments on the top left of the page and enter the best number for the top adjustment in the T space. Go ahead and transfer this number over to the computation area for Z so that you don't forget later.
  • Page 164 5022-xxx Reprint the cyan Quick Test page and observe. Make additional adjustments if necessary before proceeding on to Quick Test step two page. Obtain left (L), right (R), and Bow (P) value using the same method as obtaining T from Quick Test Step 1. Reprint the Quick Test to ensure the settings are correct.

  • Page 165: Printer Removal Procedures

    5022-xxx Printer removal procedures Precautions to take before maintenance work Do not implement any operation, removal, or modification and so on, which are not presented in this manual. Turn the printer power off and unplug the power cable from the outlet prior to starting removals or checks. Prior to starting any repairs, read and understand the warnings in this manual.

  • Page 166: Cru/Fru And Supplies Removals

    5022-xxx CRU/FRU and supplies removals There are FRU/CRUs and supply items that will need to be removed prior to some of the removal procedures. The removal procedure will specify when the part must be removed. 4-12 Service Manual...

  • Page 167: Fuser Removal

    5022-xxx Fuser removal Warning: Fuser can be extremely hot. Use care when handling to avoid burns. Turn off printer. Open top access door. Rotate fuser thumbscrew (A) counterclockwise until loosened. Grasp handles (B), lift fuser straight up and away from printer. 4-13 Repair information...

  • Page 168: Photoconductor Unit Removal

    5022-xxx Photoconductor unit removal Warning: To avoid damaging the photoconductor drum, hold the photoconductor units by their handle and place the photoconductor units on a clean surface. Open top access and front access doors. Lift right end handle (A) of photoconductor unit, releasing from mount. Lift unit up and away from left side of printer, ensuring left end of photoconductor is released from holding pin (B).

  • Page 169: Transfer Belt Removal

    5022-xxx Transfer belt removal Remove all photoconductor units. See “Photoconductor unit removal” on page 4-14. Disconnect connector (A) on top of transfer belt. Pull out on transfer belt locking handles (B) until they release; lift belt up and away from printer. Waste toner assembly removal Depress release latch.

  • Page 170: Cover Removals

    5022-xxx Cover removals Exit tray cover removal Grasp exit tray and lift away from printer. 4-16 Service Manual...

  • Page 171: Rear Cover Removal

    5022-xxx Rear cover removal Loosen eight screws (A). Do not remove screws. Lift up on rear cover and remove from back of printer. 4-17 Repair information...

  • Page 172: Right Cover Removal

    5022-xxx Right cover removal Open top access door. Open front access door. Ensure power cord is removed. Remove two screws (A). Lift cover and remove from right side of printer. 4-18 Service Manual...

  • Page 173: Front Access Cover Assembly Removal

    5022-xxx Front access cover assembly removal Remove 250-sheet tray. Remove right cover. See “Right cover removal” on page 4-18. Remove transport belt. See “Transfer belt removal” on page 4-15. Note: In order to speed up the removal process, you can leave the photoconductor units on the transport belt when removing.

  • Page 174: Left Cover Removal

    5022-xxx Raise front access door to closed position. Looking down at keyed end of restraint (D), twist the end clockwise, slide restraint upward through slit (E) and slip end of restraint (D) through keyed hole (F). Repeat for other side. Slide front access cover assembly forward, away from printer.

  • Page 175: Operator Panel Outer Bezel Removal

    5022-xxx Operator panel outer bezel removal Using a flathead screwdriver or similar tool, disengage lock tabs (A) on upper left and upper right of outer bezel. Note: Top portion of operator panel will disengage with outer bezel. Flex top of outer bezel to disengage operator panel.

  • Page 176: Operator Panel Assembly Removal

    5022-xxx Operator panel assembly removal Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 177: Top Access Cover Assembly Removal

    5022-xxx Top access cover assembly removal Remove operator panel. See “Operator panel assembly removal” on page 4-22. Remove left cover. See “Left cover removal” on page 4-20. Remove rear cover. See “Rear cover removal” on page 4-17. Remove exit tray. See “Exit tray cover removal”...
  • Page 178 5022-xxx Remove four screws (B) exposed after removing fuser. Remove screw (C) exposed after removing exit tray. 4-24 Service Manual...
  • Page 179 5022-xxx Remove screw (D) from rear. Disconnnect fan (JFAN1), operator panel (JOPP1), high volt power supply connector (JHVPS1) and bin-full sensor (JBIN1-network printers only) cables from system card. Unplug connector (E) from CN1 on high volt power supply (HVPS). Lift and remove top access cover assembly. 4-25 Repair information...

