Page 1 Lexmark C52x and C53x 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 Service checks ..............2-27 110.xx—Mirror motor service check .
Page 5 5022-xxx Diagnostic aids ............... . . Accessing service menus .
Page 6 5022-xxx Energy Conserve ............. . . 3-23 Event Log .
Page 7 5022-xxx Operator panel inner bezel removal—models C52x only ......4-22 Operator panel assembly removal ..........4-23 Paper tray dust cover removal .
Page 8 5022-xxx Preventive maintenance ............. . . Scheduled maintenance .
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, as well as general environmental and safety instructions, are discussed.
Page 19: General Information
5022-xxx 1. General information The Lexmark™ C52x and C53x 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...
Page 20: Specifications
5022-xxx – Lexmark Bar Code Card is available on models C534n, C534dn, and C534dtn – Lexmark ImageQuick™ Card is available for the models C534n, C534dn, and C534dtn • DBCS font cards – Simplified Chinese – Traditional Chinese – Japanese –...
Page 21: Power Requirements
5022-xxx Power requirements Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts (W). Maximum current is given in Amperes (A). Lexmark C524, Lexmark C534n, Lexmark Lexmark C520n, Printing states C524n, C524dn, C534dn,...
Page 22: Environment
5022-xxx Environment Environment Specifications Operating Air Temperature—Product Operating 15.6 to 32.2° C (60 to 90.0° F) Air Temperature—Product Power Off 10.0 to 40.0° C (50 to 104.0° F) Air Relative Humidity Relative Humidity 8 to 80% Wet Bulb Temperature—Product Operating 22.8°...
Page 23: Dimensions
5022-xxx Dimensions Description Models Height Width Depth Weight Basic printer with no C520, C522n, C524, C524n, 19 in. 17.3 in. 16.1 in. 57.5 lb extensions C524dn (484 mm) (440 mm) (408 mm) (26.1 kg) C532n, C534n 19 in. 17.3 in. 16.1 in.
Page 24: Media Specifications
5022-xxx Media specifications Paper and specialty media guidelines Media guidelines Media characteristics The following media characteristics affect print quality and reliability. Consider these characteristics when evaluating new media stock. Weight The printer can automatically feed media weights from 60 to 176 g/m (16 to 47 lb bond) grain long.
Page 25: Unacceptable Media
5022-xxx Unacceptable media The following media types are not recommended for use with the printer: • Chemically treated media used to make copies without carbon paper, also known as carbonless papers, carbonless copy paper (CCP), or no carbon required (NCR) paper •...
Page 26: Using Media
To prevent print quality problems, avoid getting fingerprints on the transparencies. • Before loading transparencies, fan the stack to prevent sheets from sticking together. • We recommend Lexmark part number 12A8240 for letter-size and Lexmark part number 12A8241 for A4-size transparencies. Using envelopes •...
Page 27: Using Labels
Using labels Print samples on the labels being considered for use before buying large quantities. For detailed information on label printing, characteristics, and design, see the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com/publications. Note: Vinyl labels are not supported on this product. Use only paper labels.
Page 28: Storing Media
5022-xxx • Be aware that preprinting, perforation, and creasing may significantly affect the print quality and cause jams or other paper handling problems. • Check with the manufacturer or vendor to ensure the card stock can withstand temperatures up to 180°C (356°F) without releasing hazardous emissions.
Page 29: Media Weight
5022-xxx Media Sizes (continued) ✓ ✓ 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. Media weight Size Type Weight Primary tray and 500-sheet optional tray Letter, Legal, A4...
Page 30: Input And Output Capacities
5022-xxx Media weight Size Type Weight A5, B5, JIS-B5, Exec., Xerographic Long Grain 20 to 47 lb (75 to 177 g/m Statement, Folio and Bonds Short Grain 24 to 58 lb (90 to 218 g/m Envelope Monarch, 7 ¾, #9, #10, DL, B5, 16 to 28 lb (60 to 105 g/m C5, C6-C5, C6, B6 Duplex unit...
Page 31: Serial Number And Machine Type
5022-xxx Serial number and machine type The serial number is located on the label on the rear of the right cover and on the service tag located on the inside right frame of the printer. The service tag also contains the configuration IDs, machine type, and model information.
Page 32: Acronyms
5022-xxx Acronyms Cyan Customer Replaceable Unit DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory ElectroPhotographic (process) EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HVPS High Voltage Power Supply Black LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode LVPS...
Page 33: 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 34: Operator Panel And Menus
5022-xxx Operator panel and menus Operator panel The operator panel consists of these items: Buttons and light description Button or light Function Display The display shows messages and pictures that communicate the status of the printer. button functions as a select button. Press this button to: Note: It has a check •...
Page 35 5022-xxx Button or light Function Indicator light The two-toned light emitting diode called the indicator light on the operator panel gives information about the status of the printer using the colors red and green. Indicator light Indicates status Printer power is off. Blinking green Printer is warming up, processing data, or printing a job.
Page 36: Menus
5022-xxx Menus Note: Some menu items may not be available based on the printer model or the options installed. Supplies Menu Paper Menu Reports Settings Replace Supply Default Source Menu Settings Page Setup Menu Cyan Cartridge Paper Size/Type Device Statistics Finishing Menu Magenta Cartridge Configure MP...
Page 37: 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 main fan turns on. The operator panel turns on.
Page 38: Symptom Tables
5022-xxx Symptom tables Printer symptom table Symptom Action Dead printer Go to “Dead printer service check” on page 2-51. Operator panel—one or more buttons do Go to “One or more operator panel buttons fail” on not work. page 2-53. Operator panel—display is blank. Printer Go to “Operator panel display blank, five beeps, and LED sounds five beeps.
Page 39: Error Codes And Messages
5022-xxx Error codes and messages Service error codes and paper jam messages Error code Description Action 1xx service error codes 110.01–110.06 Mirror A mirror motor error has occurred. POR the printer. If the error message persists, see Motor “110.xx—Mirror motor service check” on page 2-27.
Page 40 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 146.01–146.08 Motor Duplex motor has failed. POR the printer. If the error message persists, see Error “146.xx—Motor (duplex) error service check” on page 2-36. 147.01–147.08 Motor Tray 2 motor has failed. POR the printer.
Page 41 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 200.22 Pick (tray 1) motor stalled. • Check for anything in the paper path that might cause the paper to jam. Possible causes: • If clearing a paper jam does not fix the problem, •...
Page 42 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 201.10 Input sensor flag broke early. • Check for anything in the paper path that might cause the paper to jam. Possible causes: • If clearing a paper jam does not fix the problem, •...
Page 43 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 202.17 Exit sensor is made when the printer • Check for anything in the paper path that might powers up or covers are closed. cause the paper to jam. •...
Page 44 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 230.04 During duplex printing, the input • If clearing a paper jam does not fix the problem, sensor is made while the previous go to “Input sensor service check” on page is still in the aligner.
Page 45 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 241.05 While feeding from tray 1, the input • Ensure proper media is set for the type of paper sensor is never made. used. • Fan media, and stack it flat in the tray or MPF. Possible causes: •...
Page 46 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 242.05 While feeding from tray 2, the input • Ensure proper media is set for the type of paper sensor is not made. used. • Fan media, and stack it flat in the 500-sheet tray (tray 2).
Page 47 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 250.05 While feeding from the MPF, the input • Ensure proper media is set for the type of paper sensor is not made. used. • Fan media, and stack it flat in the tray or MPF. •...
Page 48 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 908.00–908.99 Engine Unrecoverable system software POR the printer. If the error persists, replace the Software error errors. system card. See “System card removal” on page 4-79. 910.01 Transparency Transparency sensor failed “910.01—Transparency sensor error service Sensor...
Page 49 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 945.03 Transfer Roll Magenta transfer roll has failed. POR the printer. If the error message persists, see “945.xx, 946.xx, 947.xx—Transfer roll error service check” on page 2-48. 945.04 Transfer Roll Black transfer roll has failed.
Page 50 5022-xxx Service error codes and paper jam messages (continued) Error code Description Action 954.01–954.99 NVRAM System card NVRAM failure. POR the printer. If the error message persists, Failure replace the system card. See “System card removal” on page 4-79. 955.01–955.99 Code System board memory failure.
Page 51: User Status And Attendance Messages
5022-xxx User status and attendance messages User status and attendance messages Error code Action 3x through 8x attendance messages 31 Defective or Missing • Reseat the specified toner cartridge. <color> Cartridge • For models C52x: Inspect the smart chip card contacts (A) for damage, contamination or positioning error.
Page 52 5022-xxx User status and attendance messages (continued) Error code Action 34 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. •...
Page 53 5022-xxx User status and attendance messages (continued) Error code Action 37 Insufficient memory, • The printer was unable to restore some or all of the confidential or held jobs on the hard some held jobs were lost disk. Continue appears, and then press •...
Page 54 5022-xxx User status and attendance messages (continued) Error code Action 54 Network <x> • Press until Continue appears, and then press to clear the message and software error continue printing. The job may not print correctly. • Program new firmware for the network interface. •...
Page 55 5022-xxx User status and attendance messages (continued) Error code Action 62 Disk full • Press until Continue appears, and then press to clear the message and continue processing. Any information not previously stored on the hard disk is deleted. • Delete fonts, macros, and other data stored on the hard disk. •...
