Lexmark C52, C53 Service Manual

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Revision: March 30, 2007

Lexmark™ C52x an d C 53x

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• 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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L E M i

T i p

C L

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r I P

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T a

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dition: March 30, 2007 he following paragraph does not apply to any country where such provisions are inconsistent with local law:

EXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,

ITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF

ERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of expres s or

mplied warranties in certain transacti ons; therefor e, this statement ma y not apply to you.

his publication could include technical inaccuracies or typographical errors. Changes are periodically made to the

nformation her ein; these changes will be inco rpora ted in later editions. Improvements or changes in the products or the

rograms described may be made at any time.

omments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 W est New Circle Road, exington, Kentucky 40550, U .S.A or e-mail at ServiceInfoAndTraining@Lexmark. com . Lexmark may use or distribute an f the inf ormati on you supply in any way it belie ves appropriate without incurring any obligation to you.

exmark, Lexmark with diamond design, MarkNet , and MarkVi sion are trademarks of Lexmark International, Inc.,

egistered in the Unit ed Stat es and/or other countries.

mageQuick and PrintCryption are trademarks of Le xm ark I nternat ional, Inc.

CL® is a registered trademark of the Hewlett-Packard Company. PCL is Hewlett-Packard Com pany’s designation of a se f printer commands ( language) and funct ions inc luded in its printer products . This printer is intend ed to be compat ib le wit

he PCL language. This means the printer recognizes PCL comm ands used in various application programs , and that the

rinter emulates the functions corresponding to the commands.

ll other trademarks are the property of their respective owners.

10/2/06 1:00 pm Lexmark International, Inc.

NITED STATES GOVERNMENT RIGHTS

his softwar e and any accompanyin g d ocumentation provi ded under this agreement ar e comme rcial computer software nd documentation developed exclusively at private expense.

P/N 12G9669

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Table of contents

Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Performance factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Media specificat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Paper and specialty media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Unacceptable media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Selecting media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Selecting preprinted forms and letter head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Using media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Using letterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Using transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Using envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Using labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Using card stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Storing media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Supported sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Media weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Input and output capaciti es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Print area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Serial number and machine typ e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Paper jam messages (2xx.xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator panel and menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Buttons and light description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Power-on self test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Error codes and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

User status and attendance me ssages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

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Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

110.xx—Mirr or mot or service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check . . . . . . . . . . . . . . . . . . . . . .2-27

120.01, 120.02, 120.08–120.10, 120.13–120.15—Fuser error servi ce check . . . . . . . . . . . . . . . . .2-28

120.03—Fuser error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 3 0

120.04–120.07— Fuser error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

140.xx—Autocomp (t ray 1) motor error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

142.xx and 906.01–906.04—Moto r (fuser) error servic e check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

143.xx—Motor (EP drive assembly top cartridge) error service check . . . . . . . . . . . . . . . . . . . .2-34

144.xx—Motor (EP drive assembly bottom cartridge) error service check . . . . . . . . . . . . . . . . .2-35

145.xx and 906.05–906.08—Motor (bump aligne r) error service check . . . . . . . . . . . . . . . . . . . .2-36

146.xx—Motor (duplex) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

147.xx, 149.xx—M otor (500-sheet/550-sheet option tray 2 motor) err or service check . . . . . . .2-37

148.xx—MPF motor error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

910.01—Transparency sensor error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

920.01—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

920.02—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

920.03—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

920.04—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

920.05—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

920.06—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

920.07—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

920.08—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

920.09-12—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

920.13—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

920.14—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

920.15—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

920.16—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

920.17—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

920.18—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

920.19—POST (power on self test) error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

925.01—Fan error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -47

945.xx, 946.xx, 947.xx—Transfer roll error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

950.00–950.29 EPROM misma tch f ailure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

950.30–950.60 EPROM misma tch f ailure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

Dead printer service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Input sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

One or more operator panel buttons fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Operator panel di splay blank, five beeps, and LED off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Operator panel di splay blank, five beeps, LED on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Operator panel di splay all diamonds, no beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Operator panel di splay all diamonds, fiv e beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Print quality —bac kground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 5

Print quality—blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 5 6

Print quality—blurred or fuzzy print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Print quality —half-color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5 9

Print quality —hor izontal banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Print quality—horizontal line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 9

Print quality—insufficient fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 9

Print quality —missing image at edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Print quality—mottle (2–5mm speckles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Print quality—narrow vertical line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Print quality —r andom m arks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

Print quality —r esidual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

Print quality—solid color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6 1

Print quality—vertical banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6 2

iv S e rv ice Manual

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Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Diagnostics menu stru cture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Print registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Motor tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

General motor tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Mirror Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Motor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Servo Laser Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Input source tes ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Print quality test pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Print Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Top Margin (duplex ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Motor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Bin Full Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Page Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Fuser Temperature (Fuser Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

DC Charge Adjust, Dev Bias Adj, Transfer Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Reset Fuser Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Color Lock Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Prt Quality Pgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Size Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Download Emuls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Auto Align Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Auto Color Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Enforce Color Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Color Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Motor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Env Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Jobs on Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Duplex Gloss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

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

Error jam locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Paper jams in the multipurpose feeder or manual feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Loading media in the multi purpose feeder or manual feeder . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Clearing a paper jam in the multipurpose feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Clearing paper jams in the manual feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 3 0

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

Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 2

Print media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Mechanical drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Paper sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Electrophotogr aphic (EP) process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 4 4

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

Exposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Developing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

Transferring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53

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

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

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

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal and cleaning precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handing the photoconduct or uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Parts not to be touched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Printhead mechani cal alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Skew (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Registration (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Alignment (cyan, yellow, and magenta) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

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

Precautions to take before maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Exit tray cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Front access door cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Gearbox shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

vi Se rvi c e M anua l

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Left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Operator panel outer bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Operator panel inner bezel removal—models C52x only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Operator panel assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Paper tray dust cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Top access cover assembl y removal—model C52x only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Top access cover assembl y removal—model C53x only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Bin full sensor removal—models C52x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Bin full sensor removal—models C53x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Bump aligner gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Bump aligner motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Bump aligner rollers and springs removal—models C53x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Contact springs removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Deflector assembl y removal—models C53x only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Electrophotogr aphic (EP) drive assembly removal—model C5 2x only . . . . . . . . . . . . . . . . . . . 4-48

Electrophotogr aphic (EP) drive assembly removal—model C5 3x only . . . . . . . . . . . . . . . . . . . 4-51

Front access door 5 V interlock switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Front door assembly fron t cabl e rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Fuser cable cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

High voltage power supply (HVPS) remov al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Left bellcrank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Low voltage power supply (LVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Multipurpose fee der (MPF) swing arm assembly removal—mo dels C52x only . . . . . . . . . . . . 4-67

Paper pick mechanis m asse mbl y rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Photoconductor unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Pick roll rubber tires rem oval and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Printer pad removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Printhead removal, installation, and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Printhead installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Printhead alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Skew (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Registration (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Alignment (cyan, yellow, and magenta) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Right bellcrank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Smart chip card removal—models C52x only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91

System card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

System card support shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

Top access door 24 V interlock switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98

Top cover camshaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99

Transfer belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

Transfer contact assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104

Waste toner assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

CRU and FRUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

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Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Printer cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

System card (network)—models C52x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

System card (non-networ k)— m odels C52x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Connector listing—models C52x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 1 3

System card (network)—models C53x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Connector listing—models C53x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 1 9

Preventive mainte nan ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 5: Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 6: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 7: Customer replaceable units (CRUs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 8: Contact spri ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 9: Cable parts packet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 10: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

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Laser no tices

Laser no tice

The printer is certified in the U .S. to confo rm to the requir ements of DHHS 21 CFR Subchapter J for Class I (1) laser product s, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

Class I laser products are not consi dered to be hazardous. The pri nter contains internal ly a Class IIIb (3b) laser that is nominally a 5 milliwatt galli um arsenide laser operati ng in the wav elength region of 770-795 nanometers. The laser system and printer are designed so there is never an y hum an access to laser radiation ab ove a Class I level during normal operation, user maintenance, or pr escri bed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigu ng der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestäti gung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pa ys: cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comm e des produits non dangereux. Cette imprimante est équipée d’un l aser de Classe IIIb (3b) (arséniure de gall ium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son sys tème laser sont conçus pour impossible, dans des conditions normales d’uti lisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements lase r supérieurs à des rayonnements de Classe I .

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Avvertenze sui prodotti laser

Questa stampant e è certificata negli St ati Uniti per ess ere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti las er di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conf orme ai requisiti del la norma CEI 60825-1.

I prodotti laser di class e non sono con sider ati pericol osi. La stampan te contiene al suo interno un l aser di classe IIIb (3b) all’arseniuro di gallio dell a potenza di 5mW che opera sulla lunghezza d’onda compresa t ra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzio namento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran pel igrosos. La impre sora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nomin al a 5 miliv atios en una longi tud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de for ma que ninguna persona pueda verse afectada por ningún tipo de radiac ión láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situaci ón de servic io técnico.

Declaração sobre Laser

A impressora está ce rtificada no s E. U .A. e m conf ormidade co m os r equi sito s da reg ulamenta ção DHHS 2 1 CFR Subcapítulo J para a Cla sse I (1) de produt os laser. Em outros locais, está certifi cada como um produto lase r da Classe I, em conf ormidade com os requisitos da norma IEC 60825-1.

Os produtos lase r da Classe I não sã o conside rados peri gos os. I nternamente , a impr esso ra cont ém um produ to laser da Classe IIIb (3b), designado laser de arseneto de potássio , de 5 milliwatts ,oper ando numa faixa d e comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca ex ist ir qualquer possiblidade de acesso humano a radi ação laser superior a um nív el de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assist ência prescritas.

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Laserinformatie

De printer v oldoet aan de eis en die ges teld w orde n aan ee n laserprodukt v an klass e I. Voor de Ver enigde Stat en zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden nie t al s ongevaarlij k aangemerkt. De printer is voor zien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met e en g olflengte van 770-795 nanometer . Het laser gedeelt e en de printer zij n zo ont worpen dat bij normaal gebru ik, bij onde rho ud of repar atie conform de voorschriften, nooit blootstelling mogelijk is aan laserst raling boven een niveau zoals voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet sål edes, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

Huomautu s las er laittees ta

Tämä kirjoi tin on Yh dysv alloi ssa lu okan I ( 1) lase rlait teide n DHHS 21 CFR Subchapt er J -mää rityks en muk ainen ja muualla luo kan I l aserl aitteiden IEC 60825-1 -määri tyksen mukainen.

Luokan I las e r la itt e id e n e i ka ts o ta ol evan vaarallis ia käyttä jä lle . K irjoittim e s sa on si sä i ne n l uok a n IIIb (3 b ) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Lase rjärjestelmä ja kirjoitin on suunnitelt u siten, että käyttäj ä ei al tistu luokan I määrityksi ä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Av attaessa ja suojalukitus ohitettaessa olet alttiina näky mättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserst rålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

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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 skriv aren kraven för laserprodukter av Kl ass 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 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystem et och skrivaren är utformade så att det aldrig finns ris k för att någon person utsätts f ör laserstrå lning över Klass I-ni vå vid normal användning, underhåll som utförs av användaren eller annan föreskriv en serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kra vene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter , og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-la serprodukter er ikke å betrakte som f arlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer . Lasersystem et og skriveren er utformet slik at personer al dri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk , vedlikehol d som utf øres av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat al s Estats Units , aquesta impressor a complei x els req uisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes l àser de classe I no es consideren perillosos. Aquesta impressora conté un làse r de cl asse IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un niv ell de classe I durant una oper ació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Japanese Laser Notice

Laser notices xiii

5022-xxx

Korean Laser Notice

xiv Service Manual

5022-xxx

Safety information

• The safety of this product is based on testi ng and approvals of t he original design and specific

components . The manufacturer is not responsibl e 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.

• There may be an increased risk of electric shoc k and personal injury during disassem bly and servicing of

this product . Pro fessional service personnel should understand this and take necessary precautions.

• CAUTION: When you see th is symbol , ther e is a danger f rom hazard ous v olt age in the ar ea of the

product where y ou ar e working . Unplug the product bef ore you beg in, or use c autio n if t he produc t must receive power in order to perform the task.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particulier s. Le fabricant n'ass ume aucune respon sabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de répar ati on de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessai res.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous tra vaillez. Débranchez le produit a vant de commencer ou f aites preuve de vigilance si l' exécution de la t âche exige que le produit reste sous tension.

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzion e non autorizzata delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato .

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni al la persona è più elev ato. Il per sonale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indica la presenza ditensione pericolosa nell'area del prodotto.

Scollegare il pr odotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.

Safety information xv

5022-xxx

Sicherheitshinweise

• Die Sicherheit di eses Produkts basiert auf Tests und Zulassungen des ursprüngl ichen Modells und

bestimmter Baut eil e. Bei Verwendung nicht genehmigter Ersatztei le wi rd vom Hersteller kei ne Verantwortung oder Haft ung für die Sicherheit übernommen.

• Die Wartungsinformationen für dies es Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusät zliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zus tändige Fachpersonal sollte entsprechende Vorsichtsmaßn ahm en treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem

Bereich des Produkts auftreten kann. Zie hen Sie vor den Arbeiten am Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Segu ridad

• La seguridad de este prod ucto se basa en pruebas y aprobaciones del diseño original y component es

específico s. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe may o r riesg o de de scarga el éctrica y de dañ os person al es duran te e l desmont aj e y la r eparac ión de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje dela parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do mode lo original e de componentes

específico s. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.

• As informações de segurança relativas a este produto dest inam-se a profissionais destes serviços e não

dev em ser utilizadas por outr as pessoas.

• Risco de choques eléct ricos e ferimentos graves durante a desmontagem e manutenção deste produto .

Os profissio nais destes serviços devem estar avis ados deste facto e tomar os cuidados necessários .

• CUIDADO: Quando vir este sí m bolo, existe a possível presença de uma potencial tens ão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligu e o produto da tomada eléctrica ou s eja cui dado so caso o pro duto te nha d e estar liga do à corrent e eléc trica para realizar a tarefa necessária.

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Inf ormació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i apr ovació del disseny original i els components

específics. El fabricant no es fa responsable de les qüestions de seguretat si s'u tilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusiv ame nt a professional s i no està

destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augment ar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures con venients.

• PRECAUCIÓ: aquest símbol in dica que el voltatge de la part de l'equip am b la qual esteu

treballan t és perillós . Abans de començar, desendolleu l'equ ip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

Safety information xvii

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Preface

This manual contains maintenance procedures for service personnel. It is divided into t he following ch apters:

1. General in fo rma tion contains a general description of t he prin ter and the maintenance appro ach used to

repair it. Speci al tools and test equipment, as well as general environmental and safety instructions, are discussed.

2. Diagn o sti c information contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagn osti c aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair info rma tion provides instructions for making printer adjustments and removing and installing

FRUs.

5. Connecto r locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contai ns the lubrication specifications and recommendations to prev ent

problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Conventions

Note: A note provides addition al i nformation. Warning: A warning identifies something that might damage the product hardware or software.

There are several types of cauti on statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution i ndicates there is a danger fro m haz ardous voltage in the area of the product where you are working. Unplug the product befor e you begin, or use caution if the product must recei ve power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution i ndicates a tipping hazard.

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1. General information

The Lexmark™ C52x and C53x color laser printe rs deliver superior t ext and brilliant gr aphics. 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 Network 5022-410 Lexmark C524dn Network 5022-430 Lexmark C530dn Duplex, network 5022-130 Lexmark C532n Network 5022-310 Lexmark C532dn Duplex, network 5022-330 Lexmark C534n Network 5022-510 Lexmark C534dn/dtn Duplex, network (550-sheet tray) 5022-530

Maintenance approach

The diagnostic information in this manua l le ads you to the correct fiel d replaceable unit (FRU) or part. Use the error code charts, symptom tables, and service checks to determine the sympt om and repai r the failure. You may find that the removals in the Repair information chapter will help you identify parts. After you complete the repair, perform tests as needed to verify the repai r. Begin at “Start” on page 2-1.

Options and features

The foll owing options or features are avai lable. Some options are not avail able in every count ry. Contact your point of purcha se for options available in your country.

• Memory options of 128MB, 256MB, and 512MB SDRAM

• Flash memory options of 32MB and 64MB

• Hard disk—40GB with adapter (models C524, C524n, and C524dn and models C534n, C534dn, and

C534dtn)

• Media handling oper ations – 500-sheet optional tr ay assembly f or models C522n, C524, C524n, and C524d n and 550-sheet

optional tray assembly for models C532n, C532dn, C534n, and C534dn.