  • Page 180: Front Removals

    5022-xxx Front removals 4-26 Service Manual...

  • Page 181: Fuser Cable Cover Removal

    5022-xxx Fuser cable cover removal Open top access cover Open front access door Remove yellow and cyan toner cartridges. While releasing locking tab (A) on left side of cable cover, slide cable to left, lower and remove. printer pad removal Slide corner of printer containing damaged pad over corner of work area.

  • Page 182: Multipurpose Feeder (Mpf) Swing Arm Assembly Removal

    5022-xxx Multipurpose feeder (MPF) swing arm assembly removal Remove 250-sheet paper tray. Open top access door. Open front access door. Remove three mounting screws (A). Remove swing arm assembly from frame. 4-28 Service Manual...
  • Page 183 5022-xxx Refer to the following illustration 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 installation. 4-29 Repair information...

  • Page 184: Paper Pick Mechanism Assembly Removal

    5022-xxx Paper pick mechanism assembly removal Remove rear cover. See “Rear cover removal” on page 4-17. Disconnect JTRAY1 and JTRAY2 connectors from system card. Remove all toner cartridges. If installed, remove MPF swing arm assembly. See “Multipurpose feeder (MPF) swing arm assembly removal”...

  • Page 185: Bump Aligner Gear Removal

    5022-xxx Bump aligner gear removal Remove paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on page 4-30. Close front access door for better access to gears. Remove three e-clips and washers (A). Remove gears. When reinstalling gears, apply a light coat of the packaged grease. Note: The following illustration shows proper orientation of gears for installation.

  • Page 186: Front Door Assembly Removal

    5022-xxx Front door assembly removal Remove front access cover assembly. See “Front access cover assembly removal” on page 4-19. Remove rear cover. See “Rear cover removal” on page 4-17. Disconnect JTRANS1 cable from system card. Disconnect cable (A) from right side of frame. Be careful not to lose grounding clip (B). Close front door assembly.
  • Page 187 5022-xxx Release left and right front door assembly cable restraint springs (C) from front door assembly. Unwrap cable restraints. Remove mounting screw (D) and cap (E). Open front door assembly, slide to the right, and remove. “Front door assembly restraint cable removal” on page 4-36 for proper installation of cable restraints.

  • Page 188: Duplex Front Door Assembly Removal

    5022-xxx Duplex front door assembly removal Remove low volt power supply. See “Low volt power supply (LVPS) removal” on page 4-38. Disconnect JDUPLX1 and JTRANS1 cable from system card. Disconnect cable (A) from right side of frame. Be careful not to lose grounding clip (B). Remove front access cover assembly.
  • Page 189 5022-xxx Release left and right front door assembly cable restraint springs (C) from duplex front door assembly. Unwrap cable restraints. Remove mounting screw(D) and cap (E). Open duplex front door assembly, slide to the right, and remove. “Front door assembly restraint cable removal” on page 4-36 for proper installation of cable restraints.

  • Page 190: Front Door Assembly Restraint Cable Removal

    5022-xxx Front door assembly restraint cable removal Remove front access cover assembly. See “Front access cover assembly removal” on page 4-19. For either right or left, release cable spring (A) from front door assembly. For right cable, remove four screws (B) and gearbox/switch shield (C). There is a locking tab on the back of the gearbox shield.

  • Page 191: Right Side Removals

    5022-xxx Right side removals 4-37 Repair information...

  • Page 192: Low Volt Power Supply (Lvps) Removal

    5022-xxx Low volt power supply (LVPS) removal Remove right side cover. See “Right cover removal” on page 4-18. Remove rear cover. See “Rear cover removal” on page 4-17. Unplug JLVPS1 connector from system card. Remove five LVPS mounting screws (A). Disconnect cable from LVPS (B).
  • Page 193 5022-xxx When installing new LVPS, ensure voltage switch (C) is set for proper value (115 or 230 V), depending on the country. 4-39 Repair information...

  • Page 194: Electrophotographic Process (Ep) Drive Assembly Removal

    5022-xxx Electrophotographic Process (EP) drive assembly removal Remove low volt power supply. See “Low volt power supply (LVPS) removal” on page 4-38. Open top access door. Open front access door. Remove all toner cartridges. Disconnect JCART1, JCART2, and JTRANS2 connectors from system card. Remove six inner screws (A).
  • Page 195 5022-xxx Remove nine outer screws (B). 4-41 Repair information...
  • Page 196 5022-xxx Remove EP drive assembly from printer. Note: Ensure that top access door is open and EP drive is retracted when installing new EP drive assembly. 4-42 Service Manual...