Page 56 5022-xxx User status and attendance messages (continued) Error code Action 82 Waste toner box • Insert the waste toner box. missing • Inspect the top cover camshaft assembly for proper operation. When the top access cover is closed, the printer should mechanically interlock. •...
Page 57 5022-xxx User status and attendance messages (continued) Error code Action 84 <color> PC Unit • Scroll down the operator panel to see if the printer is showing that all four of the PC units missing are missing. If so, check the HVPS cable between the system card and the HVPS. Ensure that the cable is not plugged in backwards on the HVPS.
Page 58 5022-xxx User status and attendance messages (continued) Error code Action 87 Fuser missing • Install the fuser. Replace the fuser if the problem persists. • If the problem continues, turn the printer off and remove the rear cover. Check the JFUSER1 connector for proper connection to the system card, the cable for pinch points, and the cable or the connector for any other damage.
Page 59: Service Checks
5022-xxx Service checks 110.xx—Mirror motor service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the printhead. See Go to step 2. Check the connector JMIRR1 for proper “Printhead removal” on connection to the system card, the printhead page 4-74.
Page 60: Fuser Error Service Check
5022-xxx 120.01, 120.02, 120.08–120.10, 120.13–120.15—Fuser error service check Step Questions / actions Check the input voltage switch on the back of Go to step 2. Set the switch for proper the low voltage power supply (LVPS). country voltage. Is the voltage level (115/230) properly set? Remove the fuser, and check the camshaft Go to step 3.
Page 61 5022-xxx Step Questions / actions Check for the following continuity between the Go to step 7. Replace the DC fuser cable. DC autoconnect and FUSER1. pin 10 pin 6 5 7 9 pin 1 4 6 8 pin 8 pin 8 configuration DC autoconnect JFUSER1...
Page 62: 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 the switch for proper the the low voltage power supply (LVPS). country voltage. Is the voltage level (115/230) properly set? Turn the printer off, and remove the rear cover.
Page 63 5022-xxx Step Questions / actions Check for the following continuity between DC Go to step 5. Replace the DC fuser cable. autoconnect and JFUSER1. pin 10 pin 6 5 7 9 pin 1 4 6 8 pin 8 pin 8 configuration DC autoconnect JFUSER1...
Page 64: Xx-Autocomp (Tray 1) Motor Error Service Check
5022-xxx 140.xx—Autocomp (tray 1) motor error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the paper pick Go to step 2. Check the connector JTRAY2 for proper mechanism. See “Paper connection to the system card, the cable for pick mechanism assembly pinch points, and the cable or connector for removal”...
Page 65: And 906.01-906.04-Motor (Fuser) Error Service Check
5022-xxx 142.xx and 906.01–906.04—Motor (fuser) error service check Step Questions / actions Is the top access door completely closed? Go to step 2. Close the top access door. Turn the printer off, and remove the fuser. Lift the top access door to its Go to step 3.
Page 66: Xx-Motor (Ep Drive Assembly Top Cartridge) Error Service Check
5022-xxx 143.xx—Motor (EP drive assembly top cartridge) error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the JCART1 cable. Go to step 2. Check the connector JCART1 for proper connection to the system card, the cable for pinch points, and the cable or connector for any other damage.
Page 67: Xx-Motor (Ep Drive Assembly Bottom Cartridge) Error Service Check
5022-xxx 144.xx—Motor (EP drive assembly bottom cartridge) error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace JCART2 cable. Go to step 2. Check the connector JCART2 for proper connection to the system card, the cable for pinch points, and the cable or connector for any other damage.
Page 68: And 906.05-906.08-Motor (Bump Aligner) Error Service Check
5022-xxx 145.xx and 906.05–906.08—Motor (bump aligner) error service check Step Questions / actions Is the top access door completely closed? Go to step 2. Close the top access door. Open the top access door, and slowly close it. Replace the top access door Go to step 3.
Page 69: Xx, 149.Xx-Motor (500-Sheet/550-Sheet Option Tray 2 Motor) Error Service Check
5022-xxx 147.xx, 149.xx—Motor (500-sheet/550-sheet option tray 2 motor) error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the option cable. Go to step 2. Check the connector JOPT1 for proper connection to the system card, the cable for pinch points, and the cable or connector for any other damage.
Page 70: Transparency Sensor Error Service Check
5022-xxx 910.01—Transparency sensor error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the paper pick Go to step 2. Check the connector JTRAY1 for proper mechanism. See “Paper connection to the system card, the cable for pick mechanism assembly pinch points, and the cable or connector for removal”...
Page 71: Post (Power On Self Test) Error Service Check
5022-xxx 920.04—POST (power on self test) error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the fuser cable. Go to step 2. Check the connector JFUSER1 for proper connection to the system card, the cable for pinch points, and the cable or connector for any other damage.
Page 72: Post (Power On Self Test) Error Service Check
5022-xxx 920.06—POST (power on self test) error service check Step Questions / actions Replace the paper pick mechanism. See Problem solved. Replace the system card. “Paper pick mechanism assembly removal” “System card on page 4-68. removal” on page 4-79. Does the error clear? 920.07—POST (power on self test) error service check Step Questions / actions...
Page 73 5022-xxx Step Questions / actions Check for the following continuity between the Go to step 4. Replace the DC fuser cable. DC autoconnect and FUSER1. pin 10 pin 6 5 7 9 pin 1 4 6 8 pin 8 pin 8 configuration DC autoconnect JFUSER1...
Page 74 5022-xxx Step Questions / actions Reconnect JHVPS1 cable to the system card Replace the toner level Go to step 5. and the HVPS. Do not reinstall the left cover, sensor that has 5 V dc on but make sure the front access door and the pin 1.
Page 75: 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 cover. Replace the JCART1 cable. Go to step 2. Check the connector JCART1 for proper The cable parts packet connection to the system card, the cable for contains one cartridge pinch points, and the cable or connector for...
Page 76: 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 cover. Replace the JCART2 cable. Go to step 2. Check the connector JCART2 for proper The cable parts packet connection to the system card, the cable for contains one cartridge pinch points, and the cable or connector for...
Page 77: Post (Power On Self Test) Error Service Check
5022-xxx 920.15—POST (power on self test) error service check Models C52x only Step Questions / actions Turn the printer off, and remove the rear cover. Replace the front door Go to step 2. Check the connector JTRANS1 for proper assembly. See “Front door connection to the system card, the cable for assembly removal”...
Page 78: 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 cover. Replace the top access Go to step 2. Check the connector JBIN1 for proper cover assembly. See “Top connection to the system card, the cable for access cover assembly pinch points, and the cable or connector for...
Page 79: Fan Error Service Check
5022-xxx Models C53x only Step Questions / actions Turn the printer off, and remove the rear cover. Replace the JTRANS1 Go to step 2. Check the connector JTRANS1 for proper cable. connection to the system card, the cable for pinch points, and the cable or connector for any other damage.
Page 80: Xx, 946.Xx, 947.Xx-Transfer Roll Error Service Check
5022-xxx 945.xx, 946.xx, 947.xx—Transfer roll error service check Step Questions / actions Turn the printer off, and remove the rear cover. Replace the top access Go to step 2. Check the connector JHVPS1 for proper cover assembly. See “Top connection to the system card, the cable for access cover assembly pinch points, and the cable or connector for removal—model C52x...
Page 81 5022-xxx Step Questions / actions Remove the HVPS. See “High voltage power Go to step 4. Replace the transfer contact supply (HVPS) removal” on page 4-62. assembly. See “Transfer Check for continuity between the contacts contact assembly (yellow1 and yellow2, cyan1 and cyan2, removal”...
Page 82: 950.29 Eprom Mismatch Failure
5022-xxx 950.00–950.29 EPROM mismatch failure Warning: When replacing any one of the following components: • Operator panel assembly • System card • Printhead assembly Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
Page 83: Dead Printer Service Check
5022-xxx Models C53x only Step Questions / actions Has the printhead been recently replaced? Replace the printhead with Replace the system card a new, and not previously with a new, and not installed smart chip card. previously installed system “Printhead removal” card.
Page 84: Exit Sensor Service Check
5022-xxx Step Questions / actions Turn the printer off. Connect the JLVPS1 cable Replace the faulty part. Contact your next level of to the system card. Remove one option/feature support. at a time, and turn the printer on to isolate the failing part.
Page 85: Operator Panel Service Check
5022-xxx Operator panel service check Warning: When replacing any one of the following components: • Operator panel assembly • System card • Printhead assembly Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
Page 86: Operator Panel Display Blank, Five Beeps, Led On
5022-xxx Operator panel display blank, five beeps, LED on Service tip: The printer has detected a problem with the system card, the operator panel assembly cable (part of the top cover access assembly), or the operator panel assembly if POST does not complete. The printer emits five beeps, and sticks in a continuous pattern until the printer is turned off.
Page 87: Print Quality Service Check
Measure all voltages from the connector to the printer ground. Print quality—background Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.
Page 88: Print Quality-Blank Page
5022-xxx Step Questions / actions Replace the PC unit. See “Photoconductor Problem solved. Go to step 3. unit removal” on page 4-70. Does this fix the problem? Check the high voltage contact from the HVPS Replace the spring or the Go to step 4.
Page 89 5022-xxx Step Questions / actions Check the high voltage contact from the HVPS Replace the transfer contact Go to step 6. to the photoconductor charge roll. Ensure the assembly. See “Transfer contact springs are properly mounted and that contact assembly the charge roll contact spring is making good removal”...
Page 90: Print Quality-Blurred Or Fuzzy Print
5022-xxx Print quality—blurred or fuzzy print Blurred or fuzzy print is usually caused by a problem in the EP drive assembly or in the transfer belt assembly. Check the EP drive assembly and transfer belt assembly for correct operation. Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, or duplex paper path.