– Duplex—not an optio n, available only on models C524dn, C524dtn, C530dn, C532dn, and

C534dn/dtn (factory installed).

• Integrat ed network options – Token-Ring – Ethernet – External serial adapter – PRESCRIBE card assembly – Bar code card assembly – Parallel interface card – MarkNet™ Print Servers – Lexmark PrintCryption™ card – Lexmark Forms card (single-byte and Simplified Chinese) on models C534n, C534dn, and C534dtn

General inf ormation 1-1

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 – Korean

Specifications

Resolution

• 1200 x 1200 dpi

• 4800CQ

Data streams

• PostScript 3 emulation

• PCL 5c and 6 (XL) emulation

• PDF 1.5 emulation

• PPDS (if activated)

Memory configuration

Memory type

Standard DRAM (MB) 128 128 64 128 128 128 128 1 28 128 256 Optional memory (MB)

(100 pin DDR SDRAM unbuffered DIMMs)

Maximum (MB) 640 640 576 640 640 640 640 640 640 768 Optional flash memory 32 and 64 MB available

Performance factors

Per formance speed depends on:

• Interface to the host (USB, serial, parallel, network)

• Host system and appli cation

• Page compl exity and content of the page

• Printer options i nstalled or selected

• Av ailable memory in the printer

• Media size and type

• Resolution

C520n

C522n

Models

C524

C524n

128, 256, and 512 MB available

C524dn

C530dn

C532n

C532dn

C534n

C534dn/dtn

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Power requirem ents

Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts (W) . Ma ximum current is given in Amperes (A).

Printing states

Idle—avera ge pow er

Power Saver on<18 W<16 W<18 W<17 W Power Saver off 105 W 105 W 120 W 120 W

Printing—average power

Basic printer 350 W 350 W 410 W 410 W All options 375 W 350 W 410 W 410 W

Printing—maximum average current

100 V 4.5 A 4.5 A 2.5 A 2.5 A 110 V 4.0 A 4.0 A 5.0 A 5.0 A 220 V 2.0 A 2.0 A 5.5 A 5.5 A

Electrical specifications

Low volta ge model

Lexmark C524, C524n, C524dn, C524dtn

Lexmark C520n, C522n

Lexmark C534n, C534dn, C534dtn

Lexmark C530dn, C532n, C532dn

•

110 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)

• 198 to 259 V ac, ext reme

100 V mod el

100 V ac at 47 to 63 Hz nominal

•

• 90 to 110 V ac, extreme

Notes:

• Using a 220 to 110 power converter with the 110 V printer is not recomm ended.

• Using an inverter (12 V dc to 120 V ac for example) to power the printer is not recommended.

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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 Oper ating 22.8° C (73.0° F) Maximu m Web Bulb Temperature—Product Power Off 26.7° C (80.1° F) Maximum Altitude 0 to 3048 meters (10,000 feet) Atmospheric Pressure 74.6 kPa

†

Ambient Operating Environment

Shipping / Storage

Cartridges -40° C to +40° C (104° Fahrenheit) Printer with Cartridges -40° C to +40°C (104° Fahrenheit) Printer without Cartridges -40° C to +40°C (104° Fahrenheit) Air Relative Humidity Relative Humidity 8 to 80% Altitude 10,300 meters (34,000 feet) Web Bulb Temperature—Product Power Off 26.7° C (80.1° F) Maximum

†

In some cases performance specifications (such as paper OCF, EP cartridge usage) are specified to be

measured at an ambient condi ti on.

15.6 to 32.2° C (60 to 90°F) and 8% to 80% RH

Acoustics

All measurements are made in accordance with ISO 7779 and conform with ISO 9296.

C520n, C522n, C524n

C524dn, C524dtn

C532n, C534n

C530dn, C534dn, C534dtn

Printer Operating mode

Printing 51 dBA Idle 32 dBA Printing 51 dBA Duplex printing 52 dBA Idle 32 dBA Mono printing 53 dBA 6.7B Color printing 51 dBA 6.6B Idle 31 dBA 4.6B Mono printing 53 dBA 6.7B Color printing 51 dBA 6.6B Duplex printing 53 dBA 6.7B Idle 31 dBA 4.6B

1-Meter Average

Bystander Sound

Pressure @4800 CQ

Declared Sound

Power Level @4800

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Dimensions

Description Models Height Width Depth Weight

Basic printer with no extensions

Printer with exit tray extended

Print er, dupl ex unit , 500-sheet assem bly

Print er, dupl ex unit , 550-sheet assem bly

Optional 500-sh eet assembly only

Optional 550-sh eet assembly only

MPF configuration (printer with multipurpose feeder extended and exit tra y extended)

C520, C522n, C524, C524n, C524dn

C532n, C534n 19 in.

C530dn, C532dn, C534dn 19 in.

C520, C522n, C524, C524n 19 in.

C532n, C534n 19 in.

C530dn, C524dn, C534dn 19 in.

C524dtn 24 in.

C534dtn 24 in.

C52x models 5 in.

C53x models 5 in. 16.5 in.

C52x, C53x models 19 in.

19 in. (484 mm)

(484 mm)

(610mm)

(127 mm)

(484 mm)

17.3 in. (440 mm)

16.5 in. (420 mm)

(420 mm)

17.3 in. (440 mm)

16.1 in. (408 mm)

20.2 in. (512 mm)

22 in. (558 mm)

20.4 in. (518 mm)

20.4 in. 7.0 lb

26.6 in. (676 mm)

57.5 lb (26.1 kg)

57.0 lb (25.9 kg)

58.8 lb (26.7 kg)

57.5 lb (26.1 kg)

57.0 lb (25.9 kg)

58.8 lb (26.7 kg)

64.8 lb (29.4 kg)

64.0 lb (29.0 kg)

7.25 lb (3.29 kg)

(3.2 kg)

57.5 lb (26.1 kg)

Primary tray configuration (printer with paper tray adjuster ex tended and output bin installed)

Note: A buffer of 12 in. (304.8 mm) is needed on the back of the printer.

A4/letter size media 19 in.

(484 mm)

Legal size media 19 in.

(484 mm)

17.3 in. (440 mm)

20.2 in. (512 mm)

21.3 in. (540 mm)

General inf ormation 1-5

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5022-xxx

Media specifications

Paper and specialty media guidelines

Media guidelines

Media characteristics

The foll owing media characteri stics affec t print qual ity and reliability. Consider these char acteristics when evaluating new media stock.

Weight

The printer can automa ti cally feed media wei ghts from 60 to 176 g/m lighter than 60 g/m

90 g/m g/m

Curl

Curl is the tendency for media to curl at its edges. Excessive curl can cause media feeding problems. Curl can occur after the med ia passes through the printer, where it is e xposed to high temperatu res. Storing media unwrapped in hot, hum id, cold, or dry conditions, even in the trays, can contri bute to media curling prior to printing and can cause feeding problems.

(24 lb bond) grain long medi a. Fo r media smaller than 182 x 257 mm (7.2 x 10.1 in.), we reco mmend 90

or heavier media .

(16 lb) might not be sti ff enough to feed properly, causing jams. F or best performance, use

(16 to 47 lb bond) grain lo ng. Media

Smoothness

Media smoothne ss directly affects print quality. If media is too rough, toner cannot fuse to it properly. If media is too smooth, it can cause media fee din g or print qual ity issues . Alw a ys u se media bet wee n 100 and 300 Shef fiel d points; however, smoothness between 150 and 200 Sheffield points produces the best print quality.

Moisture content

The amount of moisture in media affects both print quality and the ability of the printer to feed the media correctly. Leave medi a in i ts o riginal wr apper u ntil it i s time t o use i t. Thi s limit s th e exp osur e of medi a to mo isture changes that can degrade its performance.

Condition medi a before printing by storing it in its original wrapper in the same environment as the printer for 24 to 48 hours before printing. Extend the ti me several days if the stor age or t ransportation environment is very different from the printer environment. Thick me dia may also require a longer conditioning period.

Grain direction

Grain refers to the alignment of the media fibers in a sheet of media. Grain is either grain long, running the length of the media, or grain short, running the width of the media. For 60 to 90 g/m use grain long fibers.

Fiber content

Most high-quality xe rographic media is made from 100% chem ically treated pulped wood. Thi s content provides the media with a high deg re e of stabi lity re sulti ng in f e wer media f eedi ng prob lem s and bett er print qual ity. Media containing fibers such as cotton possesses characteristics that can negatively affect media handling.

(16 to 24 lb bond) media,

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Unacce p tab l e media

The foll owing media types are not recomme nded 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

• Preprinted media with chemicals that may contaminate the printer

• Preprinted media that can be affected by the temperature in the printer fuser

• Preprinted media that requires a registration (the pr ecise print locati on on the page) greater than ±2.3 mm

(±0.09 in.), such as optical character recognition (OCR) forms In some cases, registration can be adjusted with a program to successfully print on these forms.

• Coated media (eras able bond), synthet ic media, thermal media

• Rough-edged, rough, or heavily textured surface media, or curled media

• Recycled media containing more than 25% post-consumer waste that does not meet DIN19 309

• Media weighing l ess than 60 g/m

(16 lb)

• Multiple -p a rt forms or do c um en t s

Selecting media

Using appropriate media prevents jams and helps ensure trouble-free printing. To help avoid jams and poor print qual ity:

• Always use new, undam aged media.

• Before lo ading medi a, know t he re commended print side of the media. This information is usual ly indicat ed

on the media package.

• Do not use media that has been cut or trim m ed by hand.

• Do not mix media sizes , types, or weigh ts i n the same source; mixing results in jams.

• Do not use coated media unl ess they are specifically designed f or electrophotog raphic printing.

Selecting preprinted forms and letterhead

Use these guidelines when selecting preprinted forms and letterhead:

• Use grain long papers for best results for 60 to 90 g/m

weights.

• Use only for m s and letterhead printed using an offset lithographic or engraved printing process.

• Av oid papers with rough or heavily textu red surfaces.

Use papers printed with heat -resistant inks desi gned for use in xerographic copiers. The ink must be abl e to withstand tempe ratures up to 180°C (356°F) without melting or releasing hazardous emissions. Use inks that are not affected by the resin in toner. Inks that are oxidation-set or oil -based generally m eet these requi rements; latex inks might not. When in doubt, contact the paper supplier.

Preprinted papers such as letterhead must be ab le to withstand temperatures up to 180°C (356°F) without melting or releasing hazardous emissions.

General inf ormation 1-7

5022-xxx

Using media

Using letterhead

Check with the man ufacturer or vendor to determine whether the chosen preprinted lett erhead is acceptabl e for laser printers.

Page orientation is important when printing on letterhead. Use the following table for help when loading letterhead.

Process or paper source Print side Top of page

Tray 1 Letterhead f aceup Letterhead goes toward the front of the tray Tray 2 Letterhead f aceup Letterhead goes toward the front of the tray Duplex (two-sided) printing from

trays 1 and 2 Multipurpose feeder Letterhead facedown Letterhead top edge enters first Manual feeder Letterhead facedown Letterhead top edge enters first Duplex (two-sided) printing from

the multipurpose feeder

Letterhead f acedown Letterhead goes to ward the rear of the tra y

Letterhead f aceup Letterhead top edge enter s last

Using tran sparenc ie s

Print samples on the transparencies being considered for use before buying large quantities. When printing on transparencies:

• Fr om MarkVisi on™ Professional, the printer software, or the control panel, set the Paper Type to

Transparency.

• Feed transparencies from the standard tray (Tray 1) or the mul tipurpose feeder.

• Use transparencies designed specifi cally for laser printers. Check wit h the manufacturer or vendor to

ensure transparencies are able to withstand temperatur es up to 180°C (356°F) without melting, discoloring, offsetting, or releasi ng hazardous emissions.

• Use transparencies that are 0.12–0.14 mm (4.8–5.4 mil) in thickness or 161–179 g/m

in weight.

• Print quality and dur ability depend on the tr ansparencies used.

• 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

Print samples on the envelopes being considered for use before buying large quantities.

•

When printing on envelopes:

• Fr om the control panel, set the P aper Source based on the source i n use. From the control panel, the

printer so ft ware, or MarkVision Professional, set the Paper Type to Envelope, and select t he envelope size .

• Use env elopes designed specif ically for laser printers. Check with the man ufacturer or vendor to ensure

the envelopes can withstand temperatures up to 180°C (356°F) witho ut sealing, wrinkling, curling exces sively, or rele asing hazardous emissions.

• For the bes t performance, use en vel opes made from 90 g/ m

bond) weight for envelopes as long as the cotton content is 25% or less. All-cotton envelopes must not exceed 90 g/m

(24 lb bond) weight.

(24 lb bond) paper. Use up to 105 g/m2 (28 lb

• Use only new envelopes.

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• To optimize performance and mi nimize jams, do not use en velopes that: – Have excessive curl or twist – Are stuck togethe r or damaged in any way – Have windows, holes, perforations, cutouts, or embossing – Have metal clasps, string ties, or folding bars – Have an inter locki ng desi g n – Have postage stamps attached – Have any e xposed adhesiv e when the flap is in the sealed or closed position – Have bent corners – Have rough, cockle, or laid finishes

• Adjust the width guide to fit the width of the envelopes.

Note: A combination of high humidity (over 60%) and the high printing temperature may wrinkle or seal

envelopes.

Using labels

Print samples on the labels being considered for use before buying large quantities. For detailed information on label printing, characteristics, and design, see the Card Stock & Label Guide av ailable on the L exmark Web site at www .l exmark.com/publications.

Note: Vinyl labels are not supported on this product. Use only paper labels. When printing on labels:

• From the printer software, MarkVision Professional, or the control panel, set the Paper Type to Labels.

• Use only letter-, A4-, and legal-size label sheets.

• Use labels designed specifically for laser printers. Check with the manufacturer or vendor to verify that

label adhesives, face sheet (printable stoc k), and topcoats can withstand temperatures up to 180°C (356°F) and pressure up to 30 psi without delamina ti ng, oozing around the edges , or releasing hazardous fumes. Do not use vin yl labels.

• Do not use labels with slick backing material.

• Use full label sheets. Partial sheets may cause labels to peel off during printing, resulting in a jam. Partial

sheets also cont am inate the printer and the cartridge with adhesi ve, and could voi d the printer and cartridge warranti es.

• Do not print within 1 mm (0.04 in) of the edge of the label, of the perforations, or bet ween die-cuts of the

label.

• Be sure adhesive backing does not rea ch to t he sheet edge. Zone coating of the adhesive at least 1 mm

(0.04 in) a wa y fro m edges is recommend ed. Adhesiv e mate rial contam inat es the printer and could v oi d the warranty.

• If zone coating of the adhesive is not possible, remove a 3 mm (0.125 in.) strip on th e leading and driver

edge, and use a non-oozing adhesive.

• Portrai t ori entation works best, especi ally when printing bar codes .

• Do not use labels with exposed adhesive.

Using card stock

Card stock is heavy, single-ply print media. Many of its variable char acteristics, such as moisture content, thickness, and texture, can signifi cantly impact print quality.

Print samples on the card stock being considered for use bef ore buying large quantities. When printing on card stock:

• From MarkVision Professional, the printer software, or the control panel: – Set the Paper Type to Card Stock. – Set the Paper Weight to Card Stock Weight. – Set the Card Stock Weight to Normal or Heavy.

General inf ormation 1-9

5022-xxx

• Be aware that preprinting, perforation, and cre asing may signifi cantly affec t 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 rel easing hazardous emissions.

• Do not use preprinted card stock manufactured with chemica ls t hat may contaminate the printer.

Preprinting int roduces semi-liquid and volatile components into the printer.

• Use grain long card stock when possible.

Storing media

Use these media storage guidelines to help avoid jams and uneven print qualit y:

• For best results, store media where the temperature is 21°C (70° F) and t he relative humidity is 40%.

• Store media in cartons when possib le, on a pallet or shelf, rather than on the fl oor.

• Store individual packages of media on a flat surface.

• Do not store anything on top of individual media packages.

Supported sizes

The following tables provide information on standard and optional sources for both input and output trays and bins.