  • Page 197: Front Access Door 5V Interlock Switch Removal

    5022-xxx Front access door 5V interlock switch removal Remove LVPS. See “Low volt power supply (LVPS) removal” on page 4-38. Disconnect JINT1 connector from system card. Open top access door. Open front access door. Warning: When removing gearbox/switch shield, ensure you do not damage the 5V interlock switch activation arm.
  • Page 198 5022-xxx Remove interlock switch mounting screw (C). Remove cable from cable guide and remove 5V interlock switch. 4-44 Service Manual...

  • Page 199: Bump Aligner Motor Removal

    5022-xxx Bump aligner motor removal Remove right side cover. Remove bump aligner gears. See “Bump aligner gear removal” on page 4-31. Remove two bump aligner motor mounting screws (A). Disconnect JBUMP1 connector from system card. Remove bump aligner motor from printer. 4-45 Repair information...

  • Page 200: Rear Removals

    5022-xxx Rear removals 4-46 Service Manual...

  • Page 201: System Card Removal

    5022-xxx System card removal Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
  • Page 202 5022-xxx Remove eight screws (C) from system card. 4-48 Service Manual...

  • Page 203: System Card Support Shield Removal

    5022-xxx System card support shield removal Remove left cover. See “Left cover removal” on page 4-20. Remove LVPS. See “Low volt power supply (LVPS) removal” on page 4-38. Remove system card. See “System card removal” on page 4-47. Remove 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.
  • Page 204 5022-xxx Remove four mounting 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. Lower and remove support shield. Be careful not to cut the cables that route through top frame of printer. 4-50 Service Manual...

  • Page 205: Smart Chip Card Removal

    5022-xxx Smart chip card removal Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 206: Printhead Removal

    5022-xxx Printhead removal Remove toner cartridges. Remove exit tray cover. See “Exit tray cover removal” on page 4-16. Remove transfer belt and photoconductor units. See “Photoconductor unit removal” on page 4-14 “Transfer belt removal” on page 4-15. Warning: Cover the photoconductor units with a scratch-resistant material to reduce light exposure. Remove system card support shield.
  • Page 207 5022-xxx Note: Do not install printhead mounting screws in rear of printer. When reinstalling the printhead, it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer. This allows the pages to be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw.

  • Page 208: Left Side Removals

    5022-xxx Left side removals 4-54 Service Manual...

  • Page 209: High Volt Power Supply (Hvps) Removal

    5022-xxx High volt power supply (HVPS) removal Remove left cover. See “Left cover removal” on page 4-20. Remove six mounting screws (A). Release locking tab (B) from front, lower corner of HVPS. Disconnect five connectors (C) from HVPS. 4-55 Repair information...

  • Page 210: Contact Springs Removal

    5022-xxx Contact springs removal Remove appropriate toner cartridges. Remove screw (A) and spring cap (B). Press lower half (C, D) of springs and remove springs. When installing, ensure top half (E) of spring is under straight spring (F). This is typical for both types of springs.

  • Page 211: Transfer Contact Assembly Removal

    5022-xxx Transfer contact assembly removal Remove HVPS. See “High volt power supply (HVPS) removal” on page 4-55. Remove all inside contact springs. See “Contact springs removal” on page 4-56. Remove four screws (A) and remove transfer contact assembly. Remove eight springs (B) for reuse during installation. Note: For ease of installation, put transfer contact assembly on before installing springs.

  • Page 212: Toner Level Sensor Removal

    5022-xxx Toner level sensor removal Black and Magenta Remove HVPS. See “High volt power supply (HVPS) removal” on page 4-55. Depress locking tabs (A) on sensor; remove sensor. Cyan and Yellow Remove transfer contact assembly. See “Transfer contact assembly removal” on page 4-57.

  • Page 213: Top Removals

    5022-xxx Top removals 4-59 Repair information...

  • Page 214: Top Access Door 24V Interlock Switch Removal

    5022-xxx Top access door 24V interlock switch removal Remove top access cover assembly. See “Top access cover assembly removal” on page 4-23. Disconnect JCVR1 connector from system card. Remove right cover. See “Right cover removal” on page 4-18. Remove mounting screw(A) and 24V interlock switch (B). 4-60 Service Manual...