Page 91: Print Quality-Random Marks
5022-xxx Print quality—random marks Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit, developer roll, or transfer belt. Step Questions / actions Is there any loose or foreign material on the Replace the photoconductor Go to step 2.
Page 92: Print Quality-Solid Color Page
5022-xxx Print quality—solid color page Service tip: A solid color page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum. Step Questions / actions Replace the photoconductor unit for the color...
Page 93: Print Quality-Vertical Banding
5022-xxx Step Questions / actions Replace the HVPS. See “High voltage power Problem solved. Replace the system card. supply (HVPS) removal” on page 4-62. “System card removal” on page 4-79. Did this solve the problem? Print quality—vertical banding Replace the developer cartridge. 2-61 Diagnostic information...
Page 94 5022-xxx 2-62 Service Manual...
Page 95: 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 menu 1.
Page 96: Diagnostics Menu
5022-xxx Diagnostics menu Note: Tray 2 refers to the 500-sheet tray located in the 500-sheet option assembly. Diagnostics menu structure When the Diagnostics mode is entered, each Diagnostics main menu item displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays and each individual test displays in the order shown.
Page 97 5022-xxx Diagnostics mode tests (continued) PRINT TESTS Tray 1 “Input source tests” on page 3-9. Tray 2 (if installed) Manual Feeder (if installed) MP Feeder Prt Quality Pgs “Print quality test pages (Prt Quality Pgs)” on page 3-10. HARDWARE TESTS Panel Test “Panel Test”...
Page 98: Registration
5022-xxx Registration Print registration makes sure the black printing is properly aligned on the page. This is one of the steps in aligning a new printhead. See “Printhead alignment” on page 4-3. It is also the first step in aligning the duplex registration.
Page 99: Skew
This must be performed before color skew adjustment is attempted. The following illustration shows proper alignment versus skewed alignment. Proper skew Improper skew Straight Skewed Lexmark C52X Quick Test Printer Information Margin Settings Page Count Top Margin PSAC...
Page 100: Quick Test
5022-xxx Quick Test The Quick Test contains the following information: • Print registration settings • Alignment diamonds at the left, right, top and bottom • Horizontal lines to check for skew • General printer information, including current page count, installed memory, serial number, and code level. To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper.
Page 101: Alignment
5022-xxx Alignment Alignment is part of the process of adjusting the printhead and the color planes to the black plane and to each other. Before you start, perform the black alignment (Registration). See “Registration” on page 3-4. If you are replacing a new printhead, perform the entire printhead alignment.
Page 102: Motor Tests
5022-xxx Motor tests The motor tests are run primarily to locate noises in the printer. General motor tests In some instances, when you enter a particular test, you will be given the choice to run the motor in forward or reverse.
Page 103: Motor Calibration
5022-xxx Motor Calibration This test is run to match the fuser motor speed to the belt motor speed. Select MOTOR TESTS from DIAGNOSTICS. Select Motor Calibration. The printer generates eight pages as part of this test. To stop the test, press Stop ( Servo Laser Test Select MOTOR TESTS from DIAGNOSTICS.
Page 104: Print Quality Test Pages (Prt Quality
5022-xxx • If Single is selected, a single page is printed. • If Continuous is selected, printing continues until Stop ( ) is pressed to cancel the test. If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is selected, the test pattern is printed only on the first envelope.
Page 105: Hardware Tests
5022-xxx Hardware Tests Panel Test This test verifies the operator panel LCD function. To run the Panel Test: Select HARDWARE TESTS from DIAGNOSTICS. Select Panel Test. The Panel Test continually executes. Press Stop ( ) to cancel the test. Button Test This test verifies the operator panel button function.
Page 106: Cache Test
5022-xxx CACHE Test The CACHE Test is used to verify the processor CACHE is functioning properly. Select CACHE Test from HARDWARE TESTS in DIAGNOSTICS. The machine initiates a POR of the printer, and the following screen is displayed: Resetting the Printer Upon completion of the POR, the following screen is displayed: CACHE Test x100...
Page 107: Print Test (Duplex)
5022-xxx The paper you choose to print the page on should be either Letter or A4. To run the Quick Test (duplex): Select Quick Test from DUPLEX TESTS. Select Single or Continuous. • The single Duplex Quick test cannot be canceled. •...
Page 108: Top Margin (Duplex)
5022-xxx Top Margin (duplex) This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin.
Page 109: 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 DIAGNOSTICS. Select Bin Full Test.
Page 110: 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 You can view, but not change any of the three counts displayed under PAGE COUNTS.
Page 111: Ep Setup
5022-xxx To set the configuration ID: Select Printer Setup from the Diagnostic mode. Select Configuration ID from the Printer Setup menu. Submitting Selection displays, followed by the value for Configuration ID 1. Enter the Configuration ID 1. • To select a digit or character to change, press until the digit or character is underlined.
Page 112: Event Log
• Time and date stamps • 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. 3-18 Service Manual...
Page 113: Clear Log
5022-xxx To print the event log: Select EVENT LOG from DIAGNOSTICS. Select Print Log. Press Back ( ) to return to EVENT LOG. Clear Log Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information.
Page 114: Configuration Menu (Config Menu)
5022-xxx Configuration menu (CONFIG MENU) Available tests The tests display on the operator panel in the order shown for models C53x. The order differs slightly in models C52x. Configuration menu Reset Fuser Cnt “Reset Fuser Cnt” on page 3-21. Color Lock Out “Color Lock Out”...
Page 115: Reset Fuser Cnt
5022-xxx Reset Fuser Cnt Resets the fuser count value to zero. The Event Log records each time that a user executes the Reset Fuser Count operation. See “Event Log” on page 3-23 for more information. This setting only appears if the Maintenance Warning and Intervention function is enabled in the printer Configuration ID.
Page 116: Size Sensing
5022-xxx Size Sensing Turns the automatic size sensing for print media input sources either to Auto or Off. Selections include Tray 2 Sensing, if the tray is installed, Auto (default), and Off. This is a two-level menu that displays only those print media sources which support automatic size sensing. Panel Menus Lets the system support person enable or disable the operator panel menus.
Page 117: Energy Conserve
5022-xxx Energy Conserve Affects the values that appear in the Power Saver menu item in the Setup Menu. This menu item only appears when the printer model does not support Automatic Power Saver or has deactivated Automatic Power Saver. The menu item only affects the values that are displayed in the Power Saver menu item. Select Off (default) to cause Power Saver to only display Disabled.
Page 118: Enforce Color Order
5022-xxx Enforce Color Order Lets the system support person set whether the color order of the cartridges inside the printer is enforced and if messages appear. From top to bottom, as indicated by the color labels in the printer, the enforced toner cartridges order is yellow, cyan, magenta, and black.
Page 119: Env Prompts
5022-xxx Env Prompts Controls the source the printer selects for a change envelope source message. The printer displays the change envelope message based on the size of the envelope requested and not by the envelope type. Selections include Auto, MP Feeder, and Manual Env. MP Feeder is only available on some printer models. Note: If the Configure MP setting is changed to Manual, and a power-on reset is performed, and the value of the Env Prompts menu item before the power-on reset was MP Feeder, then when the printer restarts, the printer automatically changes the Env Prompt setting to Manual Env.
Page 120: Font Sharpening
5022-xxx Font Sharpening Lets a user set a text point-size value below the setting of the high frequency screens used when printing font data. This menu item only affects the PostScript, PCL 5, PCL XL, and PDF emulators. Settings are in the range of 0–150 (24 is the default). For example, if the value is set to 24, then all fonts sized 24 points or less use the high frequency screens.
Page 121: Paper Jams
5022-xxx Paper Jams Error jam locations The following illustration shows the location and error codes generated for specific paper jams and the corresponding locations of these jams. 203 Paper Jam exit sensor retract when duplexing 202 Paper Jam fuser / exit sensor 230 Paper Jam exit sensor to 230 Paper Jam...
Page 122: Paper Jams In The Multipurpose Feeder Or Manual Feeder
5022-xxx Paper jams in the multipurpose feeder or manual feeder Note: The multipurpose feeder can also be used as a manual feeder. Loading media in the multipurpose feeder or manual feeder Use the marks above the slot to adjust the width guide for standard paper sizes. For odd sizes, once the paper is isolated, move the width guide until it lightly touches the sheet.
Page 123: Clearing Paper Jams In The Manual Feeder
5022-xxx Clearing paper jams in the manual feeder When paper is not placed far enough into the manual feeder, the display prompts you to insert paper. If the paper is pushed far enough into the manual feeder for the printer to sense it, but not far enough to feed properly, 200.xx, 200.11, or 201.08 Paper Jam messages appear.
Page 124: Theory Of Operation
5022-xxx Theory of operation Paper path Paper exit flag Fuser Transfer belt System card Bump roller align Input flag Paper pick mechanism Duplex pick 3-30 Service Manual...
Page 125 5022-xxx 3-31 Diagnostic aids...
Page 126: 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 127: 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);...
Page 128 5022-xxx Once the paper is fed onto the transfer belt, the photoconductor drums in conjunction with the transfer belt pull the print media through the paper path. Photoconductor drums Transfer belt 3-34 Service Manual...
Page 129 5022-xxx Once the print media exits the transfer belt, it enters the fuser where heat and pressure are applied to bond the toner permanently to the media. The fuser rollers continue to turn and pull the print media through the paper path until it reaches the exit drive roll.