Media Sizes

250 T ray

A4 210 x 297 mm ✓✓✓✓ ✓ A5 148 x 210 mm ✓✓✓✓ ✓ JIS B5 182 x 257 mm ✓✓✓✓ ✓ Statement Letter 8.5 x 11 in. ✓✓✓✓ ✓ Folio Legal 8.5 x 14 in. ✓✓✓✓ ✓ Executive 7.25 x 10.5 in. ✓✓✓✓ ✓ Universal

7 3/4 9 Envelope 3 7/8 10 Envelope 4 1/8

5.5 x 8.5 in. ✓✓ ✓

8.5 x 13 in. ✓✓✓✓ ✓

(width)

123.8 to 215.9 x 355.6 mm; 3.8 75 x 4.875 to 8.5 x 14 in. ✓

152.4 to 215.9 x 355.6 mm; 3.8 75 x 6 to 8.5 x 14 in. ✓✓

139.7 x 210 to 215.9 x 355.6 mm; 5.5 x 8.27 to 8. 5 x 14 in. ✓✓ ✓ 148 x 210 to 215.9 x 355.6 mm; 5.83 x 8.27 to 8.5 x 14 in . ✓✓✓✓ ✓

Envelope 3 7/8 x 7 1/2 in. ✓✓

x 8 7/8 in. ✓✓

x 9 1/2 in. ✓✓

MPF

Duplex

500 T ray

Manual

Feed Slot

DL Envelope 110 x 220 mm ✓✓ C5 Envelope 162 x 229 mm ✓✓

1-10 Service Manual

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

Primary tray and 500-sheet optional tray

Letter, Legal, A4 Xerographic

A5, B5, JIS-B5, Exec., Statement, Folio

Multipurpose feede r and manual feed slot

Letter, Legal, A4 Xerographic

Letter, Legal, A4 (continued)

250 Tray

MPF

Size Type Weight

Long Grain 16 to 47 lb (60 to 177 g/m

and Bonds

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

Card Stock (long and short)

Transparency 0.12 to 0.14

Cover 50 lb/65 lb

(135 g/m

Index 67 lb/90 lb

(120 g/m

Tag 74 lb/100 lb

(120 g/m

161 to 179 g/m

/ 176 g/m2)

/ 163 g/m2)

4.8 to 5.4 mil

Xerographic and Bonds

Long Grain 20 to 47 lb (75 to 177 g/m2) Short Grain 24 to 58 lb (90 to 218 g/m

Long Grain 20 to 47 lb (75 to 177 g/m

and Bonds

Short Grain 24 to 58 lb (90 to 218 g/m

Recycled Long Grain 20 to 47 lb (75 to 177 g/m

Short Grain 28 to 58 lb (105 to 218 g/m

Card Stock (long/short)

Labels (max) Paper 35 lb (131 g/m

Cover 50 lb/ 65 lb

(135 g/m

Index 67 lb/ 90 lb

(120 g/m

Tag 74 lb/ 100 lb

(120 g/m

/ 176 g/m2)

/ 163 g/m2)

/163 g/m2)

)

Vinyl Not Supported

Transparency Thickness: 0.12

161 to 179 g/m

to 0.13 mm

Duplex

)

500 Tray

Manual

Feed Slot

)

General information 1-11

5022-xxx

Media weight

Size Type Weight

A5, B5, JIS-B5, Exec., Statement, Folio

Xerographic and Bonds

Long Grain 20 to 47 lb (75 to 177 g/m 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

A5, B5, Executive, Statement, Folio, Letter, A4 and Legal

Xerographic and Bonds

Long Grain 20 to 32 lb (75 to 120 g/m Short Grain 24 to 32 lb (90 to 120 g/m

Recycled Long Grain 20 to 32 lb (75 to 120 g/m

Short Grain 28 to 32 lb (105 to 120 g/m

)

Input and output capacities

The following table outlines the input and output source capacities by media type.

Source Media

Maximum height

Approximate reference capacity

Input

Standard 250-sheet tray

Optional 500-sh eet tray (C52x) or Optional 550-sh eet tray (C53x)

Multipurpose feeder

Plain paper Plain paper

Plain paper 10 mm 100 sheets (75 g/m2)

54 mm 250 sheets (75 g/m2)

57.6 mm 500 sheets (80 g/m2) 550 sheets (75 g/m

Envelopes 10 envelopes (75 g/m Other Various quantities

Manual feed slot Any media Single sheet 1 sheet

Output

Standard 250-sheet output bin

1, 2

Plain Paper 35 mm 250 sheets (75 g/m2) Other Various quantities

20 lb xerographic paper at ambient environment

Capacity may vary and is subject to media speci fications and printer operating envir onm ent.

Note: Pa per input is limited to below t he input source indicator on the tray.

)

Print area

The printable area is limited to within 4.2 mm (0.167 in.) of all edges of the media. Any information placed outside this specified printable area does not print.

1-12 Service Manual

5022-xxx

Serial number and machine type

The serial number is located on the label on the rear of the right cover and on the service tag located on the inside right fr am e of the printer. The service tag also contains the confi guration IDs, machi ne type, and model information.

Config IDs Machine type Serial number

Tools required for service

Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needlenose pli ers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Par allel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964

Serial number

General information 1-13

5022-xxx

Acronyms

CCyan CRU Customer Replaceable Unit DIMM Du al Inline Memory Module DRAM Dynamic Random Access Memory EP ElectroPhotographic (pr ocess) EPROM Erasable Prog rammable Read-Only Memo ry ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HVPS High Voltage Pow er Supply KBlack LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply M Magenta MPF Multipurpose Feeder MS Microswitch NVRAM Nonvolatile Random Access Memory OPT Optical Sensor PC Photoconduct or pel Pic tur e element POR Power-On Reset POST Power-On Self Test PWM Pulse Width Modulation RIP Raster Imaging Processor SDRAM Synchronous Dual Random Access Memory SIMM Single Inline Memory Module SRAM Static Random Access Memory TAR Toner Adder Roller V ac Volts alternating cur rent V dc Volts direct current YYellow

1-14 Service Manual

5022-xxx

2. Diagnostic information

Start

CAUTION

Remove the pow er cord from the elect rical outle t befo re y ou connect or disconnec t an y 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 . Mak e sure y our fingers are not under the printer when you lift or set the prin ter down.

Use the service error code, user status message, user error message , symptom table, service checks, and diagnostic aids in this chapter to determine the cor rective action necessary to repair a malfuncti oning printer . They will lead you to solutions or service che cks, includi ng use of various tests.

Sympto m tables

If your printer completes the “Power-on self test (POST) sequence” on page 2-5 without an error, and you hav e a symptom, go to “Symptom tables” on page 2-6. Locate your symptom, and take the appropriate action.

Servic e er rors (1xx.xx/9xx.xx)

If a service error code appears whi le you ar e working on th e printer, go to “Service error codes and paper jam

messages” on page 2-7, and take the indicated action for that error.

Service error codes are ind icated by a three-digi t er ror code follow ed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown.

Paper jam messages (2 xx.xx)

User attendance messages that indicate a paper jam these have been i ncluded with the service error codes since repeated instances may indicate an underlying service issue. Go to “2xx paper jam messages” on

page 2-8.

User status and attendance messages

•

User status messages provide the user with information on the current status of the printer .

• User attendance messages are indicated b y a two-digit code that provides the user with informat ion that

explains a problem with a print cartridge, option, port, and so on. If a user error message displays, see

“User status and attendance messages” on page 2-19 or “2xx paper jam messages” on page 2-8.

Additional information

•

“Operator panel and menus” on page 2-2

• “Power-on self test (POST) sequence” on page 2-5

• “Theory of operation” on page 3-30

Diagnostic information 2-1

5022-xxx

Operator pan el an d me nus

Operator panel

The operator panel consists of these items:

Buttons and light description

Button or light Function

1 Display The display shows messages and pict ures that communicate th e

Note: It has a check

() icon.

mark

3 Navigation arrow buttons , — Press these buttons to scroll up or down through menus,

status of the printer. The button functions as a select button. Press this button to:

• Open a menu and disp la y th e fir st item in the menu ( call ed a men u item).

• Open a menu item and display the default setting.

• Save the di spla y e d menu item as the ne w user def aul t set ting . The printer issues a Saved or Submitted Selection message and returns to the menu item.

Note: When a new setting is saved as the user default setting, it remains in eff e ct until new settings are saved o r unt il factory defaults are restored. Setti ngs chosen from the softwa re appl ication can also change or override the user default settings selected from the operator panel.

menu items , or settings, called menu item values, or to scroll between screens and menu v alues. Each press moves one item in the list or a different setting for a menu item.

, —Press these buttons to scroll items that wrap off of the screen. For menu items with numeric values, such as Copies, press and hold this button t o scroll through the val ues. Release the but ton when the needed number appears.

2-2 Se rvice Ma nual

5022-xxx

Button or light Function

4 Indicator light The two-toned light emitting diode calle d the in dicator light on the

operator panel gives informati on about the status of the printer usi ng the colors red and green.

Indicator light status

Indicates

Off Printer power is off. Blinking green Printer is warming up, processing data, or

printing a job. Solid green Printer is on, but idle. Solid red Operator intervention is required.

5 Stop Press to stop or suspend all job activity. The functions as a

stop button . If printing, pressing causes the Stop screen to appear on the

display.

6 Menu Press to open the administration menus. These m enus are only

available when the printer is in the Ready state.

7 Back Press to return to the previous screen.

Note: This butt on is onl y active if appears on the top left of th e

screen. 8 USB direct port Model C534 only: Insert a USB flash drive to send data to the printer. 9 Numeric keypad Model C534 only: Consists of the numbers 0–9, a backspace button,

and a pound (#) button.

Diagnostic information 2-3

5022-xxx

Menus

Note: Some menu items may not be available based on the printer model or the options i nstalled. Supplies Menu Paper Menu Reports Settings

Replace Supply Default Source Menu Settings Page Setup Menu Cyan Cartridge Paper Size/Type Device Stati stics Finishing Menu Magenta Cartridge Configure MP Network Setup Page Quality M enu Yellow Cartridge Substitute Size Network <x> Setup Page Utilities Menu Black Cartridge Paper Texture Wireless <x> Setup Page PDF Menu Cyan PC Unit Paper Weight Profiles List PostScri pt Menu Magenta PC Unit Paper Loading NetWare Setup Page PCL Emul Menu Yellow PC Unit Custom Types Print F onts H TML Men u Black PC Unit Universal Setup Print Demo Image Menu Waste Toner Box Fuser Transfer Belt

Security Network/Ports Help

Max Invali d PIN TCP/IP Color Quality Job Expiration IPv6 Print Quality

Wireless Printing Guide Standard Network Supplies Guide Network <x> Media Guide Standard USB Pr int Defects USB <x> Menu Map NetWare Information Guide AppleTalk Connection Guide LexLink Moving Guide

2-4 Se rvice Ma nual

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 :

1. The LED turns on.

2. The main fan turns on.

3. The oper ator panel turns on.

4. A partial row of pix els appears.

5. The operator panel display clears.

6. Anothe r ro w of pi xels appears.

7. The operator panel display clears again.

8. The operator panel displays system information. For example:

*256MB 500Mhz

9. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start.

10. The operator panel LED starts blin king.

11. A cl ock face appe ars on the display.

The foll owing errors or messages may appear:

• Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge i s

missing.

• Any cartridge errors, such as Defective Cartridge or Miss ing Cartridge.

12. Ready appears on the display.

13. The main drive motor turns on.

14. The EP drive assembly drives the developer shaft located i n the toner cartridge.

15. The exit rollers tur n .

16. The printer calibrates.

Diagnostic information 2-5

5022-xxx

Sympto m 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

not work. Operator panel—di splay is blank . Printer

sounds five beeps. Operator panel—display is blank. Go to “Operator panel di splay blank, five beeps, and LED

Operator panel cont inuously displays all diamonds and does not complet e POST.

Print quality sym pto m tab le

Symptom Action

Background Go to “Print quality—background” on page 2-55. Blank page Go to “ Print quality—blank page” on page 2-56. Blurred or fuzzy print Go to “ Print quality—blurred or f uzzy print” on page 2-59. Half-color page Go to “Print quality—half-color page” on page 2-59. Horizontal banding Go to “Print quality—horizontal banding” on page 2-59. Horizontal line Go to “Print qual ity—horizontal line” on page 2-59. Insufficient fusing Go to “Print quality—i nsufficient fusing” on page 2-59. Missing image at edge G o to “Print quali ty—m issing image at edge” on page 2-59. Mottle (2–5mm speckles) Go to “Print quality—mottle (2–5mm speckles)” on

Narrow vertical lin e Go to “Print quality— narrow vertical line” on page 2-59. Random marks Go to “Print quality—random marks” on page 2-60. Residual image Go to “ Print quality—residual image” on page 2-60. Solid color page Go to “Print quality—solid color page” on page 2-61. Vertical banding Go to “Print quality—vertical banding” on page 2-62.

Go to “One or mo re operator panel buttons fai l” on

page 2-53.

Go to “Operator panel display blank, five beeps, and LED

off” on page 2-53.

Go to “Operator panel display blank, five beeps, and LED

off” on page 2-53.

page 2-59.

2-6 Se rvice Ma nual

5022-xxx

Error codes and messages

Service error codes and paper jam m essag es

Error code Description Action

1xx service error codes

110.01–110.06 Mirror Motor

111.01–111.05 Printhead Error

112.01–112.05 Printhead Error

113.01–113.05 Printhead Error

114.01–114.05 Printhead Error

120.01–120.02 Fuser Error

120.03 Fuser Error An error has occurred in the fuser. Remov e a nd reseat the f user. POR the printer. If the

120.04–120.07 Fuser Error

A mirror motor error has occurred. POR the printer. If the error message persist s, see

An error has occurr ed in the cyan channel of the printhead.

An error has occurr ed in the magenta channel of the printhead.

An error has occurr ed in the yellow channel of the printhead.

An error has occurr ed in the black channel of the printhead.

An error has occurred in the fuser. Remov e a nd reseat the f user. POR the printer. If the

An error has occurred in the fuser. Remov e and reseat the fuser. POR the printer.

“110.xx—Mirror motor service check” on page 2-27.

POR the printer. If the error message persi sts, see

“111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-27.

POR the printer. If the error message persi sts, see

“111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-27.

POR the printer. If the error message persi sts, see

“111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-27.

POR the printer. If the error message persi sts, see

“111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check” on page 2-27.

error message persists, see “120.01, 120.02,

120.08–120.10, 120.13–120.15—Fus er error service check” on page 2-28.

error message persists, see “120.03—Fuser error

service check” on page 2-30.

Check the camshaft follower on the left side. If the error message persists, see “120.04–120.07—

Fuser err or service check” on page 2-30.

120.08–120.10,

120.13–120.15 Fuser Error

140.03–140.08 Autocomp Motor Error

142.09–142.18,

142.20–142.25, 142.27 Motor Error

143.09–143.18,

143.20–143.25 Motor Error

144.09–144.18,

144.20-144.25 Motor Error

145.09–145.18,

145.20–145.25 Motor Error

An error has occurred in the fuser. Remov e a nd reseat the f user. POR the printer. If the

Tray 1 motor has failed. POR the printer. If the error message persists, see

Fuser motor has failed. POR the printer. If the error message persists, see

EP Drive assembly cartridge 1 motor has failed.

EP Drive assemb ly cartridge 2 (bottom) motor has failed.

Bump aligner motor has failed. POR the printer . If the error message persists, see

error message persists, see “120.01, 120.02,

120.08–120.10, 120.13–120.15—Fus er error service check” on page 2-28.

“140.xx—Autocomp (tray 1) motor error serv ice check” on pa ge 2-32.

“142.xx and 906.01–906.04—Motor (fuser) error service check” on page 2-33.

POR the printer. If the error message persi sts, see

“143.xx—Motor (EP drive assembly top cartridge) err or service check” on page 2-34.

POR the printer. If the error message persi sts, see

“144.xx—Motor (EP drive assembly bottom cartridge) err or service check” on page 2-35.

“145.xx and 906.05–906.08—Motor (bump aligner) error service check” on page 2-36.

Diagnostic information 2-7

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

146.01–146.08 Motor Error

147.01–147.08 Motor Error

148.01–148.08 Motor Error

149.01–149.08 Motor Error

2xx paper jam messages

200.01 Input sensor is made when printer

200.11 Input sensor does not break.

Duplex motor has failed. POR the printer. If the error message persists, see

Tray 2 motor has failed. POR the printer. If the error message persists, see

MPF motor has fail ed. POR the printer. If the error message persi sts, see

Tray 2 motor has failed. POR the printer. If the error message persists, see

tries to print from an idle st ate. Possible causes:

• Paper jam leaving page over sensor

• Defec ti ve input sensor

• Faulty system card

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Paper tray failure

• Paper pick mechanism

“146.xx—Motor (dup lex) err or se rvic e ch eck” o n page 2-36.