  • Page 215: Top Cover Camshaft Assembly Removal

    5022-xxx Top cover camshaft assembly removal Remove top access door 24V interlock switch. See “Top access door 24V interlock switch removal” on page 4-60. Remove left cover. See “Left cover removal” on page 4-20. Rotate lever arm (A) all the way up as if the top access door were open; hold lever arm (A) in place and rotate camshafts (B) down to the closed postion.

  • Page 216: Top Cover Camshaft Assembly Installation

    5022-xxx Top cover camshaft assembly installation Warning: Do not install the camshaft assembly by reversing the removal procedures. The camshaft assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed or the printer will not work correctly. Ensure EP drive assembly is engaged by sliding upper retraction plate (A) fully to the rear.
  • Page 217 5022-xxx Remove camshaft from package and place left and right mounting brackets (B) on a flat surface. 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.
  • Page 218 5022-xxx Place left side of camshaft assembly through 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. Install rear mounting screws (K). Slide spring (L) and lever arm (M) on shaft.
  • Page 219 5022-xxx Rotate lever arm (O) all the way up as if the top access door were open. While still holding lever arm (O) up, flip right lock (P) up and install front mounting screws (Q). Warning: 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.
  • Page 220 5022-xxx Note: Prior to installation, if the left side of the camshaft assembly becomes disassembled, use the following illustration: 4-66 Service Manual...

  • Page 221: Locations And Connectors

    5022-xxx 5. Locations and connectors Locations Sensors Locations and connectors...
  • Page 222 5022-xxx Service Manual...

  • Page 223: Motors

    5022-xxx Motors Locations and connectors...

  • Page 224: Printer Cards

    5022-xxx Printer cards Service Manual...

  • Page 225: Connectors

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

  • Page 226: Parallel System Card

    5022-xxx Parallel system card Legend: Jxx-connector Fx-fuse Service Manual...

  • Page 227: Wiring Diagrams

    5022-xxx Wiring diagrams See back of manual. Locations and connectors...
  • Page 228 5022-xxx Service Manual...

  • Page 229: Preventive Maintenance

    5022-xxx 6. Preventive maintenance There is no preventive maintenance for this printer. Preventive maintenance...
  • Page 230 5022-xxx Service Manual...

  • Page 231: How To Use This Parts Catalog

    5022-xxx 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Units/ Asm- Part Units/mach kit or Description Index number • Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 and the item number 1.

  • Page 232: Assembly 1: Crus

    5022-xxx Assembly 1: CRUs Service Manual...
  • Page 233 5022-xxx Assembly 1: CRUs Units/ Units/kit Index Description mach or pkg 40X1400 Fuser assembly, 115 V 40X1402 Fuser assembly, 230 V 40X1403 Fuser assembly, 100 V 40X0070 Roll, pick arm 40X1439 Assembly, 500-sheet option (includes 40X1423 tray) 40X1423 Tray assembly, 500-sheet 40X1404 Tray assembly, 250 MFP paper (C524) 40X1424...

  • Page 234: Assembly 2: Covers

    5022-xxx Assembly 2: Covers Service Manual...
  • Page 235 5022-xxx Assembly 2: Covers Units/ Units/kit Index Description mach or pkg 40X1422 Cover, exit tray 40X1427 Cover, rear 40X1425 Cover, right 40X1443 Cover assembly, duplex front access door (C524dn only) 40X1413 Cover assembly, front access door (non-duplex) 40X1426 Cover, left 40X1451 Cover assembly, network top access 40X1412...

  • Page 236: Assembly 3: Front

    5022-xxx Assembly 3: Front Service Manual...
  • Page 237 5022-xxx Assembly 3: Front Units/ Units/kit Index Description mach or pkg Cover, fuser cable (Part of 40X1430 cable parts packet) Pad, printer (Part of 40X1431 screw parts packet) 40X1446 Bellcrank assembly, right 40X1432 Parts packet, bump aligner gear 40X1420 Parts packet, front door 40X1419 Door assembly, duplex front 40X1418...

  • Page 238: Assembly 4: Right

    5022-xxx Assembly 4: Right Service Manual...
  • Page 239 5022-xxx Assembly 4: Right Units/ Units/kit Index Description mach or pkg 40X1409 Drive assembly, EP 40X1406 Power supply, low volt 115/230 V 40X1436 Switch, front door 5V interlock 40X1433 Motor, bump aligner 40X1445 Plate, ground contact Parts catalog...