Page 130 5022-xxx If the page is to be duplexed, the fuser output drive roll continues to pull the media until it clears the paper exit flag and then reverses the rotation of the roller in order to pull the media back into the printer duplex assembly. The media is then routed down through the duplex path until it reaches the bump aligner roll.
Page 131: 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 132 5022-xxx Bump aligner drive The power to turn the bump aligner roll is supplied from the bump aligner motor. The motor drives a set of bump aligner gears which causes the bump aligner roll to turn. Bump aligner roll Bump aligner gears Bump aligner gears Bump aligner motor Note: If this motor is stalling or causing waste toner box full messages, the vertical auger mechanism might be...
Page 133 5022-xxx Photoconductor unit/toner cartridge drive The photoconductor units (four) and toner cartridges (four) receive drive power from the EP drive assembly motors. The top cartridge motor 1 on the EP drive assembly provides drive to the top two photoconductor units and toner cartridges (yellow and cyan).
Page 134 5022-xxx Transfer belt drive The transfer belt unit receives drive from a motor located on the EP drive assembly. When the top access door is open, the coupler for the transfer belt disengages. Outside Inside Transfer belt Coupler motor Fuser drive The fuser drive (motor) is built into the fuser assembly and drives the fuser rollers to turn.
Page 135 5022-xxx Duplex drive The duplex motor is mounted on the front door assembly. Drive is provided to three drive shafts in the duplex unit by a belt that is driven by the motor. The drive shafts move the print media through the duplex unit during printing.
Page 136: Paper Sensing
5022-xxx Paper sensing Sensors are strategically placed in the printer to ensure that the print media is making it to specific points within a given time in the electrophotographic process. There are two paper flags: one at the bottom of the machine (paper pick) to detect input paper, including duplex second side, from all sources and one at the top (paper exit) to detect paper movement beyond the fuser.
Page 137 5022-xxx Paper exit/duplex entry sensor and bin full flag The top sensor detects movement in two directions: as the paper exits the fuser and as it is retracted from the exit tray back into the duplex path. Each sheet must be driven past the fuser exit flag and allowed to fall before being turned around and starting the duplex path.
Page 138: Electrophotographic (Ep) Process
5022-xxx Electrophotographic (EP) process Main components Fuser High voltage Printhead power supply Developer (toner) cartridge Transfer belt Photoconductor belt System card The system card is the brain of the printer. During the print process, an image is sent from a computer to the system card.
Page 139 5022-xxx High voltage power supply (HVPS) Provides a high voltage 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 •...
Page 140: Charging
5022-xxx Charging The primary component of the charging process is the high voltage power supply. The following provides information that covers the mechanical transfer of the high voltage through a set of springs to each subcomponent of the charging process. Photoconductor unit (charge roll) The following illustration shows the circuit path that allows high voltage current to flow from the HVPS to the charge roll contact on the photoconductor unit.
Page 141 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 142 5022-xxx Transfer belt The transfer belt houses four transfer rollers that provide image transfer from the photoconductor drum to the print media. The transfer belt receives its high voltage charge through spring contacts located on the transfer contact assembly as shown in the following illustration. For the sake of simplicity, only one of the roller's high voltage paths is shown.
Page 143: 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 144: 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 145: 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 146: 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 147: Cleaning
5022-xxx Cleaning The transfer belt and photoconductor drum are cleaned at the end of the electrophotographic process cycle. The transfer belt surface is cleaned as it rotates past a cleaning blade and shaft located inside the transfer belt assembly. Any waste toner that is scraped off of the belt is collected in the waste toner container located next to the belt inside the transfer belt unit.
Page 148: Electrical Interlock
5022-xxx Electrical interlock 5 V interlock switch An interlock switch triggered by the front access door disables the +5 V output to the printhead which turns off the laser. Gearbox shield removed 5V interlock switch 3-54 Service Manual...
Page 149: V Interlock Switch
5022-xxx 24 V interlock switch The 24 V dc interlock switch is mounted to the right side of the top cover camshaft assembly. Opening the top door rotates the drive retraction lockout which opens the 24 V dc interlock switch. When the top door is closed with the front access door also closed, the drive retraction lockout trips the switch arm which closes the 24 V dc interlock switch.
Page 150 5022-xxx 3-56 Service Manual...
Page 151: 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 152: Handing The Photoconductor Unit
5022-xxx Handing the photoconductor unit The following precautions must be observed when handling the photoconductor unit. The photoconductor unit is a supply item you will have to remove during some of the repair procedures: Transportation/storage Use the specified carton whenever moving or storing the photoconductor unit. Handling •...
Page 153: Adjustments
5022-xxx Adjustments Printhead alignment Overview When reinstalling the printhead, it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer. This allows the pages to 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 154 5022-xxx Remove the paper exit tray for access to the printhead alignment screw (B). Enter Diagnostic mode (turn off the printer, press and hold , turn on the printer, and release the buttons when the clock graphic displays). Select REGISTRATION. Select Skew.
Page 155: Left Margin
5022-xxx Scroll down to Quick Test, and press Select. A page similar to this one prints: Top left alignment marks Top right alignment marks Left margin alignment marks Lexmar k C5 2X Quic k Tes t Printer In format i on Margin Settings Page Count Top Margin...
Page 156 Quick Test until the top alignment marks are the same distance from the top of the media. Note: One rotation of the printhead alignment screw equals approximately 0.5 millimeter movement of the top edge print alignment marks. Straight Skewed Lexmark C52X Quick Test Printer Inf ormation Margin Settings Page Count...
Page 157: Registration (Black)
5022-xxx Registration (black) Top Margin Select Quick Test (REGISTRATION in the Diagnostics mode), or use the last Quick Test you used to adjust skew. Select Top Margin, and press Select. Adjust the values until both top alignment marks are on the top edge of the print. •...
Page 158: Alignment (Cyan, Yellow, And Magenta)
5022-xxx Left Margin Select Left Margin, and press Select. Adjust the left margin until the points of the left alignment marks touch the edge of the page. • Pressing the left arrow decreases the value and moves the left alignment marks to the left. •...
Page 159 5022-xxx Select Quick Test in the Cyan menu, and press Select. Two pages print. You may have to print these pages several times until you get T and Z aligned. Do not go to step 2 until T and Z are aligned. The first page is similar to the following: Repair information...
Page 160 5022-xxx Determine the line under Fine Adjustment that is closest. If the value is beyond the Fine Adjustment scale, use either of the Coarse Adjustment scales. Enter the number determined from the Fine Adjustment scale or the Coarse Adjustment scales on the part of the page for the “T”...
Page 161 5022-xxx Repeat this process for skew (Z). Don't forget to add the T value and the current cyan Z value to obtain the new skew (Z) value. An example is shown below: 4-11 Repair information...
Page 162 5022-xxx Continue to follow the directions on the bottom of the first page to find the Cyan Top Margin (T), the Skew (Z), and on the second page of the Quick Test page, the Left Margin (L), Right Margin (R), and Bow (P). Repeat steps 2 through 11 for yellow and magenta.
Page 163: 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 is not presented in this manual. Turn the printer power off and unplug the power cable from the outlet prior to starting removals or checks.
Page 164: Cover Removals
5022-xxx Cover removals 4-14 Service Manual...
Page 165: Exit Tray Cover Removal
5022-xxx Exit tray cover removal “Exit tray cover, C52x” on page 7-3 for the part number. Grasp the exit tray, and lift away from printer. 4-15 Repair information...
Page 166: Front Access Door Cover Assembly Removal
5022-xxx Front access door cover assembly removal See Front access door cover assembly for the part number for the models you need on page 7-3. Remove the paper tray. Remove the right cover. See “Right cover removal” on page 4-26. Disconnect the transfer belt cable (A).
Page 167 5022-xxx Looking down at the keyed end of the restraint (C), twist the end clockwise, slide the restraint upward through the slit (D), and slip the end of the restraint through the keyed hole (E). Repeat for the other side. Close the front access door.
Page 168 5022-xxx Remove the four screws (F) that attach the pivot pin to the front access door cover. Remove the front access cover assembly. 4-18 Service Manual...
Page 169: Gearbox Shield Removal
5022-xxx Gearbox shield removal Not a FRU. Remove the paper tray. Remove the right cover. See “Right cover removal” on page 4-26. Remove the four screws (A). Remove the gearbox shield (B). There is a locking tab on the back of the gearbox shield. Warning: When removing the gearbox shield, be careful not to damage the 5 V interlock switch arm.
Page 170: Left Cover Removal
5022-xxx Left cover removal “Left cover” on page 7-3 for the part number. Place the printer on the table with the left side edge hanging over slightly. Remove the waste toner assembly. See “Waste toner assembly removal” on page 4-93. Open the top access door.
Page 171: Operator Panel Outer Bezel Removal
5022-xxx Operator panel outer bezel removal “Outer bezel, C52x” on page 7-3 for the part number for the C52x models. See the same page for the specific models for the bezels for the C53x models. Using a flathead screwdriver or similar tool, unsnap the locking tabs (A) on the upper left and the upper right of the outer bezel.
Page 172: Operator Panel Inner Bezel Removal-Models C52X Only
5022-xxx Operator panel inner bezel removal—models C52x only See the part number for the inner bezel for the model you need on page 7-3. Remove the outer bezel. See “Operator panel outer bezel removal” on page 4-21. Press the top of the inner bezel to release the inner bezel (A) from the outer bezel. Gently twist to free the lower tabs (B).