“147.xx, 149.xx—Motor (500-sheet/550-sheet option tray 2 motor) error service check” on page 2-37.

“148.xx—MPF moto r error service chec k” on page 2-37.

“147.xx, 149.xx—Motor (500-sheet/550-sheet option tray 2 motor) error service check” on page 2-37.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

• Ensure proper media is set for the type of paper used.

• Fan media, and stack flat in the tray or MPF.

• Properly set media restraints in the paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• Replace the p aper p ic k mec hani sm. Se e “Paper

pick mechanism assem bly removal” on page 4-68.

200.16 Input sensor is made when printer powers up or covers are closed.

Possible causes:

• Paper jam leaving page over sensor

• Defec ti ve input sensor

• Faulty system card

200.21 Bump aligner motor stalled. Possible causes:

• Faulty cable/connector

• 24 V interlock switch not working correctly

• Faulty bump align moto r

• Faulty system card

2-8 Se rvice Ma nual

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “145.xx and 906.05–906.08— Motor

(bump aligner) error service check” on page 2-36.

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

200.22 Pick (tray 1) motor stal led. Possible causes:

• Faulty cable/connector

• Faulty pick motor

• Faulty system card

200.25 Input sensor is made when tray 1 is installed.

Possible causes:

• Improper placement of paper in tray 1

• Damaged input sensor flag or input sensor

• Faulty system card

201.06 Paper is jammed between the input sensor and the exit sensor.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Fau lt y fuser DC cable connection

•Faulty fuser

• Faulty system card

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “140.xx—Autocomp (tray 1) motor error

service check” on page 2-32.

• Fan media, and stack flat in the tray or MPF.

• Properly set media restraints in the paper tray.

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

201.07 Exit sensor is made early. Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Fau lt y fuser DC cable connection

•Faulty fuser

• Faulty system card

201.08 Exit sensor is never made. Possible causes:

• Improper loading of manual feed slot

• Paper wrapped in fuser

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Fau lt y fuser DC cable connection

•Faulty fuser

• Faulty system card

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

• Check for anything in the paper path that might cause the paper to jam.

• Load paper in the manual feed slot. See “Paper

jams in the multipurpose feeder or manual feeder” on pa ge 3-28.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

Diagnostic information 2-9

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

201.10 Input sensor flag broke early. Possible causes:

• Paper jam leaving page over sensor

• Defec ti ve input sensor

• Faulty system card

201.21 Cartridge motor 1 (top) or cartridge motor 2 (bottom) has stal led.

Possible causes:

• Faulty cable/connector

• Faulty cartridge motor

• Faulty system card

201.23 Special case. Possible cause:

• System card code failure

201.24 A 201.08 jam occurred and was not cleared.

Pos sible cause—Failure to open and close the top access door.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “143.xx—Motor (EP dri ve assembly top

cartridge) err or service check” on page 2-34

and then “144.xx—Motor (EP drive assembly

bottom cartridge) error service check” on page 2-35 if necessary.

• POR the printer. Replace the syst em card if the error message persists. See “System card

removal” on page4-92.

• If replaci ng system card does not fix the problem, contact your next level of support.

This error is generated as a protection for possible paper wrap in the fuser. Open the top access door, and check for a paper jam. Close the top access door. If the jam i s cleared , and the error does not go away, go to “Exit sensor service check” on

page 2-52.

202.02 Exit sensor is made when printer tries to prin t from an idl e s tate.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Fau lt y fuser DC cable connection

•Faulty fuser

• Faulty system card

202.12 Exit sensor broke early. Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

•Faulty fuser

• Faulty system card

202.13 Exit sensor never broke. Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

•Faulty fuser

• Faulty system card

• Fau lty output bin flag

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

The fuser exit sensor may not be functioning properly. See “Exit sensor service check” on

page 2-52.

• Check output bin flag on fuser for proper operation. Ensure that paper is not hanging on the flag.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

2-10 Service Manual

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

202.17 Exit sensor is made when the printer powers up or covers are closed.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Fau lt y fuser DC cable connection

•Faulty fuser

• Faulty system card

202.21 Fuser motor stalled. Possible causes:

• Faulty cable/connector

•Faulty fuser motor

• Faulty system card

203.09 During duplex printing retract, the exit sensor is never made.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Damaged fuser autoconnect

• Fau lt y fuser DC cable connection

•Faulty fuser

• Faulty system card

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

• Check for anything in the paper path that might cause the paper to jam.

• If clearing a paper jam does not fix the problem, go to “142.xx and 906.01–906.04— Motor

(fuser) error service check” on page 2-33.

• Check for anything in the paper path that might cause the paper to jam.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

203.14 During duplex printing retract, the exit sensor broke early.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

•Faulty fuser

• Faulty system card

203.15 During duplex printing, the exit sensor never broke.

Possible causes:

• Damaged paper exit sensor or paper exit sensor flag

• Obstructed duplex

•Faulty fuser

• Faulty system card

230.03 During duplex printing, the input sensor is never made.

Possible causes:

• Obstructed duplex path

• Defec ti ve input sensor

• Faulty system card

• Faulty duplex driv e

The fuser exit sensor may not be functioning properly. See “Exit sensor service check” on

page 2-52.

• Check the duplex paper path for damage that would obstruct the print. If damage is found, replace the duplex front door assembl y. See

“Front door assembly removal” on page 4-55.

• The fuser exit sensor may not be fun ctioning properly. See “Exit sensor service check” on

page 2-52.

• Check for anyth ing in the duplex paper pat h that might cause the paper to jam. This includes the paper guides in tray 1.

• If clearing the paper jam does not fix the problem and the paper is fan-folded, replace the front access assembly. See “Front door

assembly re mo val” on page 4-55.

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

Diagnostic information 2-11

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

230.04 During duplex printing, the input sensor is made while the previous page is still in the aligne r.

Possible causes:

• Defec ti ve input sensor

• Faulty system card

230.05 During duplex printing, the input sensor is not made.

Possible causes:

• Obstructed duplex path

• Defec ti ve input sensor

• Faulty system card

• Faulty duplex driv e

230.21 Duplex motor stalled. Possible causes:

• Obstructed duplex path

• Defec ti ve duplex motor

• Faulty system card

241.03 While feeding from tray 1, the input sensor does not break.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Paper tray failure

• Paper pick mechanism failure

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

• Check for anyth ing in the duplex paper pat h that might cause the paper to jam. This includes the paper guides in tray 1.

• If clearing the paper jam does not fix the problem and the paper is fan-folded, replace the front access assembly. See “Front door

assembly re mo val” on page 4-55.

• If clearing a paper jam does not fix the problem, go to “Input sensor service check” on

page 2-52.

• Check for anyth ing in the duplex paper pat h that might cause the paper to jam. This includes the paper guides in tray 1.

• If clearing a paper jam does not fix the problem, go to “146.xx—Motor (duplex) error service

check” on pa ge 2-36.

• Ensure proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• Properly set media restraints in paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• Replace the p aper p ic k mec hani sm. Se e “Paper

pick mechanism assem bly removal” on page 4-68.

241.04 While feeding from tray 1, the input sensor is made while the previous page is still in aligner.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Paper tray failure

• Paper pick mechanism

2-12 Service Manual

• Ensure the proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• Properly set media restraints in paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• Replace the p aper p ic k mec hani sm. Se e “Paper

pick mechanism assem bly removal” on page 4-68.

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

241.05 While feeding from tray 1, the input sensor is never made.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• Paper tray failure

• Paper pick mechanism failure

•System card

241.20 While feeding from tray 1, the transparency sensor is bloc ked.

Possible causes:

• Transparency sensor

• Paper tray failure

• Paper pick mechanism failure

•System card

241.21 Tray 1 motor stalled. Possible causes:

• Incorrect paper loading

• Paper pick mechanism failure

•System card

242.03 While feeding from tray 2, the input sensor does not break.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• 500-sheet assembly failure

• Paper pick mechanism

• Ensure proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• Properly set media restraints in paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• If the pr evious actions do not fi x the problem, go to “140.xx—Autocomp (tr ay 1) motor error

service check” on page 2-32.

• Replace the paper tray.

• If the previous action does not fix the problem, go to “910.01—Transparency sensor error

service check” on page 2-38.

• Ensure proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• If the pr evious actions do not fi x the problem, go to “148.xx—MPF motor err o r service check”

on page 2-37.

• Ensure proper media is set for the type of paper used.

• Fan media, and stack flat in 500-sheet tray (tray 2).

• Properly set media restraints in tray 2.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the 500-sheet assembly.

• If the pr evious actions do not fi x the problem, go to “140.xx—Autocomp (tr ay 1) motor error

service check” on page 2-32.

242.04 While feeding from tray 2, the input sensor is made while the previous page is still in the aligne r.

Possible causes:

• Incorrect media setting

• Incorrect paper loading

• Incorrect media restraint setting

• 500-sheet assembly failure

• Paper pick mechanism

• Ensure proper media is set for the type of paper used.

• Fan m edia, and stack it flat in the 500-sheet tray (tray 2).

• Properly set media restraints in tray 2.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the 500-sheet assembly.

• If the pr evious actions do not fi x the problem, go to “140.xx—Autocomp (tr ay 1) motor error

service check” on page 2-32.

Diagnostic information 2-13

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

242.05 While feeding from tray 2, the input sensor is not made.

242.21 The tray 2 autocomp or the redrive motor stalled.

250.03 While feeding from the MPF, the input sensor did not brea k.

• Ensure proper media is set for the type of paper used.

• Fan m edia, and stack it flat in the 500-sheet tray (tray 2).

• Properly set media restraints in tray 2.

• Check the pick arm rolls (tires) and repla ce if worn.

• If the pr evious actions do not fi x the problem, go to “147.xx, 149.xx—Motor (500-sheet/550-

sheet option tray 2 motor) erro r service check” on pa ge 2-37.

• Fan m edia, and stack it flat in the 500-sheet tray (tray 2).

• If the pr evious actions do not fi x the problem, go to “147.xx, 149.xx—Motor (500-sheet/550-

sheet option tray 2 motor) erro r service check” on pa ge 2-37.

• Ensure proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• Properly set media restraints in the paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• Replace the MPF swing arm assembly. See

“Multipurpose f eeder (MPF) swing arm assembly re moval—models C52x only” on page 4-67.

• If the pre vious actions do not fix the pro blem, replace the paper pick mechanism. See “Paper

pick mechanism assem bly removal” on page 4-68.

250.04 While feeding from the MPF, the input sensor is made while the previous page is still in the aligne r.

2-14 Service Manual

• Ensure proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• Properly set media restraints in the paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• Replace the MPF swing arm assembly. See

“Multipurpose f eeder (MPF) swing arm assembly re moval—models C52x only” on page 4-67.

• If the pre vious actions do not fix the pro blem, replace the paper pick mechanism. See “Paper

pick mechanism assem bly removal” on page 4-68.

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

250.05 While feeding from the MPF, the input sensor is not made.

250.21 MPF motor stalled. • Ensure proper media is set for the typ e of paper

9xx service error messages

• Ensure proper media is set for the type of paper used.

• Fan media, and stack it flat in the tray or MPF.

• Properly set media restraints in the paper tray.

• Check the pick arm rolls (tires) and repla ce if worn.

• Replace the paper tray.

• Models C52x only: Replace the MPF swing arm assembly. See “Multipurpose feeder

(MPF) swing arm assembly r emov al—models C52x only” on page 4-67.

• If the pre vious actions do not fix the pro blem, replace the paper pick mechanism. See “Paper

pick mechanism assem bly removal” on page 4-68.

used.

• Fan media, and stack it flat in the tray or MPF.

• Replace the MPF swing arm assembly.

“Multipurpose f eeder (MPF) swing arm assembly re moval—models C52x only” on page 4-67.

• If the pr evious actions do not fi x the problem, go to “148.xx—MPF motor err o r service check”

on page 2-37.

900.00–900.99 Sof tware Error

902.01–902.99 Engi ne Software Error

903.01–903.05 Engi ne Software Error

904.01–904.04 I nterfac e Violation by RIP

905.xx Engine Software Error

906.01–906.04 Fuser Motor Error

906.05–906.08 Bumper Motor error

907.xx Engine Software Error

Unrecoverable RIP software error. POR the printer. If the error message persists,

Unrecoverable system software errors.

Fuser motor has failed. POR the printer. If the error message persists, see

Bump aligner motor has failed. POR the printer . If the error message persists, see

Unrecoverable system software errors.

replace the syst em card. See “System card

removal” on page4-92.

POR the printer. If the error message persists, replace the syst em card. See “System card

removal” on page4-92.

POR the printer. If the error message persists, replace the syst em card. See “System card

removal” on page4-92.

POR the printer. If the error message persists, replace the syst em card. See “System card

removal” on page4-92.

POR the printer. If the error message persists, replace the syst em card. See “System card

removal” on page4-92.

“142.xx and 906.01–906.04—Motor (fuser) error service check” on page 2-33.

“145.xx and 906.05–906.08—Motor (bump aligner) error service check” on page 2-36.

POR the printer. If the error message persists, replace the syst em card. See “System card

removal” on page4-92.

Diagnostic information 2-15

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

908.00–908.99 Engi ne Software error

910.01 Transparency Sensor

920.01 POST Error Bump align motor not connected. See “920.01—POST (power on self test) error

920.02 POST Error Tray 1 motor not connected. See “920.02—POST (power on self test) error

920.03 POST Error Transfer belt not connected. See “920.03—POST (power on self test) error

920.04 POST Error Fuser motor not connected. See “920.04—POST (power on self test) error

920.05 POST Error Printhead motor not connected. See “920.05—POST (power on self test) error

920.06 POST Error Input sensor not connected. See “920.06—POST (power on self test) error

920.07 POST Error Narrow media sensor not connected. See “920.07—POST (power on self test) error

920.08 POST Error Exit sensor not connected. See “920.08—POST (power on self test) error

920.09-12 POST Error One toner sensor not connected. See “920.09-12—POST (po wer on self test) err or

Unrecoverable system software errors.

Transparency sensor failed calibration.

POR the printer. If the error persists , r eplace the system card. See “System card removal” on

page 4-92.

See “ 910.01—Transparency sensor er ror servic e

check” on pa ge 2-38.

service check” on page 2-38.

service check” on page 2-39.

service check” on page 2-40.

service check” on page 2-41.

920.13 POST Error Cartridge motor 1 (top) not co nnected. See “920.13—POST (power on self test) error

920.14 POST Error Cartridge motor 2 (bottom) not connected.

920.15 POST Error Bad transfer belt NVRAM data. See “920.15—POST (power on self test) error

920.16 POST Error Bad printhead NVRAM data. See “920.16—POST (power on self test) error

920.17 POST Error Output bin cable not connected. See “920.17—POST (power on self test) error

920.18 POST Error T ray 2 has fail ed. See “920.18—POST (power on self test) error

920.19 POST Error Stepper motor not connected. See “920.19—POST (power on self test) error

925.01 Fan Error Fan has stalled. POR the printer. If the error message persists, see

945.01 Transfer Roll Yellow transfer roll has failed. POR the printer. If the error message persists, see

945.02 Transfer Roll Cyan transfer roll has failed. POR the printer. If the error message persists, see

service check” on page 2-43.

See “920.14—POST (power on self test) error

service check” on page 2-44.

service check” on page 2-45.

service check” on page 2-46.

“925.01—Fan error service check” on page 2-47.

“945.xx, 946.xx, 947.xx—Transfer r o ll error service check” on page 2-48.

2-16 Service Manual

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

945.04 Transfer Roll Black transfer roll has f ailed. POR the printer. If the error message persi sts, see

946.01 Transfer Roll Yellow transfer roll has failed. POR the printer. If the error message persists, see

946.02 Transfer Roll Cyan transfer roll has failed. POR the printer. If the error message persists, see

946.03 Transfer Roll Magenta transfer roll has failed. POR the printer. If the error message persists, see

946.04 Transfer Roll Black transfer roll has f ailed. POR the printer. If the error message persi sts, see

947.01 Transfer Roll Yellow transfer roll has failed. POR the printer. If the error message persists, see

947.02 Transfer Roll Cyan transfer roll has failed. POR the printer. If the error message persists, see

“945.xx, 946.xx, 947.xx—Transfer r o ll error service check” on page 2-48.