  • Page 240: Assembly 5: Rear

    5022-xxx Assembly 5: Rear 7-10 Service Manual...
  • Page 241 5022-xxx Assembly 5: Rear Units/ Units/kit Index Description mach or pkg 40X1417 Printhead assembly 40X1408 Card, system network (C524n, C524dn) 40X1442 Card, system network (C520n, C522n) 40X1429 Shield, system card support 40X1410 Card, smart chip 7-11 Parts catalog...

  • Page 242: Assembly 6: Left

    5022-xxx Assembly 6: Left 7-12 Service Manual...
  • Page 243 5022-xxx Assembly 6: Left Units/ Units/kit Index Description mach or pkg 40X1416 Sensor, toner level 40X1428 Contact assembly, transfer 40X1411 Power supply, high volt 7-13 Parts catalog...

  • Page 244: Assembly 7: Top

    5022-xxx Assembly 7: Top 7-14 Service Manual...
  • Page 245 5022-xxx Assembly 7: Top Units/ Units/kit Index Description mach or pkg 40X1421 Assembly, top cover camshaft 40X1437 Switch, top access door 24V interlock 40X1440 Sensor, bin full with cable (network printers only) 7-15 Parts catalog...

  • Page 246: Assembly 8: Contact Springs Packet

    5022-xxx Assembly 8: Contact Springs Packet 7-16 Service Manual...
  • Page 247 5022-xxx Assembly 8: Contact Springs Packet Units/ Units/kit Index Description mach or pkg 40X1434 Parts packet, contact springs • Contact spring, torsion PCD • Contact spring, torsion CR • Cap, contact spring • Contact spring, charge roll • Contact spring, HVPS tar •...

  • Page 248: Assembly 9: Cable Parts Packet

    5022-xxx Assembly 9: Cable Parts Packet 7-18 Service Manual...
  • Page 249 5022-xxx Assembly 9: Cable Parts Packet Units/ Units/kit Index Description mach or pkg 40X1430 Parts packet, cable • Cable, cartridge motor • Cable, fuser AC • Cable, fuser DC • Cable, smart chip • Cable, option • Cover, fuser cable (see Front Assembly for part identification and location) •...

  • Page 250: Assembly 10: Miscellaneous

    5022-xxx Assembly 10: Miscellaneous Units/ Units/kit Index Description mach or pkg 40X1431 Parts packet, screw (Contains one of each screw used in the printer, with the exception of the parts specifically called out.) 40X1508 128 MB SDRAM, 100-pin 40X1509 256 MB SDRAM, 100-pin 40X1510 512 MB SDRAM, 100-pin 40X1454...

  • Page 251: Index

    5022-xxx Index 1-12 accessing service menus machine type tag location 1-13 acronyms mechanical drive 1-22 bump aligner drive 1-25 duplex drive Card Stock & Label Guide 1-24 fuser drive configuration menu 1-21 paper pick mechanism drive accessing photodeveloper unit/developer (toner) cartridge drive connectors 1-23 network system card...
  • Page 252 5022-xxx 2-72 2-26 print quality—solid color page 110.xx—Mirror motor service check 2-73 2-26 print quality—vertical banding 111.xx—Printhead error service check 2-27 printer adjustments 112.xx—Printhead error service check 2-26 2-28 printer service checks 113.xx—Printhead error service check 2-29 printhead alignment 114.xx—Printhead error service check 2-30 120.01/02/08-10/13-15—Fuser error service check 2-32...
  • Page 253 5022-xxx 2-52 925.01—Fan error service check 945.00, 946.00, 947.01—Transfer roll (yellow) error 2-53 service check 945.01, 946.01, 947.02—Transfer roll (cyan) error 2-55 service check 945.02, 946.02, 947.03—Transfer roll (magenta) error 2-57 service check 945.03, 946.03, 947.04—Transfer roll (black) error 2-59 service check 2-61 950.00 through 950.29 EPROM mismatch failure...
  • Page 254 5022-xxx Service Manual...

  • Page 255: Part Number Index

    5022-xxx Part number index Description Page 1010042 US 802.11g wireless print adapter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-20 1010043 International 802.11g wireless print adapter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 256 5022-xxx 40X1425 right cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X1426 left cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X1427...
  • Page 257 Wiring diagram–Motors and CRUs...
  • Page 258 Wiring diagram–HVPS...
  • Page 259 Wiring diagram–Printhead,LVPS, system card...

This manual is also suitable for:

C524 seriesC524C524nC522 seriesC524dnC520n ... Show all

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