Page 173: Operator Panel Assembly Removal
5022-xxx Operator panel assembly removal “Operator panel assembly, C52x” on page 7-3 for the part number. See the same page for the individual part numbers for the C53x models. Warning: When replacing any one of the following components: • Operator panel assembly •...
Page 174: Paper Tray Dust Cover Removal
5022-xxx Paper tray dust cover removal “Paper tray dust cover with dust cover spring, C53x” on page 7-3 for the part number. Unplug the power cord from the printer. Remove the exit tray. See “Exit tray cover removal” on page 4-15.
Page 175: Rear Cover Removal
5022-xxx Rear cover removal “Rear cover” on page 7-3 for the part number. Loosen the eight screws (A). Note: Do not remove the screws. Lift up on the rear cover, and slide to the right to remove from the back of the printer. 4-25 Repair information...
Page 176: Right Cover Removal
5022-xxx Right cover removal “Right cover” on page 7-3 for the part number. Make sure the power cord is removed. Place the printer on the table with the right side edge hanging over slightly. Open the top access door. Open the front access door. Remove the three screws (A).
Page 177 5022-xxx Installation note: Be sure the tab (B) is fully engaged. 4-27 Repair information...
Page 178: Top Access Cover Assembly Removal-Model C52X Only
5022-xxx Top access cover assembly removal—model C52x only “Top access cover assembly (network), C520n/C522n/C524n/C524dn” on page 7-3 “Top access cover assembly (non-network), C524” on page 7-3 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-25.
Page 179 5022-xxx Remove the screw (B) exposed after removing the exit tray. If the top access door is open, close it. Warning: Ensure that the top access door is closed before removing the linkage screw. Failing to close the door leaves the linkage under a load, which may result in the linkage screw being catapulted away from the printer when removed.
Page 180 5022-xxx Remove the linkage screw (C). 4-30 Service Manual...
Page 181 5022-xxx Remove the screw (D) from the rear. Disconnect the cables for the fan at JFAN1 (E), the operator panel at JOPP1 (F), the high voltage power supply connector at JHVPS1 (G), and the bin full sensor at JBIN1(H) (for network printers only) from the system card.
Page 182: Top Access Cover Assembly Removal-Model C53X Only
5022-xxx Top access cover assembly removal—model C53x only “Top access cover assembly (network), C532n/C534n” on page 7-3 “Duplex top access assembly (network), C530dn/C532dn/C534dn” on page 7-3 for the part number. Remove the right cover. See “Right cover removal” on page 4-26.
Page 183 5022-xxx Remove the screw (B) exposed after removing the exit tray. If the top access door is open, close it. Warning: Ensure that top access door is closed before removing the linkage screw. Failing to close the door leaves the linkage under a load, which may result in the linkage screw being catapulted away from the printer when removed.
Page 184 5022-xxx Remove the linkage screw (C). 4-34 Service Manual...
Page 185 5022-xxx Disconnect the cables for the fan at JFAN1 (D), the operator panel at JOPP1 (E), the high voltage power supply connector at JHVPS1 (F), and the bin full sensor at JBIN1(G), and USB at J1 (H) (model C534 only) from the system card.
Page 186 5022-xxx Disconnect the ground cable (J). Lift and remove the top access cover assembly. 4-36 Service Manual...
Page 187: Bin Full Sensor Removal-Models C52X
5022-xxx Bin full sensor removal—models C52x “Bin full sensor with cable, C520n/C522n/C524n/C524dn” on page 7-3 for the part number. Open the top access door. Remove the fuser. See “Fuser removal” on page 4-60. Disconnect the spring (A). Remove the seven screws (B) securing the inner access cover. Remove the inner access cover.
Page 188: Bin Full Sensor Removal-Models C53X
5022-xxx Bin full sensor removal—models C53x “Bin full sensor with cable, C53x” on page 7-3 for the part number. Remove the top access cover assembly. See “Top access cover assembly removal—model C53x only” on page 4-32. Remove the three screws (A) from the cable cover. Turn the cable cover over, and press the side of the bin full sensor (B) to snap it loose from the cable cover.
Page 189: Bump Aligner Gear Removal
5022-xxx Bump aligner gear removal See the Bump aligner gear kit on page 7-5 for the part number. Remove the paper pick mechanism assembly. See “Paper pick mechanism assembly removal” on page 4-68. Close the front access door for better access to the gears. Remove the three e-clips and washers (A).
Page 190: Bump Aligner Motor Removal
5022-xxx Bump aligner motor removal “Bump aligner motor” on page 7-7 for the part number. Remove the right side cover. Remove the bump aligner gears. See “Bump aligner gear removal” on page 4-39. Remove the two bump aligner motor mounting screws (A). 4-40 Service Manual...
Page 191 5022-xxx Disconnect the JBUMP1 connector (B) from the system card. Remove the bump aligner motor from the printer. 4-41 Repair information...
Page 192: Bump Aligner Rollers And Springs Removal-Models C53X
5022-xxx Bump aligner rollers and springs removal—models C53x “Bump aligner roller and spring” on page 7-5 for the part number. Remove the paper tray. Push up and back to relase the bump aligner spring. Lower the bump aligner spring to remove it. 4-42 Service Manual...
Page 193 5022-xxx Remove the bump aligner roller. Installation note: Make sure to support the bump aligner roller in the arms of the bump aligner spring. 4-43 Repair information...
Page 194: Contact Springs Removal
5022-xxx Contact springs removal “Contact springs” on page 7-17 for the part number. Remove all the toner cartridges. Remove the screw (A) and the spring cap (B) of the appropriate contact spring. Press the lower half (C, D) of the springs and remove the springs. 4-44 Service Manual...
Page 195 5022-xxx Installation notes: When installing, make sure the top half (E) of the spring is under the straight spring (F). This is typical for both types of springs. Also make sure the bottom half (D,G) of both springs are compressed and locked by the appropriate locking tabs (H, I).
Page 196: Deflector Assembly Removal-Models C53X Only
5022-xxx Deflector assembly removal—models C53x only “Deflector assembly, C53x” on page 7-5 for the part number. Remove the right cover. See “Right cover removal” on page 4-26. Remove the screw (A) securing the deflector assembly on the right side. Place a flathead screwdriver between the deflector assembly and the right side frame, and lever the deflector away from the frame.
Page 197 5022-xxx Installation notes: Align the two studs (A) to the two alignment holes (B) in the left side frame. Align the stud (C) with the alignment hole (D) on the right frame. Snap into place. Replace the screw on the right side. 4-47 Repair information...
Page 198: Electrophotographic (Ep) Drive Assembly Removal-Model C52X Only
5022-xxx Electrophotographic (EP) drive assembly removal—model C52x only “EP drive assembly, C52x” on page 7-7 “EP drive assembly, C53x” on page 7-7 for the part number. Remove the low voltage power supply. See “Low voltage power supply (LVPS) removal” on page 4-65.
Page 199 5022-xxx Remove the six inner screws (D). Remove the nine outer screws (E). Note: Access the top two screws through the top cover. Remove the EP drive assembly from the printer. 4-49 Repair information...
Page 200 5022-xxx Installation note: Ensure that the top access door is open and EP drive is retracted when installing the new EP drive assembly. Note: When retracted, the upper (F) and lower retraction plates (G) will be fully forward. If not, slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers.
Page 201: Electrophotographic (Ep) Drive Assembly Removal-Model C53X Only
5022-xxx Electrophotographic (EP) drive assembly removal—model C53x only “EP drive assembly, C53x” on page 7-7 for the part number. Remove the right cover. See “Right cover removal” on page 4-26. Open the top access door. Open the front access door. Remove all the toner cartridges.
Page 202 5022-xxx Remove the nine outer screws (E). Note: Access the top two screws through the top cover. Remove the EP drive assembly from the printer. 4-52 Service Manual...
Page 203 5022-xxx Installation note: Ensure that the top access door is open and the EP drive is retracted when installing the new EP drive assembly. Note: When retracted, upper (F) and lower retraction plates (G) will be fully forward. If not, slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers.
Page 204: Front Access Door 5 V Interlock Switch Removal
5022-xxx Front access door 5 V interlock switch removal “Front door 5 V interlock switch” on page 7-7 for the part number. Remove the LVPS. See “Low voltage power supply (LVPS) removal” on page 4-65. Disconnect the JINT1 connector (A) from the system card. Open the top access door.
Page 205: Front Door Assembly Removal
5022-xxx Front door assembly removal See the part number for the Front door assembly for the specific model you need on page 7-5. Remove the front access cover assembly. See “Front access door cover assembly removal” on page 4-16. Remove the rear cover. See “Rear cover removal”...
Page 206 5022-xxx Models C52x only: Disconnect the cable (C) from the right side of the frame. Be careful not to lose the grounding clip (D). Remove the gearbox shield. See “Gearbox shield removal” on page 4-19. Close the front door assembly. Release the left and right front door assembly cable restraint springs (E) from the front door assembly.
Page 207 5022-xxx Unwrap and remove the cable from the left and right pulleys (F). Remove the mounting screw (G) and the cap (H). 4-57 Repair information...
Page 208 5022-xxx Open the front door assembly, slide it to the right, and remove. You need to press firmly to slide the front door assembly to the right. Installation note: See “Front door assembly front cable removal” on page 4-59 for proper installation of the cable restraints.
Page 209: Front Door Assembly Front Cable Removal
5022-xxx Front door assembly front cable removal See the part number for the Front door parts packet for the model you need on page 7-5. Removal procedures are for either the left or the right front door assembly restraint cables. Right restraint cable Remove the front access cover assembly.
Page 210: Fuser Removal
5022-xxx Fuser removal “Fuser assembly, 115 V” on page 7-15, “Fuser assembly, 230 V” on page 7-15, or “Fuser assembly, 100 V” on page 7-15 for the part number. CAUTION The fuser can be extremely hot. Use care when handling to avoid burns. Turn off the printer.
Page 211: Fuser Cable Cover Removal
5022-xxx Fuser cable cover removal “Fuser cable cover, included in parts packet (P/N 40X1430), C52x” on page 7-5 “Fuser cable cover, included in parts packet (P/N 40X3598), C53x” on page 7-5 for the part number. Open the top access door. Open the front access door.
Page 212: High Voltage Power Supply (Hvps) Removal