947.03 Transfer Roll Magenta transfer roll has failed. POR the printer. If the error message persists, see

947.04 Transfer Roll Black transfer roll has f ailed. POR the printer. If the error message persi sts, see

950.00–950.29 NVRAM Mismatch

950.30–950.60 NVRAM Mismatch

951.01–951.99 NVRAM Failure

952.01–952.99 NV Failure:n

953.01–953.99 NVRAM Failure

Mismatch between operator panel assembl y NVRAM and system card NVRAM.

Mismatch between system card NVRAM and smart chip card or printhead NVRAM.

Smart chip card or printhead NVRAM failure.

CRC error has occurred. This is recoverable.

Operator panel assembly NVRAM. POR the printer. Replace oper ator panel assembly if

“945.xx, 946.xx, 947.xx—Transfer r o ll error service check” on page 2-48.

POR the printer. If the error message persi sts, see

“950.00–950.29 EPROM mismatch failure” on page 2-50.

POR the printer. If the error message persi sts, see

“950.30–950.60 EPROM mismatch failure” on page 2-50.

POR the printer.

• For C52x: if the error message persist s, replace the smart chip card. See “Smar t chip card

removal—models C52x only” on page 4-91.

• For C53x: if the error message persist s, replace the printhead. See “Printh e ad remov al ,

installation, and adjustment” on page 4-74.

Perform a POR to clear the error.

the error message per sists. See “Operator panel

assembly re mo val” on page 4-23.

Diagnostic information 2-17

5022-xxx

Service error codes and paper jam messages (continued)

Error code Description Action

954.01–954.99 NVRAM Failure

955.01–955.99 Code Failure

956.01–956.99 System card

958.01–958.99 Mem ory Failure

960.01—960.99 Memory Error

961.01–961.99 Mem ory Failure

990.xx Option Error Tray 2 fail ure. Replace 500-sheet assem bly.

System card NVRAM fai lure. POR the printer. If the error message persists,

replace the syst em card. See “System card

removal” on page4-92.

System card memory failure. POR the printer. If the error message persists,

replace the syst em card. See “System card

removal” on page4-92.

Processor failure. POR the printer. If the error message persists,

replace the syst em card. See “System card

removal” on page4-92.

Processor failure. POR the printer. If the error message persists,

replace the syst em card. See “System card

removal” on page4-92.

Memory failure . RAM soldered on card is bad. Replace the system

card. See “System card removal” on page 4-92.

Memory failure. POR the printer. If the error message persists,

replace the syst em card. See “System card

removal” on page4-92.

2-18 Service Manual

5022-xxx

User status and attendance messages

Error code Action

3x through 8x atten d ance m essages

31 Defectiv e or Missing <color> Cartridge

32 Unsupported Cartridge

• Reseat the specif ied toner cartridge.

• For models C52x: Inspect th e smart chip card contact s (A) for damage, contamination or positioning error. If dam aged, contact your next level of service.

• Inspect the toner cartridge contact s for damage/contamination. Replace the toner cartridge if defect ive.

• Inspect the JSBTN1 cabl e connection. Properly connect the cable if not connected properly. Replace the cable if damaged.

• For models C52x: Replace the smart chip card. See “Smart chip card removal—

models C52x only” on page 4-91.

• If the problem still exists, replace the system card. See “System card removal” on

page 4-92.

• Check to see if th e toner cartridge is a supported cartridge. Note: Once the cartridge shipped with the prin ter is exhausted, it m ust be replaced by a

supp ly ca rtr idge (r ef er to the User’s Guide for part number s.) If the specified toner cartridge is a supported cartridge, reseat the cartridge.

• For models C52x: Inspect the smart chip card contacts (A) for damage, contamination, or positioning error. If damaged, contact your next level of service.

• Inspect the toner cartridge contact s for damage or contamination. Replace the toner cartridge if defect ive.

• Inspect JSBTN1 cable connection. Properl y connect the cable if not connected properly. Replace the cabl e if dam aged.

• For models C52x: Replace the smart chip card. See “Smart chip card removal—

models C52x only” on page 4-91.

• If the problem st ill exist s, re p la c e the system card. See “System car d rem oval” on

page 4-92.

Diagnostic information 2-19

5022-xxx

User status and attendance messages (continued)

Error code Action

34 Sh ort Pape r

34 Incorrect Media • Load the appropriate media in the selected source.

35 Insufficient mem o ry to support Resource Save feature

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• The printer does not automatically reprint the page t hat prompted the message.

• Check the tray length and width guides to ensure the media is properly fitted.

• Make sure the print job is requesting the corre ct si ze of media.

• Adjust the Paper Size setting for the media size being used.

• If the MP Feeder Siz e is set to Uni versal, make sure the media is large enough f or the formatted dat a.

• Cancel the curren t job. Replace the paper pic k m echanism. See “Paper pick

mechanism assembly removal” on page 4-68.

• If the problem st ill exist s, re p la c e the system card. See “System car d rem oval” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and print the job using a different paper source.

• POR the printer to reca li brate transpar ency sensor .

• Ensure the transpar ency sensor is mounted cor rec tly in t he paper pick mechanism . If not, snap it into place.

• Replace the paper pi ck mechanism. See “Paper pick mechanism assembly removal ”

on page 4-68.

• If the problem st ill exist s, re p la c e the system card. See “System car d rem oval” on

page 4-92.

• Press until Continue appears, and then press to disabl e Resource Save and continue prin ti ng.

• To enable Resource Save after receiving thi s message:

- Make sure the link buffers are set to Auto, then exit the menus to activate the li nk buffer changes.

- When Ready is displayed, enable Resource Save.

• Install additional memory.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

37 Insufficient mem o ry to collate job

37 Insufficient mem o ry for Flash Memory Defragment operation

37 Insufficient mem o ry, some held jobs were deleted

• Press until Continue appears, and then press to print the portion of the job already stor ed and begin collating the rest of t he job.

• Cancel the current job.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then press to stop the defragm ent operation and continue printing.

• Delete fonts, macros, and other data in printer memory.

• Install additional printer memory.

• If this does not fi x the problem, replac e the system. See “System card removal” on

page 4-92.

• The printer deleted some held jobs in order to process current jobs.

• Press until Continue appears, and then pres s to clear the messag e.

• If this does not f ix the prob lem, replace the syst em card . See “System ca rd rem ov al ” on

page 4-92.

2-20 Service Manual

5022-xxx

User status and attendance messages (continued)

Error code Action

37 Insufficient mem o ry, some held jobs were lost

38 Memory Full

50 PPDS font error

51 Defective flash detected

• The printer was unable to restore some or all of th e confidential or held jobs on the hard disk.

• Press until Continue appears, and then pres s to clear the messag e.

• If this message occ urs again, replace the hard drive.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

The job may not print correctly.

• Cancel the current job.

• Install additional printer memory.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

The job may not print correctly.

• Cancel the current job.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Install different flash mem ory bef ore downloading any resources to flash.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

52 Not enough free space in flash memory for resour c es

53 Unformatted flash detected

54 Serial option <x> error

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

Downloaded fonts and macros not previously stored i n fl ash m em ory are deleted.

• Delete fonts, macros, and other data stored in flash memory.

• Install a larger capacity flash memory card.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Format the flas h memory before storing any res ources on it. If the error message remains, replace the flash memory.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Make sure the serial link is set up correctl y and the appropriate cable is in use .

• Make sure the seria l interface param eters (protocol, baud, parity, and data bits) are set correctly on the pri nter and host computer.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

The job may not print correctly.

• POR the printer . If this does not fix the problem, replace the PCI card.

Diagnostic information 2-21

5022-xxx

User status and attendance messages (continued)

Error code Action

54 Network <x> softw are error

55 Unsupported option in slot <x>

56 Parallel port <x> disabled

56 Stand ard par allel port disabled

56 Serial port <x> disabled

56 Standard USB port disabled

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

The job may not print correctly.

• Program new fi rmware for the network interface.

• POR the printer . If this does not fix the problem, replace the PCI card.

• Turn the printer off .

• Unplug the power cord from the wall outlet.

• Remove the unsupported option.

• Connect the power cord to a properly grounded outlet.

• Turn the printer on.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e. The printer discards any data received through the parallel port.

• Make sure the Parallel Buf fer menu item is not set to Disabled.

• If this does not fi x the pr oblem, replace the PCI card.

• Press until Continue appears, and then pres s to clear the messag e. The printer discards any data received through the serial port.

• Make sure the Serial Buffer menu item is not set to Disabled.

• If this does not fi x the pr oblem, replace the PCI card.

• Press until Continue appears, and then pres s to clear the messag e. The printer discards any data received through the USB port.

• Make sure the USB Buff er menu item is not set to Disabled.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

58 Too many flash options installed

58 Too many trays attached

61 Remove defective disk

2-22 Service Manual

• Turn off and unplug the printer.

• Remove the excess flash memory.

• Plug in the printer, and turn it on.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

This printer does not support the 500-sheet assembly.

• Turn off and unplug the printer.

• Remove the 500-sheet paper tray assembly.

• Plug in the printer, and turn it on.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Install a different hard disk before performing any operations that require a hard disk.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

5022-xxx

User status and attendance messages (continued)

Error code Action

62 Disk full

63 Unformatted disk

64 Unsupported disk format

80 Fuser life warning

• Press until Continue appears, and then pres s to clear the messag e and continue processing.

Any information not previously stored on the hard disk is deleted.

• Delete fonts, macros, and other data stored on the hard disk.

• Install a larger hard disk.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Format the disk.

• If the error message remains, replace t he hard disk.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Format the disk.

• If the error message remains, replace t he hard disk.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Order a replacement fuser. When print quality is reduced, install the new fuser usin g the instruction sheet that comes with the replacement fuser.

• If this does not fix the problem, replace the system card.See “System card remov al” on

page 4-92.

80 Replace fuser • Replace the fuser.

• If this does not f ix the prob lem, replace the syst em card . See “System car d remo v al” on

page 4-92.

82 Waste toner box nearly full

82 Replace waste toner box

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• If printing continues, order a replacem ent waste toner box immediately.

• If the problem persists, open the front access door and check the bump aligner shaft for binding. Clear the binding if possib le. If not possible, contact your next level of service.

• Replace the waste toner box using the instruct ion sheet that comes with the replacement waste toner box.

• Ensure that there is no i nterference bet ween the waste toner bo x and the printer.

• If the problem persists, open the front access door and check the bump a li gner shaft for binding. Clear th e binding if possible.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

• If the problem persists, contact your next level of service.

Diagnostic information 2-23

5022-xxx

User status and attendance messages (continued)

Error code Action

82 Waste toner box missing

83 Transfer belt missing • Inser t the transfer belt.

• Insert the waste toner box.

• Inspect the top co v er cams haft as semb ly f or prop er oper atio n. When the t op ac cess co v er is closed, the printer should mechanically interlock.

• Check the JB UMP1 connection/cabl e connected to the system card for defects and proper connecti on. If the cable wiring or the cable connection is defective, replace the bump aligner motor. See “Bump aligner motor removal” on page 4-40. If the JBUMP1 connector is damaged on the system card, replace the system card. See “System card

removal” on page 4-92.

• Check the bump aligner shaft and the mechanical system for binds.

• Replace the bump aligner motor. See “Bump aligner motor removal” on page 4-40.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

• For models C52x: Check connector JTRANS1 for proper connection to the system card, the cable for pinch points, and the cable or connector for any other damage. If the connector is damaged on system card, replace the system card. See “System card

removal” on page 4-92.

For models C53x: Check connector JTRANS2 for proper connection to the system card,

the cable f or pinch points , and the cab le con nector f or an y othe r damage. If the conn ect or is damaged on the system card, replace the system card. See “System card removal”

on page 4-92.

If the JTRANS1 cable (model C52x) or the JTRANS2 cable (model C53x) i s dam aged, replace the front door assembly. See “Front door assembly removal” on page 4-55.

• Replace the transfer belt assembly. See “Transfer belt removal” on page 4-103.

• If the problem persists, replace the system card. See “System card remov al” on

page 4-92.

83 Transfer belt life warning

83 Replace transfer belt • Replace the transfer belt using the instruction sheet that comes with the replacement

84 <color> PC Uni t life warning

84 Replace <color> PC Unit

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• Order a replacement transfer belt. When print quality is reduced, install the new transfer belt using the instruction sheet that comes with the replacement tra nsfer belt.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

transfer belt. See “Transf er belt removal” on page 4-103.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

• Press until Ignore appears, and then pres s to clear the message and cont inue printing.

• Order the specified photoconductor uni t. When print quality is reduced, install the new specified photocon duct or uni t usi ng the ins truction sheet t hat comes wit h the rep lacement specified photoconductor unit.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

• Replace the speci fied phot oconduct or unit using th e instruct ion shee t that comes with the replacement specified photoconductor unit.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

2-24 Service Manual

5022-xxx

User status and attendance messages (continued)

Error code Action

84 <color> PC Unit missing

• Scroll down the operator panel to see if the print er i s showing that all four of the PC units are missing. If so , check the HVPS cabl e betwee n th e system c ard and t he HVPS . Ensur e that the cable is not plugged in backw ards on the HVPS. Disconnect and reconnect the cable to make sure there is good contac t.

• Insert or reinstall the specified photoconductor unit and see if problem clears. See

“Photoconductor uni t removal” on page 4-70.

• Remove the top access cover assembly (see “Top access cover assembl y rem oval—

model C52x only” on pa ge 4-28 or “Top access cover assembly removal—model C53x only” on page 4-32), and confirm that the camshaft follower (A) on the left side is

not out of the groo v e (B). If the camshaft fol low er is out of the gr oo ve , r aise t he arm, use a screwdriver to ease the camshaft follower back into the groove. You need to press down to snap it into position.

• Check the high voltage contact s path, especially the “finger” on the specified photoconductor unit (printer is shown wit h com ponents remov ed for clarity).

High voltage

power supply

High voltage

contact path

Finger

• If the contacts are good, replace the HVPS. See “High voltage power supply (HVPS)

removal” on page 4-62.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

Diagnostic information 2-25

5022-xxx

User status and attendance messages (continued)

Error code Action

87 Fuser missing • Install the fuser. Replace the f user if the prob lem persists.

• If the problem continues, turn the printer of f and remove the rear cover. Check the JFUSER1 connector for proper connect ion to the system car d, the cable for pinch points, and the cable or t he connector for any other damage. If the connector is damaged on system card, replace the system card. See “System card remov al” on page 4-92. If the fuser cable is damaged, replace the cable.

• Check for the following continuity between the DC autoconnect and FUSER1.

pin 6

pin 1

pin 10

DC autoconnect JFUSER1

Pin 3 Pin 3 Pin 4 Pin 4 Pin 6 Pin 6 Pin 7 Pin 7 Pin 8 Pin 8 Pin 9 Pin 9 Pin 10 Pin 10

• If continuity is not present, replace the fuser cable. If the problem persists after replacing cable, replace the system car d. See “System card removal” on page 4-92.

88 <color> Cartridge low • Replace the specified toner cartridge.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• If the message does not clear, replace the smart chip card. See “Smart chip card

removal—models C52x only” on page 4-91.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

pin 8

123

579

468

Pin configuration

88 Replace <color> cartridge

• Replace the specified toner cartridge.

• Press until Continue appears, and then pres s to clear the messag e and continue prin ti ng.

• If the message does not clear, replace the smart chip card. See “Smart chip card

removal—models C52x only” on page 4-91.

• If the probl em persists, replace the system card. See “System card removal ” on

page 4-92.

2-26 Service Manual

5022-xxx

Service checks

110.xx—Mirror motor service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JMIRR1 for proper connection to th e system card, the printhead cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged? Replace the printhead. See “Printhead

removal , installation, and adjustment” on page 4-74.

Does the error clear?

Replace the printhead. See

“Printhea d re moval, installation, and adjustment” on pa ge 4-74.

Problem solved. Replace the system card.

Go to step 2.

See “System card

removal” on page4-92.

111.xx, 112.xx, 113.xx, and 114.xx—Printhead error service check

Step Questions / actions Yes No

1 Is the front access door completely closed? Go to step 2. Properly cl ose the door.

Turn the printe r of f, and remove the re ar cover.

Check the connector JINT1 (5 V interlock switch cable) for proper connection to the system card, the cab le fo r pinch points, and the cable or connector for any other damage.

Is the cable damaged? Turn the printer po wer on, and che c k f or 5 V dc

between JINT1 pin (red wire) and ground. Is voltag e present?

Replace the front access door 5 V interlock switch. See “Front access door

5 V interlock switch removal” on page 4-54.

Replace the front access door 5 V interlock switch. See “Front access door

5 V interlock switch removal” on page 4-54.

Go to step 3.