5022-xxx High voltage power supply (HVPS) removal “High voltage power supply, C52x” on page 7-11 “High voltage power supply, C53x” on page 7-11 for the part number. Remove the left cover. See “Operator panel outer bezel removal” on page 4-21. Remove the six mounting screws (A).
Page 213 5022-xxx Disconnect the five connectors (C) from the HVPS. Installation notes: Be sure to replace the spring when replacing the HVPS. See the illustration for proper orientation. 4-63 Repair information...
Page 214: Left Bellcrank Removal
5022-xxx Left bellcrank removal “Left bellcrank assembly” on page 7-5 for the part number. Remove the left cover. See “Left cover removal” on page 4-20. Remove the C-clip (A). Remove the left bellcrank. 4-64 Service Manual...
Page 215: Low Voltage Power Supply (Lvps) Removal
5022-xxx Low voltage power supply (LVPS) removal “Low voltage power supply, 115/230 V” on page 7-7 for the part number. Remove the right side cover. See “Right cover removal” on page 4-26. Remove the rear cover. See “Rear cover removal” on page 4-25.
Page 216 5022-xxx Installation note: When installing the new LVPS, make sure the voltage switch (D) is set for the proper value (115 V or 230 V), depending on the country. 4-66 Service Manual...
Page 217: Multipurpose Feeder (Mpf) Swing Arm Assembly Removal-Models C52X Only
5022-xxx Multipurpose feeder (MPF) swing arm assembly removal—models C52x only “MPF swing arm assembly, C52x” on page 7-5 for the part number. Open the top access door. Open the front access door. Remove the three mounting screws (A). Remove the swing arm assembly from the frame. Installation note: Refer to the following illustration if the swing arm crank comes loose from the swing arm assembly.
Page 218: Paper Pick Mechanism Assembly Removal
5022-xxx Paper pick mechanism assembly removal “Paper pick mechanism assembly, C52x” on page 7-5 “Paper pick mechanism assembly, C53x” on page 7-5 for the part number. Remove the rear cover. See “Rear cover removal” on page 4-25. Disconnect the JTRAY1 (A) and JTRAY2 (B) connectors from the system card. Remove all toner cartridges.
Page 219 5022-xxx Remove the three mounting screws (C). Release the front locking tabs (D). Slide the paper pick mechanism forward until the rear locking tabs (E) release. Lower the paper pick mechanism, and remove through the front of the printer. Note: Make sure the JTRAY1 and JTRAY2 connectors do not bind when passing through the frame access hole.
Page 220: 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. See “Handing the photoconductor unit” on page 4-2 for additional information. Open the top access door. Open the front access door.
Page 221: Pick Roll Rubber Tires Removal And Replacement
5022-xxx Pick roll rubber tires removal and replacement “Pick arm roll” on page 7-15 for the part number. The autocompensator pick roll tires are located in the base printer. There are also tires in all input options. If you have additional input options, and you are having problems with media picking, replace these tires also. Always replace the pick tires in pairs.
Page 222 5022-xxx Remove the rubber tire (B) from the pick roll assembly (C). Repeat for the other pick roll assembly. Installation notes: Install the new rubber tires with the surface texture (D) turning in the direction as shown. Note: Feel the rubber surface to verify it turns properly in the direction shown. 4-72 Service Manual...
Page 223: Printer Pad Removal
5022-xxx Printer pad removal “Printer pad, included in parts packet , screws (P/N 40X1431)” on page 7-5 for the part number. Slide the corner of the printer containing the damaged pad over the corner of the table. Pull the pad (A) from the bottom of the printer. Installation Note: When installing the new pad, remove the appropriate side cover that corresponds to the damaged pad.
Page 224: Printhead Removal
5022-xxx Printhead removal “Printhead assembly, C52x” on page 7-9 “Printhead assembly, C53x” on page 7-9 for the part number. Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card (C52x) or printhead assembly (C53x) Only replace one component at a time.
Page 225 5022-xxx Remove the three mounting screws (C) from the front of the printhead. Warning: Secure the printhead when removing the printhead alignment screw. Failure to do this allows the printhead to fall out of the printer, potentially damaging the printhead. Close the top access cover and remove the printhead alignment screw (D), and remove the printhead.
Page 226 5022-xxx Installation notes: Do not install the printhead mounting screws in the rear of the printer. When reinstalling the printhead, it is important to keep in mind that the printhead mounting screws should be initially tightened just enough to hold the printhead in the printer.
Page 227: Right Bellcrank Removal
5022-xxx Right bellcrank removal “Right bellcrank assembly” on page 7-5 for the part number. Open the front access cover. Remove the gearbox/switch shield. See “Gearbox shield removal” on page 4-19. Remove the C-clip (A). Remove the right bellcrank. 4-77 Repair information...
Page 228: Smart Chip Card Removal-Models C52X Only
5022-xxx Smart chip card removal—models C52x only “Smart chip card, C52x only” on page 7-9 for the part number. Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card (C52x) or printhead assembly (C53x) Only replace one component at a time.
Page 229: System Card Removal
5022-xxx System card removal See the system card part number for the model you need on page 7-9. Warning: When replacing any one of the following components: • Operator panel assembly • System card • Smart chip card (C52x) or printhead assembly (C53x) Only replace one component at a time.
Page 230 5022-xxx Remove the screw (B) from the USB connector. For models C52x only: If a non-network system card is installed, also remove the two screws (C) from the parallel connector. Network system card Non-network system card Remove the eight screws (D) from the system card. Remove the system card.
Page 231: System Card Support Shield Removal
5022-xxx System card support shield removal “System card support shield, C52x” on page 7-9 “System card support shield, C53x” on page 7-9 for the part number. Remove the right cover. See “Right cover removal” on page 4-26. Remove the left cover. See “Left cover removal”...
Page 232 5022-xxx Remove the four mounting screws (D) from the top and bottom of the support shield. Note: Only the printhead cables come through the access holes in the system card support shield. Lower and remove the support shield. Be careful not to damage the cables that route through the top frame of the printer.
Page 233: Toner Level Sensor Removal
5022-xxx Toner level sensor removal “Toner level sensor” on page 7-11 for the part number. Note the locations of the toner sensors. Yellow Cyan Black Magenta Remove the HVPS. See “High voltage power supply (HVPS) removal” on page 4-62. For yellow and cyan only: Remove the transfer contact assembly. See “Transfer contact assembly removal”...
Page 234 5022-xxx For all colors: It is difficult to press both locking tabs at the same time. Using a spring hook, press the locking tab (A), and disengage the sensor on that side. Press the other locking tab (B), and remove the sensor. 4-84 Service Manual...
Page 235: Top Access Door 24 V Interlock Switch Removal
5022-xxx Top access door 24 V interlock switch removal “Top access door 24 V interlock switch” on page 7-13 for the part number. Remove the top access cover assembly. See “Top access cover assembly removal—model C52x only” on page 4-28. Disconnect the JCVR1 connector (A) from the system card.
Page 236: Top Cover Camshaft Assembly Removal
5022-xxx Top cover camshaft assembly removal “Top cover camshaft assembly” on page 7-13 for the part number. Remove the top access door 24 V interlock switch. See “Top access door 24 V interlock switch removal” on page 4-85. Remove the left cover. See “Operator panel outer bezel removal”...
Page 237 5022-xxx Installation notes: Warning: Do not install the camshaft assembly by reversing the removal procedures. The camshaft assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed, or the printer will not work correctly. Ensure the EP drive assembly is engaged by sliding the upper retraction plate (A) fully to the rear.
Page 238 5022-xxx Place the left side of the camshaft assembly through the opening in the waste toner shutter (G). Make sure the cam (H) engages the waste toner shutter (G). Also make sure the drive pinion (I) engages the upper retraction plate (J). Install the rear mounting screws (K).
Page 239 5022-xxx Rotate the lever arm (O) all the way up as if the top access door were open. While still holding the lever arm (O) up, flip the right lock (P) up and install the front mounting screws (Q). Warning: Failure to place the camshaft assembly in the open position prevents the front access door from closing and may cause damage to the door.
Page 240 5022-xxx Note: If the left side of the camshaft assembly becomes disassembled, use the following illustration: 4-90 Service Manual...
Page 241: Transfer Belt Removal
5022-xxx Transfer belt removal “Transfer belt assembly, C52x” on page 7-15 “Transfer belt assembly, C53x” on page 7-15 for the part number. Remove all photoconductor units. See “Photoconductor unit removal” on page 4-70. Warning: To avoid damaging the photoconductor drum, hold the photoconductor units by their handle and place the photoconductor units on a clean surface.
Page 242: Transfer Contact Assembly Removal
5022-xxx Transfer contact assembly removal “Transfer contact assembly” on page 7-11 for the part number. Remove the HVPS. See “High voltage power supply (HVPS) removal” on page 4-62. Remove all the inside contact springs. See “Contact springs removal” on page 4-44.
Page 243: Waste Toner Assembly Removal
5022-xxx Waste toner assembly removal Not a FRU. Press release latch (A). Swing front of waste toner away from printer and remove. 4-93 Repair information...
Page 244 5022-xxx 4-94 Service Manual...
Page 245: Locations And Connectors
5022-xxx 5. Locations and connectors Locations Covers Locations and connectors...
Page 246: Front
5022-xxx Front Fuser cable cover Paper pick mechanism assembly MPF swing arm assembly (models C52X only) Front door Deflector assembly assembly Bellcrank assembly Printer Bump aligner gears Front door Right front door Left front door assembly restraint assembly restraint cable cable Service Manual...
Page 247: Right
5022-xxx Right EP drive assembly Bump aligner motor 5 V interlock switch Locations and connectors...
Page 248: Rear
5022-xxx Rear Service Manual...
Page 249: Left
5022-xxx Left Toner level sensor High voltage Transfer contact assembly power supply Locations and connectors...
Page 250: Top
5022-xxx Top cover camshaft assembly Top access door 24V interlock switch with cable Service Manual...
Page 251: Cru And Frus
5022-xxx CRU and FRUs Locations and connectors...
Page 252: Sensors