Go to step 4.

Replace the printhead. See “Printhead

removal , installation, and adjustment” on page 4-74.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-27

5022-xxx

120.01, 120.02, 120.08–120.10, 120.13–120.15—Fuser error service check

Step Questions / actions Yes No

1 Check the in put voltage swi tch on the back of

the low voltage power supply (LVPS). Is the voltage level (115/230) properly set?

Remove the fuser, and check the camshaft

follower on the right side. If the camshaft follower (A) is above the crescent-shape d groove, it needs to be pressed down into the proper location.

Is the camshaft f ollower on the right si de properly placed in the groove?

Turn the printe r of f, and remove the re ar cover.

Check the connector JFUSER1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged?

Go to step 2. Set the swi tch for proper

country voltage.

Go to step 3. Press the camshaft follower

into the groove.

Replace the fuser cable. Go to step 4.

Check the connector JLVPS1 for proper

connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Remove the fuser. See “Fuser removal” on

page 4-60. Check the AC and DC

autoconnects on both the fuser and the printer for damage.

Are the connectors damaged?

Replace the LVPS cable. See “Low voltage power

supply (LVPS) removal” on page 4-65.

Replace the appropriate cable.

Go to step 5.

Go to step 6.

2-28 Service Manual

5022-xxx

Step Questions / actions Yes No

Check for the fol lowing continuity between the

DC autoconnect and FUSER1.

pin 6

pin 1

pin 10

pin 8

Pin configuration

DC autoconnect JFUSER1

Pin 9 Pin 9 Pin 10 Pin 10

Is continuity present? Check fo r con tinu ity betwe en th e f ollo win g pins

of the AC autoconnect and the pins of the connector that connects to the LVPS.

pin 5

pin 1

pin 3

AC autoconnect LVPS connector

123

579

468

Go to step 7. Replace the DC fuser cable.

Go to step 8. Replace the AC fuser cable .

LVPS connector AC autoconnect

Pin 1 Pin 5 Pin 2 Pin 4

Pin 3 Pin 1 Is continuity present? Replace the fuser. See “Fuser removal” on

page 4-60.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-29

5022-xxx

120.03—Fuser error service check

Step Questions / actions Yes No

1 Check the in put voltage swi tch on the back of

the low voltage power supply (LVPS). Is the voltage level (115/230) properly set?

Turn the printe r of f, and remove the re ar cover.

Check the connector JFUSER1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Check the connector JLVPS1 for proper

connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Replace the fuser. See “Fuser removal” on

page 4-60.

Does the error clear?

Go to step 2. Set the switch for proper the

Replace the fuser cable. Go to step 3.

Replace the LVPS. See

“Low voltage power supply (LVPS) removal” on page 4-65.

Problem solved. Replace the system card.

country voltage.

Go to step 4.

See “System card

removal” on page4-92.

120.04–120.07—Fuser error service check

Step Questions / actions Yes No

1 Check the in put voltage swi tch on the back of

the low voltage power supply (LVPS). Is the voltage level (115/230) properly set?

Go to step 2. Set the switch for the proper

country voltage.

Turn the printe r of f, and remove the re ar cover.

Check the connector JFUSER1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Remove the fuser. See “Fuser removal” on

page 4-60. Check the AC and DC

autoconnects on both the fuser and the printer for damage.

Are the connectors damaged?

Replace the fuser cable. Go to step 3.

Go to step 4. Replace the appr opri ate

cable.

2-30 Service Manual

5022-xxx

Step Questions / actions Yes No

Check for the fol lowing continuity between DC

autoconnect and JFUSER1.

pin 6

pin 1

pin 10

pin 8

Pin configuration

DC autoconnect JFUSER1

Pin 9 Pin 9 Pin 10 Pin 10

Is continuity present? Check fo r con tinu ity betwe en th e f ollo win g pins

of the AC autoconnect and the pins of the connector that connects to the LVPS.

pin 5

123

579

468

Go to step 5. Replace the DC fuser cable.

Go to step 6. Replace the AC fuser cable .

pin 1

pin 3

AC autoconnect LVPS connector

LVPS connector AC autoconnect

Pin 1 Pin 5

Pin 2 Pin 4

Pin 3 Pin 1 Is continuity present? Reinstall the fus er. See “Fuser removal” on

page 4-60.

Does the error clear? Replace the fuser. See “Fuser removal” on

page 4-60.

Does the error clear?

Problem solved. Go to step 7.

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-31

5022-xxx

140.xx—Autocomp (tray 1) motor error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRAY2 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage. See “Connectors” on

page 5-11 for the location of connectors.

Is the cable damaged? Measure the resist ance across fuse F2 on the

system card.

Replace the paper pick mechanism. See “Paper

pick mechan ism assembly removal” on page 4-68.

Replace the system card. See “System card

removal” on page 4-92.

Go to step 2.

Go to step 3.

Is the fuse blown? Replace the paper pick mechanism. See

“Paper pi ck mechanism asse mbly remo val” on page 4-68.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

2-32 Service Manual

5022-xxx

142.xx and 906.01–906.04—Motor (fuser) error service check

Step Questions / actions Yes No

1 Is the top acces s door completely close d? Go to step 2. Close the top access door.

Tur n the printer off, and remove the fuser.

Is the right bellcrank (A) out of its slot? Turn the printe r of f, and remove the re ar cover.

Check the connector JFUSER1 for the proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Turn the printer power on, and check for

24 V dc between JCVR1 pin 1 (red wire) and ground.

Note: The g round lead of the v oltmeter can be placed on the metal frame to obtain ground.

Is voltag e present?

Lift the top acce ss door t o its widest position, and put the right bellcrank (A) into its slot.

Replace the fuser cable. Go to step 4.

Replace the t op acce ss door 24 V interlock s witch. See

“Top access door 24 V inte rlock switch re m o val” on page 4-98.

Go to step 3.

Go to step 5.

Replace the fuser. See “Fuser removal” on

page 4-60.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-33

5022-xxx

143.xx—Motor (EP drive assembly top cartridge) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JCART1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Measure the resistance across fuse F4 and F5

on the system card.

Replace the JCART1 cable. Go to step 2.

Replace the system card. See “System card

removal” on page 4-92.

Go to step 3.

Is either fuse blown? Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal—mode l C52x only” on pa ge 4-48 or “Electrophotographic (EP) drive assembly removal —model C53x only” on page 4-51.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

2-34 Service Manual

5022-xxx

144.xx—Motor (EP drive assembly bottom cartridge) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JCART2 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Measure the resistance across fuse F5 and F6

on the system card.

Replace JCART2 cable. Go to step 2.

Replace the system card. See “System card

removal” on page 4-92.

Go to step 3.

Is either fuse blown? Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal—mode l C52x only” on pa ge 4-48 or “Electrophotographic (EP) drive assembly removal —model C53x only” on page 4-51.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-35

5022-xxx

145.xx and 906.05–906.08—Motor (bump aligner) error service check

Step Questions / actions Yes No

1 Is the top acces s door completely close d? Go to step 2. Close the top access door.

Open the top access door, and slowly close it.

You should hear the top access door 24 V interlock switch closing when the door almost shuts. If y ou do not, check the switch for damage.

Is the swit ch dam aged? Close the top access door. Turn printer power

on, and check for 24 V dc between JCVR1 pin 1 (red wire) and ground.

Note: The g round lead of the v oltmeter can be placed on the metal frame to obtain ground.

Is voltag e present? Replace the bump aligner motor. See “Bump

aligner motor removal” on page 4-40.

Does the error clear?

Replace the t op acce ss door 24 V interlock switch. See

“Top access door 24 V inte rlock switch re m o val” on page 4-98.

Replace the t op acce ss door 24 V interlock switch. See

“Top access door 24 V inte rlock switch re m o val” on page 4-98.

Problem solved. Replace the system card.

Go to step 3.

Go to step 4.

See “System card

removal” on page4-92.

146.xx—Motor (duplex) error service check

Step Questions / actions Yes No

1 Is the top acces s door completely close d? Go to step 2. Close the top access door.

Turn the printe r of f, and remove the re ar cover.

Check the connector JDUPLX1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged?

Replace the duplex front door assembly. See “Front

door assembly removal” on page 4-55.

Go to step 3.

Close the front access door. Turn the power

on, and check for 24 V dc between JCVR1 pin 1 (red wire) and ground.

Note: The g round lead of the v oltmeter can be placed on the metal frame to obtain ground.

Is voltag e present? Replace the duple x front door assembl y. See

“Front door assembly removal” on page 4-55.

Does the error clear?

2-36 Service Manual

Replace the t op acce ss door 24 V interlock s witch. See

“Top access door 24 V inte rlock switch re m o val” on page 4-98.

Problem solved. Replace the system card.

Go to step 4.

See “System card

removal” on page4-92.

5022-xxx

147.xx, 149.xx—Motor (500-sheet/550-sheet option tray 2 motor) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JOPT1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Replace the 500-she et assembly or the

550-sheet assembly. Does the error clear?

Replace the option cable. Go to step 2.

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

148.xx—MPF motor error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRAY2 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Measure the resist ance across fuse F2 on the

system card.

Replace the paper pick mechanism. See “Paper

pick mechan ism assembly removal” on page 4-68.

Replace the system card. See “System card

removal” on page 4-92.

Go to step 2.

Go to step 3.

Is the fuse blown? Replace the paper pick mechanism. See

“Paper pi ck mechanism asse mbly remo val” on page 4-68.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-37

5022-xxx

910.01—Transparency sensor error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRAY1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Check the transparency sensor f or correct

mounting. Is the transpa rency sensor properly mounte d

in the paper pick me chanism?

Replace the paper pick mechanism. See

“Paper pi ck mechanism asse mbly remo val” on page 4-68.

Does the error clear?

Replace the paper pick mechanism. See “Paper

pick mechan ism assembly removal” on page 4-68.

Go to step 3. Remov e the paper pick

Problem solved. Replace the system card.

Go to step 2.

mechanism, pr operl y install the transpar ency sensor and reinstal l paper pick mechanism. See “Paper

pick mecha nism assembly removal” on page4-68.

See “System card

removal” on page4-92.

920.01—POST (power on self test) error service check

Step Questions / actions Yes No

1 Replace the bump aligner motor. See “Bump

aligner motor removal” on page 4-40.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

920.02—POST (power on self test) error service check

Step Questions / actions Yes No

1 Replace the paper pick mechanism. See

“Paper pi ck mechanism asse mbly remo val” on page 4-68.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

920.03—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRANS2 (model C52x) or JTRANS1 (model C53x) for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal —model C52x only” on page 4-48.

Does the error clear?

Replace the damaged cable.

Problem solved. Replace the system card.

Go to step 2.

See “System card

removal” on page4-92.

2-38 Service Manual

5022-xxx

920.04—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JFUSER1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Remove the fuser. See “Fuser removal” on

page 4-60. Check the DC autoconnects on

both the fuser and the printer for damage. Are the connectors damaged?

Check for the fol lowing continuity between the

DC autoconnect and FUSER1.

pin 6

pin 1

pin 10

pin 8

DC autoconnect JFUSER1

Pin configuration

123

579

468

DC autoconnect JFUSER1

Pin 3 Pin 3

Pin 8 Pin 8

Pin 9 Pin 9

Pin 10 Pin 10

Replace the fuser cable. Go to step 2.

Replace the DC

Go to step 3.

autoconnect cable.

Go to step 4. Replace the DC fuser cable.

Is continuity present? Replace the fuser. See “Fuser removal” on

page 4-60.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

920.05—POST (power on self test) error service check

Step Questions / actions Yes No

1 Replace the printhead card. See “Printhead

removal , installation, and adjustment” on page 4-74.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-39

5022-xxx

920.06—POST (power on self test) error service check

Step Questions / actions Yes No

1 Replace the paper pick mechanism. See

“Paper pi ck mechanism asse mbly remo val” on page 4-68.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

920.07—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRAY1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Check the transparency sensor f or correct

mounting. Is the transpa rency sensor properly mounte d

in the paper pick me chanism?

Replace the paper pick mechanism. See

“Paper pi ck mechanism asse mbly remo val” on page 4-68.

Does the error clear?

Replace the paper pick mechanism. See “Paper

pick mechan ism assembly removal” on page 4-68.

Go to step 3. Remov e the paper pick

Problem solved. Replace the system card.

Go to step 2.

mechanism, pr operl y install the transpar ency sensor , and reinstall the paper pick mechanism. See “Paper

pick mecha nism assembly removal” on page4-68.

See “System card

removal” on page4-92.

920.08—POST (power on self test) error service check

Step Questions / actions Yes No

Turn the printe r of f, and remove the re ar cover.

Check the connector JFUSER1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Remove the fuser. See “Fuser removal” on

page 4-60. Check the DC autoconnects on

both the fuser and the printer for damage. Are the connectors damaged?

Replace the fuser cable. Go to step 2.

Replace the JFUSER1 cable.

Go to step 3.

2-40 Service Manual

5022-xxx

Step Questions / actions Yes No

Check for the fol lowing continuity between the

Go to step 4. Replace the DC fuser cable.

DC autoconnect and FUSER1.

pin 6

pin 1

pin 10

pin 8

DC autoconnect JFUSER1

Pin configuration

123

579

468

DC autoconnect JFUSER1

Pin 6 Pin 6

Pin 7 Pin 7

Pin 8 Pin 8 Is continuity present?

Replace the fuser. See “Fuser removal” on

Problem solved. Replace the system card.

page 4-60.

Does the error clear?

920.09-12—POST (power on self test) error service check

See “System card

removal” on page4-92.

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JHVPS1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged?

Replace the top access cover assem bly. See “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x

Go to step 2.

only” on page 4-32.

Remove the left cover. See “Left cover

removal” on page4-20. Check all the toner

level sensor cables connected to the rear of the HVPS for proper connection to HVPS, the

Replace the damaged sensor. See “Toner level

sensor removal” on page 4-96.

Go to step 3.

cable for pinch points, and the cable or connector for any other damage.

Are any of the cables damaged? Disconnect JHVPS1 from the system car d and

the HVPS. Check f or the followi ng continuity.

JHVPS1 cable HVPS end System card end Pin 14 Pin 14

Is continuity present?

Go to step 4. Replace the t op access

cover assembly. See “Top

access cover assem bly removal—model C52x only” on page4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Diagnostic information 2-41

5022-xxx

Step Questions / actions Yes No

Reconnect JHVPS1 cable to the system card

and the HVPS. Do not reinstall the left cover, but make sure the front access door and the top cover assembly are closed, and that the waste toner assembly is reinst alled. Turn the printer on. Attach t he negative end of the voltmeter to the ground, and check the v oltage on pin 1 of each toner level sensor cable. You will need to c hec k this on t he back o f the HVPS (see the illustration below).

Pin1 (typical) 4X

Replace the toner level sensor that has 5 V dc on pin 1. See “Toner leve l

sensor removal” on page 4-96.

Negative lead

Go to step 5.

Waste toner assembly

Is there appro ximately 5 V dc on any of the pins?

Replace the HVPS. See “High voltage power

supply (HVPS) removal” on page 4-62.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

2-42 Service Manual

5022-xxx

920.13—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JCART1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Remove the right co ver . Check f or the fo llowing

continuity between JCART1 and top cartridge connector.

Pin 1

Replace the JCART1 cable. The cable parts pack et contains one cartridge motor cable that works for either of the cartridge motors.

Go to step 3. Replace the JCART1 cable.

Pin 3

Pin 2

Go to step 2.

The cable parts pack et contains one cartridge motor cable that works for either of the cartridge motors.

Pin 1

JCART1 To cartridge motor

Pin 1 Pin 1 Pin 2 Pin 2 Pin 3 Pin 3

Is continuity present? Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal—mode l C52x only” on pa ge 4-48 or “Electrophotographic (EP) drive assembly removal —model C53x only” on page 4-51.

Does the error clear?

connector

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-43

5022-xxx

920.14—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JCART2 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Remove the right co ver . Check f or the fo llowing

continuity between JCART2 and bottom cartridge connector.

Pin 1

Replace the JCART2 cable. The cable parts pack et contains one cartridge motor cable that works for either of the cartridge motors.

Go to step 3. Replace the JCART2 cable.

Pin 3

Pin 2

Pin 1

Go to step 2.

The cable parts pack et contains one cartridge motor cable that works for either of the cartridge motors.

JCART1 Bottom cartridge

Pin 1 Pin 1 Pin 2 Pin 2

Pin 3 Pin 3 Is continuity present? Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal—mode l C52x only” on pa ge 4-48 or “Electrophotographic (EP) drive assembly removal —model C53x only” on page 4-51.