5022-xxx Sensors Toner level sensor Toner patch sensor (TPS) Service Manual...
Page 253: Motors
5022-xxx Motors Locations and connectors...
Page 254: Printer Cards
5022-xxx Printer cards 5-10 Service Manual...
Page 255: Connectors
5022-xxx Connectors System card (network)—models C52x 5-11 Locations and connectors...
Page 256: System Card (Non-Network)-Models C52X
5022-xxx System card (non-network)—models C52x 5-12 Service Manual...
Page 257: Connector Listing-Models C52X
5022-xxx Connector listing—models C52x (see “System card (network)—models C52x” on page 5-11 “System card (non-network)—models C52x” on page 5-12) Connector Pin no. Signal Pin no. Signal JBIN1 V_BF (+5 SW) S_BIN_FB Ground JBUMP1 VS_BUMP_LED S_BUMP_ENC Ground V_BUMP_M- V_BUMP_M+ JCART1 V_JC1-1 V_JC1-2 V_JC2-3 V_JC1-4...
Page 258 5022-xxx Connector listing—models C52x (see “System card (network)—models C52x” on page 5-11 “System card (non-network)—models C52x” on page 5-12) (continued) Connector Pin no. Signal Pin no. Signal JHVPS1 Ground V_24VD C-DEVPWM M-DEVPWM Y-DEVPWM K-DEVPWM Ground +5V_SW HV_EMPTY_C HV_EMPTY_M HV_EMPTY_Y HV_EMPTY_K HV_CHRG_PWM TONER_CHK HV_XFER_PWM_C...
Page 259 5022-xxx Connector listing—models C52x (see “System card (network)—models C52x” on page 5-11 “System card (non-network)—models C52x” on page 5-12) (continued) Connector Pin no. Signal Pin no. Signal JOPP1 I2C_DATA5_OP V_PANEL+5V I2C_CLK_OP Ground I2CIRQ5_R +3.3 V dc Ground JPH1 Ground D_VDO_M- D_VDO_M+ Ground D_VDO_C-...
Page 260 5022-xxx Connector listing—models C52x (see “System card (network)—models C52x” on page 5-11 “System card (non-network)—models C52x” on page 5-12) (continued) Connector Pin no. Signal Pin no. Signal JPH1 (continued) D_VDO_K- D_VDO_K+ Ground D_VDO_Y- D_VDO_Y+ Ground JSBTN1 S_SB_Y S_SB_K S_SB_M S_SB_C Ground I2C_DATA_SB I2C_CLK_SB...
Page 261 5022-xxx Connector listing—models C52x (see “System card (network)—models C52x” on page 5-11 “System card (non-network)—models C52x” on page 5-12) (continued) Connector Pin no. Signal Pin no. Signal JTRAY2 VS_TRAY_ENC_LED S_TRAY_ENC Ground V_TRAY_PICK_M- V_TRAY_PICK_M+ 5-17 Locations and connectors...
Page 262: System Card (Network)-Models C53X
5022-xxx System card (network)—models C53x 5-18 Service Manual...
Page 263: Connector Listing-Models C53X
5022-xxx Connector listing—models C53x (see “System card (network)—models C53x” on page 5-18) Connector Pin no. Signal Pin no. Signal V FHUSB_+5 JB_USB_RD- JB_USB_RD+ Ground Ground JBIN1 V_BF (+5 SW) S_BIN_FB Ground JBUMP1 VS_BUMP_LED S_BUMP_ENC Ground V_BUMP_M- V_BUMP_M+ JCART1 CART1_HALL_U CART1_HALL_V CART2_HALL_U CART1_FG Ground...
Page 264 5022-xxx Connector listing—models C53x (see “System card (network)—models C53x” on page 5-18) (continued) Connector Pin no. Signal Pin no. Signal JFUSER1 V_FUSER_M+ V_FUSER_M- VS_FUSER_LED S_FUSER_ENC Ground GND/BR_THERM FUSER_EXIT_SNSD VS_FUSER+5V FUSER_HR_SNS FUSER_HR_THM_RTN JHVPS1 Ground V_24VD HV_EMPTY_C HV_EMPTY_M HV_EMPTY_Y HV_ENPTY_K Ground +5V_SW TONER_C TONER_M TONER_Y...
Page 265 5022-xxx Connector listing—models C53x (see “System card (network)—models C53x” on page 5-18) (continued) Connector Pin no. Signal Pin no. Signal JOPP1 I2C_DATA5_OP V_PANEL+5V I2C_CLK_OP Ground I2CIRQ5_R +3.3 V dc Ground JPH1 Ground D_VDO_C- D_VDO_C+ Ground D_VDO_Y- D_VDO_Y+ Ground PH_EMS1_SNS_R VDO_BOOST1 VDO_LPOW1 VDO_LADJ01 VDO_HADJ01...
Page 266 5022-xxx Connector listing—models C53x (see “System card (network)—models C53x” on page 5-18) (continued) Connector Pin no. Signal Pin no. Signal JPH1 (continued) D_VDO_K- D_VDO_K+ Ground D_VDO_M- D_VDO_M+ Ground JSBTN1 S_SB_Y S_SB_K S_SB_M S_SB_C Ground I2C_DATA_SB I2C_CLK_SB +3.3 V dc JTRANS1 V_TRANS_PHA+ V_TRANS_PHA- V_TRANS_PHB+...
Page 267: Wiring Diagrams
5022-xxx Wiring diagrams Wiring diagrams are attached to the end of this document. Diagrams are designed for 11 x 17 in. or A3 paper. Print the individual wiring diagram pages separately on larger paper for best effect. 5-23 Locations and connectors...
Page 268 5022-xxx 5-24 Service Manual...
Page 269: Preventive Maintenance
5022-xxx 6. Preventive maintenance Scheduled maintenance The operator panel displays 80 Replace Fuser at 120K page count interval. The fuser assembly and the transfer roll should be changed at this interval to maintain the print quality and reliability of the printer. The following maintenance items are available for the customer: Maintenance items Description...
Page 270 5022-xxx Service Manual...
Page 271: Parts Catalog
NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. Model information used in the parts catalog. Model name Configuration Machine type Lexmark C520n Network 5022-010 Lexmark C522n Network 5022-210...
Page 272: Assembly 1: Covers
5022-xxx Assembly 1: Covers Service Manual...
Page 273 5022-xxx Assembly 1: Covers Units/ Units/ Index Description mach 40X1415 Outer bezel, C52x 40X1448 Inner bezel, C524/C524n/C524dn 40X1449 Inner bezel, C522n 40X1450 Inner bezel, C520n 40X1414 Operator panel assembly, C52x 40X3608 Bezel, C530dn 40X3585 Bezel, C532n 40X3586 Bezel, C532dn 40X3582 Operator panel assembly, C530dn/C532n/C532dn 40X3587 Bezel, C534n...
Page 274: Assembly 2: Front
5022-xxx Assembly 2: Front Service Manual...
Page 275 5022-xxx Assembly 2: Front Units/ Units/ Index Description mach Fuser cable cover, included in parts packet (P/N 40X1430), C52x Fuser cable cover, included in parts packet (P/N 40X3598), C53x Printer pad, included in parts packet , screws (P/N 40X1431) 40X1446 Right bellcrank assembly 40X1432 Bump aligner gear kit, including:...
Page 276: Assembly 3: Right
5022-xxx Assembly 3: Right Service Manual...
Page 277 5022-xxx Assembly 3: Right Units/ Units/ Index Description mach 40X1409 EP drive assembly, C52x 40X3578 EP drive assembly, C53x 40X3574 Low voltage power supply, 115/230 V 40X1433 Bump aligner motor 40X1436 Front door 5 V interlock switch 40X1445 Ground contact plate, C52x only Parts catalog...
Page 278: Assembly 4: Rear
5022-xxx Assembly 4: Rear Service Manual...
Page 279 5022-xxx Assembly 4: Rear Units/ Units/ Index Description mach 40X1417 Printhead assembly, C52x 40X3589 Printhead assembly, C53x 40X4218 System card (network), C524n/C524dn 40X4219 System card (network), C520n/C522n 40X4217 System card, C524 40X3575 System card (network), C530dn/C532n/C532dn 40X3576 System card (network), C534n 40X3577 System card (network), C534dn 40X1429...
Page 280: Assembly 5: Left
5022-xxx Assembly 5: Left 7-10 Service Manual...
Page 281 5022-xxx Assembly 5: Left Units/ Units/ Index Description mach 40X1416 Toner level sensor 40X1428 Transfer contact assembly 40X1411 High voltage power supply, C52x 40X3579 High voltage power supply, C53x 7-11 Parts catalog...
Page 282: Assembly 6: Top
5022-xxx Assembly 6: Top 7-12 Service Manual...
Page 283 5022-xxx Assembly 6: Top Units/ Units/ Index Description mach 40X3613 Top cover camshaft assembly 40X1437 Top access door 24 V interlock switch 7-13 Parts catalog...
Page 284: Assembly 7: Customer Replaceable Units (Crus)
5022-xxx Assembly 7: Customer replaceable units (CRUs) 7-14 Service Manual...
Page 285 5022-xxx Assembly 7: CRUs Units/ Units/ Index Description mach 40X3569 Fuser assembly, 115 V 40X3570 Fuser assembly, 230 V 40X3571 Fuser assembly, 100 V 40X3607 Pick arm roll 40X1439 Option tray assembly, 500-sheet option (includes tray), C522n/C524/ C524n/C524dn 40X3600 Option tray assembly, 550-sheet option (includes tray), C532n/C532dn/ C534n/C534dn 40X1423 Tray assembly, 500-sheet, C522n/C524/C524n/C524dn...
Page 286: Assembly 8: Contact Springs
5022-xxx Assembly 8: Contact springs 7-16 Service Manual...
Page 287 5022-xxx Assembly 8: Contact springs Units/ Units/ Index Description mach 40X1434 Contact springs kit, including: • A—Torsion PCD contact spring (4) • B—Torsion CR contact spring (4) • C—Contact spring cap (4) • D—Charge roll contact spring (8) • E—HVPS TAR contact spring (4) •...
Page 288: Assembly 9: Cable Parts Packet
5022-xxx Assembly 9: Cable parts packet 7-18 Service Manual...
Page 289 5022-xxx Assembly 9: Cable parts packet Units/ Units/ Index Description mach 40X1430 Cables, C52x, including • A—Cartridge motor cable (1) • B—Fuser AC cable (1) • C—Fuser DC cable (1) • D—Smart chip cable (1) • E—Option cable (1) • Fuser cable cover (1) (see“Front”...
Page 290: Assembly 10: Miscellaneous
5022-xxx Assembly 10: Miscellaneous Units/ Units/ Index Description mach 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 291: Index
5022-xxx Index Numerics 7-18 1xx service error codes – cables, parts catalog 3-12 24 V interlock switch CACHE Test locations card stock 7-12 3-24 parts catalog Color Alignment 4-85 3-21 removal Color Lock Out 3-55 3-21 theory Color Trapping 2-15 3-16 2xx paper jam codes –...
Page 292 5022-xxx deflector assembly Right Margin parts catalog Skew 4-46 removal Top Margin 3-22 Demo Mode dimensions 3-25 diagnostic aids Disk Encryption 3-11 diagnostics menu DRAM Test accessing duplex 3-14 ALIGNMENT Motor Test 3-13 available tests Print Test 3-12 Base Sensor Test Quick Test 3-15 3-41...
Page 293 5022-xxx 4-60 removal letterhead 3-21 Reset Fuser Cnt transparencies Fuser Motor Test media specifications 1-12 input and output capacities 1-12 print area high voltage power supply (HVPS) selecting media locations 1-10 supported sizes 7-10 parts catalog using media 4-62 removal 1-12 weight how to use this parts catalog...
Page 294 5022-xxx 3-16 paper path Prt Color Pg Count 3-30 3-31 3-16 diagram Prt Mono Pg Count 3-32 main components Prt Quality Pgs 3-37 3-21 mechanical drive configuration menu 3-42 3-10 paper sensing diagnostic menu 3-33 print media transport paper pick mechanism 3-12 Quick Test (duplex) parts catalog...
Page 295 5022-xxx 4-92 2-53 transfer contact assembly operator panel 4-93 2-55 waste toner assembly print quality 3-21 Reset Fuser Cnt service error codes 4-59 1-13 restraint cable, removal service tag location Servo Laser Test 3-22 Size Sensing safety information skew sensors smart chip card—C52x 7-12 bin full...
Page 296 5022-xxx toner level sensor locations 7-10 parts catalog 4-83 removal 3-23 Toner Patch Sensing (TPS) 1-13 tools required top cover camshaft assembly 4-87 installation locations 7-12 parts catalog 4-86 removal transfer belt locations 7-14 parts catalog 4-91 removal transfer contact assembly locations 7-10 parts catalog...
Page 297: Part Number Index
5022-xxx Part number index Description Page 40X0274 Power cord—Switzerland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 40X0275 Power cord—Israel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 298 5022-xxx 40X1436 Front door 5 V interlock switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X1437 Top access door 24 V interlock switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13...
Page 299 5022-xxx 40X3607 Pick arm roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 40X3608 Bezel, C530dn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 300 5022-xxx I-10 Service Manual...