Does the error clear?

2-44 Service Manual

motor connector

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

5022-xxx

920.15—POST (power on self test) error service check

Models C52x only

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRANS1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage. See “System card

(network)—m odels C52x” on page 5-11 for

the location of JTRANS1. Is the cable damaged?

Replace the transfer belt assembly. See

“Transfer belt removal” on page 4-103.

Does the error clear?

Replace the front door assembly. See “Front door

assembly removal” on page 4-55.

Problem solved. Replace the system card.

Go to step 2.

See “System card

removal” on page4-92.

Models C53x only

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRANS2 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage. See “Connector listing—

models C53x” on page 5-19 for the location

of JTRANS2. Is the cable damaged?

Replace the transfer belt assembly. See

“Transfer belt removal” on page 4-103.

Does the error clear?

Replace the front door assembly See “Front door

assembly removal” on page 4-55.

Problem solved. Replace the system card.

Go to step 2.

See “System card

removal” on page4-92.

920.16—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JPH1 (large printhead cable) for proper connection to the system card, the cabl e for pinch points, and the cable or connector f or any other damage.

Is the cable damaged? Replace the system car d. See “System card

removal” on page4-92.

Does the error clear?

Replace the printhead. See

“Printhea d re moval, installation, and adjustment” on pa ge 4-74.

Problem solved. Replace the printhead. See

Go to step 2.

“Pri nthead removal , installation, and adjustment” on page 4-74.

Diagnostic information 2-45

5022-xxx

920.17—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JBIN1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged?

Replace the top access cover assembly. “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assembly removal—model C53x only” on page4-32.

Does the error clear?

Replace the top access cover assem bly. See “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Problem solved. Replace the system card.

Go to step 2.

See “System card

removal” on page4-92.

920.18—POST (power on self test) error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JOPT1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged? Replace the 500-she e t assembly (C52x

models) or the 550-sheet assembly (C53x models).

Does the error clear?

Replace the option cable. Go to step 2.

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

920.19—POST (power on self test) error service check

Models C52x only

Step Questions / actions Yes No

1 Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal —model C52x only” on page 4-48.

Does the error clear?

2-46 Service Manual

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

5022-xxx

Models C53x only

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JTRANS1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage. See “Connector listing—

models C53x” on page 5-19 for the location

of the JTRANS1 connector. Is the cable damaged?

Replace the EP drive assembly. See

“Electrophotographic (EP) drive assembly removal—mode l C52x only” on pa ge 4-48 or “Electrophotographic (EP) drive assembly removal —model C53x only” on page 4-51.

Does the error clear?

Replace the JTRANS1 cable.

Problem solved. Replace the system card.

Go to step 2.

See “System card

removal” on page4-92.

925.01—Fan error service check

Step Questions / actions Yes No

1 Replace the top access cover assembly. See

“Top access cover assembly removal— model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-47

5022-xxx

945.xx, 946.xx, 947.xx—Transfer roll error service check

Step Questions / actions Yes No

1 Turn the printer off , and remov e the rear cover.

Check the connector JHVPS1 for proper connection to the system card, the cable for pinch points , and the cable or connect or for any other damage.

Is the cable damaged?

Disconnect JHVPS1 from system card and

HVPS. Check for the following continuity.

Pin 1

Pin 24

Pin 23

Pin 2

Pin 1Pin 2

Error code Color JHVPS1 cab le t o:

945.01, 946.01, 957.01 Yellow Pin 19 Pin 19

945.02, 946.02, 957.02 Cyan Pin 15 Pin 15

945.03, 946.03, 957.03 Magenta Pin 17 Pin 17

945.04, 946.04, 957.04 Black Pin 23 Pin 23

Replace the top access cover assem bly. See “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Go to step 3. Replace the t op access

Pin 23

Go to step 2.

cover assembly. See “Top

access cover assem bly removal—model C52x only” on page4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Pin 24

HVPS System card

Pin 20 Pin 20

Pin 16 Pin 16

Pin 18 Pin 18

Pin 24 Pin 24

Is continuity present?

2-48 Service Manual

5022-xxx

Step Questions / actions Yes No

Remove the HVPS. See “High v o ltage power

supply (HVPS) removal” on page 4-62.

Check for continuity between the contacts (yello w1 and yellow2, cyan1 and cyan2, magenta1 and magenta2, or black1 and black2) on the transfer contact assembly.

yellow2

cyan2

magenta2

black2

Go to step 4. Replace the transfer contact

assembly. See “Transfer

contact assembly removal” on page4-104.

yellow1

cyan1 magenta1

black1

Is continuity present?

4 Replace the HVPS. See “High voltage power

supply (HVPS) removal” on page 4-62.

Does the error clear?

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

Diagnostic information 2-49

5022-xxx

950.00–950.29 EPROM mismatch failure

Warning: When replacing any one of the following components:

• Operator panel assem bly

• 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. If this proce dure is not followed, the printer will be rendered inoperable.

Warning: Never install and r em ove components listed above as a method of t roubleshooting components.

Once a component has been i nstalled in a printer, it cannot be used in anot her printer. It mu st be return ed to the m a nu fa c t u rer.

This error code indicates a mismatch between the operator panel assembly and the system card.

Step Questions / actions Yes No

1 Has the operator panel assembly been

recently replaced?

950.30–950.60 EPROM mismatch failure

Warning: When replacing any one of the following components:

• Operator panel assem bly

• System card

• Printhead assembly

Warning: Never install and r em ove components listed above as a method of t roubleshooting components.

Once a component has been i nstalled in a printer, it cannot be used in anot her printer. It mu st be return ed to the m a nu fa c t u rer.

This error code indicates a mismatch between the system card and the smart chip card.

Models C52x only

Replace the operator panel assembly with a new, and not previously installed operator panel assem bly. See “Operator panel

assembly removal” on page 4-23.

Replace the syste m card with a new, and not previously installed system card. See “System card

removal” on page4-92.

Step Questions / actions Yes No

1 Has the smart chip card been recently

replaced?

2-50 Service Manual

Replace the smart chi p card with a new, and not previously installed smart chip card. See “Smart chip

card removal—models C52x only” on page 4-91.

Replace the syste m card with a new, and not previously installed system card. See “System card

removal” on page4-92.

5022-xxx

Models C53x only

Step Questions / actions Yes No

1 Has the printhead been recently replaced? Replace the printhead with

a new, and not previously installed sma rt chip card. See “Prin th e a d re moval,

installation, and adjustment” on pa ge 4-74.

Dead printer service check

A dead printer is a condition wher e the display is b lank, the LED on the operator panel is off, no fans turn, no motors turn, and the fuser lamp does not come on.

If a 500-sheet option assembly (C52x mode ls) or a 550-sheet option assembly (C53x models) is inst alled, remov e the opti on and chec k the base printer f o r correc t opera tion. If the bas e printer oper ates cor rec tly, replace the 500-sheet opt ion assembly.

Warning: Observe all necessary ESD precautions when remo ving and handling the system card or any

installed op ti on cards or assemblies. See “Handling ESD-sensitive parts” on page 4-1.

CAUTION

When you see thi s symbol, ther e is a d anger from haz ardous volt age in the a rea of the p roduct where you are working. Unplug the product before you begin , or use caution if the product must receive power in order to perform the task.

Remove any input and output paper handl ing options from the printer.

Replace the syste m card with a new, and not previously installed system card. See “System card

removal” on page4-92.

Step Questions / actions Yes No

1 Check the AC line voltage.

Is the line vo lt age correct? Is the AC line co rd damaged? Replace the line cord. Go to step 3.

Check the system card for +5 V dc between

JLVPS1 pin 1 and ground. Is the voltage correct?

Is the JLVPS1 cable correctly installed at

JLVPS1 on the system card? Tur n the printer off. Disconnect the JLVPS1

cable from the system card. Turn the printer on, and measure the voltage between the JLVPS1 cable pin 1 and th e JLVPS1 pin 14 (black wire).

Does this measure approximately +5 V dc?

Go to step 2. Inform the customer.

Replace the system card. See “System card

removal” on page 4-92.

Go to step 5. Reseat the JLVPS1 cable.

Go to step 6. Replace the LVPS. See

Go to step 4.

“Low voltage power supply (LVPS) removal” on page 4-65.

Diagnostic information 2-51

5022-xxx

Step Questions / actions Yes No

Turn the printer off. Connect the JLVPS1 cable

to the syst em car d. Remove one option/featur e at a time, and turn the printer on to isolate the failing part.

Warning: Observe all the ESD precautions (see “Handling ESD-sensitive parts” on

page 4-1) and turn the printer off before any

feature or option cards are removed or replaced.

Is a failing part found?

Replace the faulty part. Contact your next level of

support.

Exit sensor service check

Step Questions / actions Yes No

1 Verify the paper is loaded properly in the

manual feed slot. See “Loading media in the

multipurpose feeder or manual feeder ” on page 3-28.

Is the paper properly lo aded in the manual feed slot?

Is the exit sensor flag damaged? Replace the fuser. See

Is the JFUSER1 properly connect ed to the

system card?

Go to step 2. Load paper in th e man ual

feed slot. See “Clearing

paper jams in the manual feeder” on pa ge 3-29.

Go to step 3.

“Fuser removal” on page 4-60.

Go to step 4. Reseat the connector.

Place a voltmeter between the JFUSER1 pin 7

and ground. Initially, the meter should indicate 5 V dc. Activate the exit sensor fl ag.

Does the volta ge drop to 0 V dc?

Replace the system card. See “System card

removal” on page 4-92.

Replace the exit sensor.

Input sensor service check

Step Questions / actions Yes No

1 Is the input sensor flag damaged? Replace the paper pick

Is the JTRAY cable connector properly

connected to the system card? Place a voltmeter between JTRAY1 pin 2 and

ground. Initially, the meter should indicate +5 V dc. Activate the input sensor flag.

Does the volta ge drop to 0 V dc?

mechanism. See “Paper

pick mechan ism assembly removal” on page 4-68.

Go to step 3. Reseat the connector.

Replace the system card. See “System card

removal” on page 4-92.

Go to step 2.

Replace the paper pick mechanism. See “Paper

pick mecha nism assembly removal” on page4-68.

2-52 Service Manual

5022-xxx

Operator panel service check

Warning: When replacing any one of the following components:

• Operator panel assem bly

• System card

• Printhead assembly

Warni ng: Never install and remove components listed above as a method of troubl eshooting

components. On ce a component has been installed in a printer, it cannot be used i n another printer. It must be returned to the manufacturer.

One or more operator panel buttons fail

Step Questions / actions Yes No

1 Run the Button Test. See “Button Test” on

page 3-11 in Diagnostics mode.

Did any of the buttons fail the test?

Disconnect the operator panel assem bly cable

from JOPP1 on the system card, and measure the voltag e on pin 6 and ground.

Does the volta ge me asure approximately +3.3 V dc?

Replace the operator panel assembly. See “Operator

panel assembl y rem oval” on page 4-23.

Replace the operator panel assembly. See “Operator

panel assembl y rem oval” on page 4-23. If this does

not fix the problem, replace the top cov er access assembly. See “T op acce ss

cover assembly removal— model C52x only” on page 4-28 or “Top access cover assembly removal— model C53x only” on page 4-32.

Go to step 2.

Replace the syste m card. See “System card

removal” on page4-92.

Operator panel display blank, five beeps, and LED off

Service tip: The printer ha s detected a problem with the system card, the operator panel assembly cable (part of the top cover access assemb ly) , or the operator panel assembly if POST does not complet e. The printer emits five beeps, and sticks in a continuous pattern until the printer is turned off.

Step Questions / actions Yes No

1 Is the opera tor panel assembly cable properly

installed at system card JOPP1 and at the operator panel assem bly?

Go to step 2. Reinstal l the cable.

Measure the voltage between JOPP1 pin 2

and ground on the system card. Is the voltage approximately +5 V dc?

Check continuity of the operator panel

asse m bly cabl e. Is there continuity?

Go to step 3. Replace the system card.

Replace the operator panel assembly. See “Operator

panel assembl y rem oval” on page 4-23.

See “System card

removal” on page4-92.

Replace the top cover access ass em bly. See “Top

access cover assem bly removal—model C52x only” on page4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Diagnostic information 2-53

5022-xxx

Operator panel display blank, five beeps, LED on

Step Questions / actions Yes No

1 Check for ground between JOPP1 pi n 4 and

ground. Is the voltage approximately 0 V dc?

Check the operator panel assembly cable.

Is the cable damaged?

Replace the operator panel assembly. See “Operator

panel assembl y rem oval” on page 4-23.

Replace the top cover access assembl y. See “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Go to step 2.

Replace the syste m card. See “System card

removal” on page4-92.

Operator panel display all diamonds, no beeps

Step Questions / actions Yes No

1 Check the operator panel assembly cable.

Is the cable damaged?

Measure the voltage between JOPP1 pin 2

and ground on the system card. Is the voltage approximately +5 V dc?

Replace the top access cover assem bly. See “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Replace the operator panel assembly. See “Operator

panel assembl y rem oval” on page 4-23.

Go to step 2.

Replace the syste m card. See “System card

removal” on page4-92.

Operator panel display all diamonds, five beeps

Step Questions / actions Yes No

1 Check the operator panel assembly cable.

Is the cable damaged?

Measure the voltage between JOPP1 pin 2

and ground on the system card. Is the voltage approximately +5 V dc?

2-54 Service Manual

Replace the top access cover assem bly. See “Top

access cover assem bly removal—model C52x only” on page 4-28 or “Top access cover assem bly removal—model C53x only” on page 4-32.

Replace the operator panel assembly. See “Operator

panel assembl y rem oval” on page 4-23.

Go to step 2.

Replace the syste m card. See “System card

removal” on page4-92.

5022-xxx

Print quality servic e chec k

Note: This symptom m ay require replacement of one or more CRUs (Customer Replaceable Unit s) designated as supplies or maintenance i tems, which are the responsibi lity of the customer. Wi th the customer' s permission, you may need to install a dev eloper (toner) cartridge or photoc onductor unit.

Service tip: Befo re tr oubleshooting any print quality probl em s, do the following:

1. Print a menu sett ings page, and check the life status of all supplies. Any suppl ies that are low should be

replaced.

Note: Be sure and keep the original menu page to restore the customer' s custom settings if needed.

2. On the menu page, make sure the following is set t o the default level: – Color Correcti o n: Se t to Auto. – Pri nt Resolution: Set to 1200 dpi (print qual ity problems should be checked at different resolution

settings).

– Toner Darkness: Set to 4 (default). – Color Saver: Set to OFF. – RGB Brightness, RGB Contrast, RGB Saturation : Set to 0. – Color Balance: Select Reset Defaults to zero out all colors. – Check the paper type , texture and weight settings against what is loaded in the printer.

Once the printer has been restored to its default levels, do the fol lowing:

3. Inspe ct t he transfer bel t for damage. Repla ce if damaged.

4. Inspe ct the OPCs and toner cartridges for damage. Replace if damaged.

5. If paper other than 20lb plain letter /A4 paper is being used, load 20lb plai n letter/A4 and print the Print

Quality pages to see if the problem remains.

6. Use Tray 1 to test print quality problems .

7. Print the Print Qual ity Pages, and looked for vari ations in the print from what is expected.

An incorrect printer d rive r f or the in st alled softw are can c ause prob lems . Incorrect cha ract ers could print , a nd the copy may not fit the page correc tl y.

Measure all voltages from the connector to the printer ground.

Print quality—background

Service tip: Some background p roblems 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 backgr ound problems. Some problem s occur with printers that run a large amount of graphics in a humid environment.

Step Questions / actions Yes No

1 Read the current status of the photocondu ctor

unit from the custom er menus. To view the status of the photoconductor units:

1.In Ready mode, press .

2.Select Reports, and press .

3.Select Device Statistics, and press .

Ask the customer if the photoconductor unit has been recently replaced. It is possibl e the photoconductor value was not reset and the photoconductor unit is past end of life. If the PC unit was recently rep laced, reset t he value. If the PC unit was n ot repl aced , repl ace the PC unit.

Has the photoconductor unit been recently replaced?

Reset the value. To reset this value:

1.In Ready mode, press .

2.Select Supplies Menu,

and press .

3.Select Replace Supply,

and press .

4.Select the PC color unit

you want to change , and press .

5.Select Yes, and press

If this does not fix the problem, go to st ep2.

Go to step 2.