This manual is also suitable for:

C520 C532 C534 5022 C530 C524

Lexmark C522 Service Manual

Laser Notices

Safety Information

Preface

Conventions

General Information

Maintenance Approach

Options and Features

Specifications

Media Specifications

Serial Number and Machine Type

Tools Required for Service

Acronyms

Diagnostic Information

Start

Operator Panel and Menus

Power-On Self Test (POST) Sequence

Symptom Tables

Error Codes and Messages

User Status and Attendance Messages

Service Checks

XX-Mirror Motor Service Check

XX, 112.XX, 113.XX, and 114.XX-Printhead Error Service Check

Fuser Error Service Check

XX-Autocomp (Tray 1) Motor Error Service Check

And 906.01-906.04-Motor (Fuser) Error Service Check

XX-Motor (EP Drive Assembly Top Cartridge) Error Service Check

XX-Motor (EP Drive Assembly Bottom Cartridge) Error Service Check

And 906.05-906.08-Motor (Bump Aligner) Error Service Check

XX-Motor (Duplex) Error Service Check

XX, 149.XX-Motor (500-Sheet/550-Sheet Option Tray 2 Motor) Error Service Check

XX-MPF Motor Error Service Check

Transparency Sensor Error Service Check

POST (Power on Self Test) Error Service Check

POST (Power on Self Test) Error Service Check

POST (Power on Self Test) Error Service Check

POST (Power on Self Test) Error Service Check

POST (Power on Self Test) Error Service Check

POST (Power on Self Test) Error Service Check

POST (Power on Self Test) Error Service Check

Fan Error Service Check

XX, 946.XX, 947.XX-Transfer Roll Error Service Check

950.29 EPROM Mismatch Failure

950.30-950.60 EPROM Mismatch Failure

Dead Printer Service Check

Exit Sensor Service Check

Input Sensor Service Check

Operator Panel Service Check

Print Quality Service Check

Diagnostic Aids

Accessing Service Menus

Diagnostics Menu

Configuration Menu (CONFIG MENU)

Paper Jams

Theory of Operation

Repair Information

Removal and Cleaning Precautions

Handling ESD-Sensitive Parts

Handing the Photoconductor Unit

Adjustments

Printer Removal Procedures

Locations and Connectors

Locations

Connectors

Preventive Maintenance

Scheduled Maintenance

Parts Catalog

How to Use this Parts Catalog

Assembly 1: Covers

Assembly 2: Front

Assembly 3: Right

Assembly 4: Rear

Assembly 5: Left

Assembly 6: Top

Assembly 7: Customer Replaceable Units (Crus)

Assembly 8: Contact Springs

Assembly 9: Cable Parts Packet

Assembly 10: Miscellaneous

Index

Part Number Index