Diagnostic information 2-55

5022-xxx

Step Questions / actions Yes No

Replace the PC unit. See “Photoconductor

unit removal” on page 4-70.

Does this fix the prob lem? Check the high volt age contact from t he HVPS

to the transfer belt assembly.

Transfer belt high voltage path (typical 4X)

Is a problem found? Reseat the JHVPS connector.

Does this fix the prob lem? Replace the HVPS. See “High voltage power

supply (HVPS) removal” on page 4-62.

Does this fix the prob lem?

Problem solved. Go to step 3.

Replace the spring or the transfer contact assembly. See “Transfer contact

assembly removal” on page 4-104.

Problem solved. Go to step 5.

Problem solved. Go to step 6.

Go to step 4.

Clean the printhead.

Does this fix the prob lem?

Problem solved. Replace the printhead. See

“Pri nthead removal , installation, and adjustment” on page 4-74.

Print quality—blank page

Step Questions / actions Yes No

1 Is all the packing material for the

photoconductor unit in question removed? Replace the photoco nductor unit for the col or

in question. Does this fix the prob lem?

Go to step 2. Remov e the packing

material.

Problem solved. Go to step 3.

2-56 Service Manual

5022-xxx

Step Questions / actions Yes No

Enter the Diagnostics mode (turn off the

printer , press and hold and , turn on the printer , and re lease the butt ons when the cloc k graphic displays), and run the appropriate cartridge drive mo tor test f or the missing color. See “General motor tests” on page 3-8.

Did the motor run?

Check the high volt age contact from t he HVPS

to the photoconduc tor charge roll. Ensure the contact springs are properly mounted and that the charge roll contact spring is making good contact with the HVPS spring that runs through the left printer frame. See “Transfer contact

assembly removal” on page 4-104 to view

the proper mounti ng and for removal procedures.

High voltage

power supply

High voltage

contact path

Go to step 5. Replace the EP drive

Replace the t ransfer contact assembly. See “Transfer

contact assembly removal” on page 4-104.

assembly. See

“Electropho tographic (EP) drive assembly removal— model C52x only” on page 4-48 or “Electropho tographic (EP) drive assembly removal— model C53x only” on page 4-51.

Go to step 6.

Are the spring(s) defective? Turn off the printer and chec k the continuity of

the HVPS cable.

Pin 1

Pin 24

Pin 23

Pin 2

Pin 1Pin 2

Is there continuity?

Go to step 7. Replace the cable assembly.

Pin 23

Pin 24

Diagnostic information 2-57

5022-xxx

Step Questions / actions Yes No

Replace the HVPS. See “High voltage power

supply (HVPS) removal” on page 4-62.

Did this fix the problem? Replace the printhead. See “Printhead

removal , installation, and adjustment” on page 4-74.

Did this fix the problem?

Problem solved. Go to step 8.

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

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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 driv e assem bly and transfer belt assemb ly for correct operation.

Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, or duplex paper path.

Check the high voltage spring contact s to ensure they are not bent, corroded, or damaged. Replace as necessary.

Print quality—half-color page

A photoconductor unit is not properly seated. Reset the specific photoconductor unit.

Print quality—horizontal banding

Step Questions / actions Yes No

1 Measure the dis tance between repeati ng

bands. Is the distance between bands either 27 or

36mm?

Replace the print cartridge. Replac e the photoconduc tor

unit. See “Photoconductor

unit removal” on page 4-70.

Print quality—horizontal line

The photoconductor unit is defect ive. Replace the photo conductor unit.

Print quality—insufficient fusing

Step Questions / actions Yes No

1 Is the fuser p roperly installed? Go to step 2. Install the fus er properly.

Replace the fuser. See “Fuser removal” on

page 4-60.

Does this fix the prob lem?

Problem solved. Replace the LVPS. see

“Low voltage power supply (LVPS) removal” on page 4-65.

Print qual i ty—missin g image at edge

Reseat the developer cartridge.

Print qual i ty—mottle (2–5mm sp eckles)

Keep running prints through, and the problem normally clears up. If the problem persists, replace the developer cartridge.

Print quality—narrow vertical line

Step Questions / actions Yes No

1 Replace the photoconductor unit. See

“Photoconductor uni t removal” on page 4-70.

Problem solved. Replace the print cartridge.

Diagnostic information 2-59

5022-xxx

Print quality—random marks

Service tip: The primary cause of random ma rks is due to lo ose m aterial moving around insi de the printer and attaching to the phot oconductor unit, de veloper roll, or transf er belt.

Step Questions / actions Yes No

1 Is there an y loose or foreign materi al on t he

photoconductor unit?

Is there any loo se or foreign material on the

cartridge roll? Is there any loo se or foreign material on the

transfer belt?

Replace the pho toconductor unit. See “Photoconductor

unit removal ” on page 4-70.

Replace the print cartridge. Go to step 3.

Replace the tran sfer belt. See “Transfer belt

removal” on page 4-103.

Go to step 2.

Contact your next level of support.

Print quality—residual image

Service tip: Install a new print cartridge if availab le before doin g thi s servic e check. Residual image can be caused by the photoconductor, cleaning blade, and other parts inside the print cartridge.

Step Questions / actions Yes No

1 Is there an y toner contamination on the fu ser

assembly?

Replace the fuser. See

“Fuser removal” on page 4-60.

Contact your next level of support.

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Print quality—solid color page

Service tip: A solid color page is generally caused by a problem in the high voltage system or an inco rr ect high voltage i n the pri nting process resulti ng in toner devel opm ent on the entire photoconductor drum.

Step Questions / actions Yes No

1 Replace the photoconductor unit for the color

in question. Does this fix the prob lem?

Check the high volt age contact from t he HVPS

to the photoconduc tor charge roll. Ensure the contact springs are properly mounted and that the charge roll contact spring is making good contact with the HPVS spring that runs through the left printer frame. See “Transfer contact

assembly removal” on page 4-104 to view

the proper mounti ng and for removal procedures.

High volt power supply

High volt contact path

Problem solved. Go to step 2.

Replace the t ransfer contact

Go to step 3.

assembly. See “Transfer

contact assembly removal” on page 4-104.

Note: Printer is shown with components removed for clarity

Are the spring(s) defective?

Diagnostic information 2-61

5022-xxx

Step Questions / actions Yes No

Tur n the printer off, and check the continuity of

the HVPS cable.

Pin 1

Pin 24

Pin 23

Pin 2

Pin 1Pin 2

Is there continuity? Replace the HVPS. See “High voltage power

supply (HVPS) removal” on page 4-62.

Did this solve the problem?

Print quality—vertical banding

Replace the developer cartridge.

Go to step 4. Replace the cable assembly.

Pin 23

Pin 24

Problem solved. Replace the system card.

See “System card

removal” on page4-92.

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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 tha t can be accessed during POR to identify problems with the printer.

Diagnostics menu 1. Turn off the printer.

2.Press and hold and .

3.Turn on the printer.

4.Release the buttons when th e clock graphic display s.

Configuration menu 1.Turn off the printer.

2.Press and hold and .

3.Turn on the printer.

4.Release the buttons when th e clock graphic display s.

To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics mode.

The Diagnostics me nu group contains the settings and operations used while manufacturing and servicing the printer.

See “Diagnostics menu” on page 3-2 for more information.

The Configuration menu group contains a set of menus, setti ngs, and operations which ar e infrequently required by a user. Generally, the options made available in this men u group are used to configure a printer for operatio n.

See “Configuration menu (CONFIG MENU)” on

page 3-20 for more info r m a tion.

Diagnostic aids 3-1

5022-xxx

Diagnostics menu

Note: T ray 2 refers to the 500-sheet tray located in the 500-sheet option assembly.

Diagnos tics menu structu re

When the Diagnosti cs mode is ent ered, each Di agnosti cs main menu i t em displays on the operator panel. When a diagnostic test is selected from the main menu, a sub menu displays and each individual test displays in the order shown. Any options that are ref erred to in the menus are displayed when the option is installed.

Available tests

The tests display on the operator panel in the order shown:

Diagnostics mode tests

REGISTRATION

Top Margin See “Registration” on page 3-4. Bottom Margin Left Margin Right Margin Skew See “Skew” on page 3-4. Qui ck Test See “Quick Test” on page 3-6.

ALIGNMENT

Cyan See “Alignment” on page 3-7. Yellow Magenta Fact ory Scanner Factory Man ual A sum m ary page for all the color alignmen t settings. Can be used in place

MOTOR TESTS (or der differs depen ding upon model)

Align Motor Test Tests the bump aligner motor. See “General motor tests” on page 3-8. Fuser Tests the fuser motor. See “General moto r tests” on page 3-8. Tray 1 Tests tray 1 motor located in the paper pick mechanism. See “General

Tray 2 (if installed) Tests tray 2 motor located in the paper pick mechanism. See “General

Bottom Cartridge T ests the bottom cartridge motor locate d on the EP drive assembly. See

Top Cartridge Tests the top cartridge motor located on the EP drive assembl y. See

Transf er Tests the transfer belt assem bly motor located on the EP drive assembly.

Mirror Motor Test Tests the mirror motor located in the printhead assembly. See “Mirror

Motor Calibration Synchronizes the bump ali gner and fuser motor speeds with the transfer

Servo Laser Test Tests servo laser located in the print head. See “Servo Laser Test” on

of alignment pages f or each individual color.

motor tests” on page 3-8.

“General motor tests” on page 3-8.

See “General motor test s” on page 3-8.

Motor Test” on page 3-8.

belt speed to ensure that out put is printed correctly. See “Motor

Calibration” on page 3-9.

page 3-9.

3-2 Se rvice Ma nual

5022-xxx

Diagnostics mode tests (continued)

PRINT TESTS

Tray 1 See “Inp ut source tests” on page 3-9. Tray 2 (if installed) Manual Feed er (i f installed) MP Feeder Prt Quality Pgs See “Print quality test pages (Prt Quality Pgs)” on page 3-10.

HARDWARE TESTS

Panel Test See “Panel Test” on page 3-11. Button Test See “Button Test” on page 3-11. DRAM Test See “DRAM Test” on page 3-11. CACHE Test See “CACHE Test” on page 3-12.

DUPLEX TESTS (if installed)

Qui ck Test See “Quick Test (duplex)” on page 3-12. Print Test See “Print Test (duplex)” on page 3-13. Top Margin See “Top Margin (duplex)” on page 3-14. Motor Test See “Motor Test (duplex)” on page 3-14.

INPUT TRAY TESTS (if Tray 2 is installed)

Tray 2 See “Inp ut Tray Tests ” on page 3-14.

BASE SENSOR TEST

Bin Full Test See “Bin Full Te st” on page 3-15. Sensor Test See “Sensor Test” on page 3-15.

PRINTER SETUP

Defaults See “Defaults” on page 3-16. PAGE COUNTS This menu contains three sub menus : Prt Color Pg Count, Mono Pg Count,

Serial Number See “Serial Number” on page 3-16. Engine Setting 1 through 4 S ee “Engine Setting 1 through 4” on page 3-16. Model Name See “Model Name” on page 3-16. Configuration ID See “Configuration ID” on page 3-16.

EP SETUP

EP Defaults See “EP Defaults” on page 3-17. Fuser Temp See “Fuser Temperature (Fuser Temp)” on page 3-17. DC Charge Adjust See “DC Ch arge Adjust, Dev Bias Adj, Transfer Adjust” on page 3-17. Dev Bias Adj Transf er Adjust

EVENT LOG

Display Log See “Display Log” on page 3-18. Print Log See “Print Log” on page 3-18. Clear Log See “Cle ar Log” on page 3-19.

EXIT DIAGNOSTICS This selection exits Diagnostics mode, and Resetting the Pri nt er

and Perm Pag e Count. See “Page Counts” on page 3-16.

displays. The printer performs a POR, and returns to normal mode.

Diagnostic aids 3-3

5022-xxx

Registration

Note: If you need to perform alignment or registration, see “Printhead alignment” on page 4-3. The foll owing information is meant to explain the uses for the menu items. Print registr ation makes sure the black printing is properly aligned on the page. This is one of the steps in

aligning a ne w printhead. It is also the first st ep in al igning the duple x regi stration. See “Quick Test (duplex)”

on page 3-12.

The settings a vailable ar e:

Top Margin Bottom Margin Left Margin Right Margin Skew Quick Test

Skew

One printhead houses th e four color planes. The black plane is aligned to the printer, and the color planes are internally aligned to black. Adju st the skew mechanically by moving th e print head with a printhead adjustment screw. See “Printhead mechanical alignment” on page 4-3 for instructions on setting printhead alignment. Electronic alignment fine tunes the alignm ent of the color planes to the black plane once the printhead is installed. Skew adjustment must be performed bef ore color alignment is attempted. The following illustrat ion shows proper alignment versus skewed alignmen t.

Lexmark C52X Quick Test

Printer Information

Page Count xx PSAC xx Installed Memory xxx MB Processor Speed xxxMHz Serial Number xxxxxxx CalStat xxxx CalSet x.xx x.xx x.xx x.xx x.xx Engine ID xx FSpeed xxx Printer Revision Levels Loader xx.xx.xxxx-x Kernel xxx.xx.xxxx-x Base xx.xx.xxxx-x Network xxx.xx.xxxxx-x Network Drvr xx.xx.xxxx-x Engine xx.xx.xxxx-x Font x.xxxxx-xx.x

Proper skew Improper skew

Straight Skewed

Lexm

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C52X

Quick Test

Printer Inform

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xx xx xxx

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Margin Settings

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Left M

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Margin Settings

Top Margin = x Bottom Margin = x Left Margin = x Right Margin = x Skew = x Cyan Top Margin = x Cyan Left Margin = xx Cyan Right Margin = x Cyan Skew = x Cyan Bow = x Yellow Top Margin = x Yellow Left Margin = x Yellow Right Margin = x Yellow Skew = x Yellow Bow = x Magenta Top Margin = x Magenta Left Margin = x Magenta Right Margin = x Magent Skew = x magenta Bow = x Dup Top Margin = x

Paper Source = Tray 1 Formatted Size = xxxxxx

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3-4 Se rvice Ma nual

5022-xxx

Print registration

To se t p r in t re g is tra tion:

1. Select REGISTRATION from the DIAGNOSTICS menu.

2. Select Quick Test, and press Select ().

To print the Quick Test page:

a. Press until the appears ne xt to Quick Test. b. Press Select ().

The message Quick Te st Printin g… appears on the display.

Retain this page to det ermine the changes you need to make to the ma rgin settings.

3. Use or to select the margin setting you need to change, and press Select ().

4. Use to decrease or to increase the offset values, and press Select ( ) to confirm the value.

The message Su bm it ting se le ct io n displays, and the original REGISTRATION screen appears with the beside the previously selected margin setting.

The print registration range is:

Description Value Direction of change

Skew Each increment corresponds to

Top margin -25 to +25 Each increment

Bottom margin -20 to + 20 Each increment causes

Left margin -25 t o +25 Each increment

Right margin -10 to +10 Each in crement

1/1200 of an inch.

corresponds to 8 scans at a 600 dpi scan rate (0.0133 inches or 0.339 mm)

approximately 0.55 mm shift in the bottom margin.

corresponds to 4 pels at 600 dpi (0.00666 in. or 0.1693 mm).

corresponds to an approximate shift of 4 pels at 600 dpi.

A positive value causes the right end of the scan line to move down the page. A negative value causes the right end of the scan line to move up the page . The l eft end stays fixed.

A positive change moves the image down the page and increases the top margin. A negative change moves t he image up and decreases the top margin.

A positive offset moves text up the page and widens the bottom margin, while a negative offset moves text down the page and narrows the bottom margin.

A positive change moves the image to the left, and a negat ive change moves the image to th e right. No compression occurs.

A positive change moves the image to the right, and a negative change moves the image to the left.

5. Continue changing the settings by repeating steps 2 through 4.

6. Print another copy of the Quick Test to verify y our changes.

7. To exit REGISTRATION, press Back ().

Diagnostic aids 3-5

5022-xxx

Quick Test

The Quick Test contains the following information:

• Print registration settings

• Alignment diamonds at the left, right, top and bott om

• Horizontal lines to check for skew

• General print er i nformation, including current page count , in stalled memory, serial number, and code level.

To print the Quick Test page:

Note: Print the Quick Test Page on letter or A4 paper.

1. Select REGISTRATION from DIAGNOSTICS.

2. Press until t he appears next to Quick Test.

The message Quick Te st Printing … appears on the display. Once the Quick Test Page completes printing, the Registration screen displays again.

3-6 Se rvice Ma nual

Lexmark C52, C53 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual