Lexmark C522 Service Manual
Lexmark C522 Manual
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- Lexmark C522 | Service Manual - Page 1
Lexmark™ C520, C522, C524, C530, C532, C534 5022-xxx • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. - Lexmark C522 | Service Manual - Page 2
™ C52x and C53x color laser printers deliver superior text and brilliant graphics. The following models are available. Model name Lexmark C520n Lexmark C522n Lexmark C524 Lexmark C524n Lexmark C524dn Lexmark C530dn Lexmark C532n Lexmark C532dn Lexmark C534n Lexmark C534dn/dtn Configuration Network - Lexmark C522 | Service Manual - Page 3
C534dn, and C534dtn - Lexmark ImageQuick™ Card is available (if activated) Memory configuration Memory type Models C520n C522n C524 C524n C524dn C530dn C532n C532dn C534n Printer options installed or selected • Available memory in the printer • Media size and type • Resolution 1-2 Service Manual - Lexmark C522 | Service Manual - Page 4
Saver on - Lexmark C522 | Service Manual - Page 5
as paper OCF, EP cartridge usage) are specified to be measured at an ambient condition. Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296. Printer Operating mode C520n, C522n dBA 51 dBA 53 dBA 31 dBA 6.7B 6.6B 4.6B 6.7B 6.6B 6.7B 4.6B 1-4 Service Manual - Lexmark C522 | Service Manual - Page 6
Optional 550-sheet C53x models 5 in. assembly only MPF configuration (printer with multipurpose feeder extended and exit tray extended) C52x, C53x models 19 in. (484 mm) Primary tray configuration (printer with paper tray adjuster extended and output bin installed) A4/letter size media 19 - Lexmark C522 | Service Manual - Page 7
problems. Curl can occur after the media passes through the printer trays, can contribute to media curling prior to printing and can cause feeding problems. Smoothness Media smoothness directly affects print quality. If media is too rough, toner the printer to feed printer printer problems - Lexmark C522 | Service Manual - Page 8
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 post-consumer waste that ensure trouble-free - Lexmark C522 | Service Manual - Page 9
laser printers. Page orientation is important when printing on letterhead. Use the following table for help when loading letterhead. Process or paper source Tray 1 Tray 2 Duplex (two-sided) printing from trays 1 and 2 Multipurpose feeder Manual prevent print quality problems, avoid getting - Lexmark C522 | Service Manual - Page 10
Guide available on the Lexmark Web site at www.lexmark.com/publications. Note: Vinyl labels are not supported on this product. Use only paper labels. When printing on labels: • From the printer the printer and the cartridge with adhesive, and could void the printer and cartridge warranties. - Lexmark C522 | Service Manual - Page 11
paper handling problems printer. Preprinting introduces semi-liquid and volatile components into the printer Supported sizes The following tables provide information on standard and optional sources for both input and output trays and bins. 250 Tray MPF Duplex 500 Tray Manual 1-10 Service Manual ✓ ✓ - Lexmark C522 | Service Manual - Page 12
lb/ 65 lb (135 g/m2 / 176 g/m2) Index 67 lb/ 90 lb (120 g/m2 / 163 g/m2) Labels (max) Tag Paper 74 lb/ 100 lb (120 g/m2 /163 g/m2) 35 lb (131 g/m2) Letter, Legal, A4 (continued) Transparency Vinyl Not Supported Thickness: 0.12 161 to 179 g/m2 to 0.13 mm General information 1-11 - Lexmark C522 | Service Manual - Page 13
operating environment. Note: Paper input is limited to below the 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 - Lexmark C522 | Service Manual - Page 14
machine type The serial number is located on the label on the rear of the right cover and on the service tag located on the inside right frame of the printer. The service tag also contains the configuration IDs, machine type, and model information. Config IDs Machine type Serial number Serial number - Lexmark C522 | Service Manual - Page 15
Photoconductor Picture element Power-On Reset Power-On Self Test Pulse Width Modulation Raster Imaging Processor Synchronous Dual Random Access Memory Single Inline Memory Module Static Random Access Memory Toner Adder Roller Volts alternating current Volts direct current Yellow 1-14 Service Manual - Lexmark C522 | Service Manual - Page 16
of the printer. • User attendance messages are indicated by a two-digit code that provides the user with information 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 - Lexmark C522 | Service Manual - Page 17
item and display the default setting. • Save the displayed menu item as the new user default setting. The printer issues a Saved or Submitted Selection message and returns to the menu item. Note: When a new setting is values. Release the button when the needed number appears. 2-2 Service Manual - Lexmark C522 | Service Manual - Page 18
keypad 5022-xxx Function The two-toned light emitting diode called the indicator light on the operator panel gives information about the status of the printer using the colors red and green. Indicator light status Off Blinking green Solid green Solid red Indicates - Lexmark C522 | Service Manual - Page 19
based on the printer model or the options installed. Supplies Menu Replace Supply Cyan Cartridge Magenta Cartridge Yellow Cartridge Black Cartridge Cyan PC Unit Magenta PC Unit Yellow PC Unit Black PC Unit Waste Toner Box Fuser Transfer Belt Paper Menu Default Source Paper Size/Type Configure - Lexmark C522 | Service Manual - Page 20
print cartridge is missing. • Any cartridge errors, such as Defective Cartridge or Missing Cartridge. 12. Ready appears on the display. 13. The main drive motor turns on. 14. The EP drive assembly drives the developer shaft located in the toner cartridge. 15. The exit rollers turn. 16. The printer - Lexmark C522 | Service Manual - Page 21
continuously displays all diamonds and does not complete POST. Action Go to "Dead printer service check" on page 2-51. Go to "One or more operator panel buttons fail 59. Go to "Print quality-solid color page" on page 2-60. Go to "Print quality-vertical banding" on page 2-61. 2-6 Service Manual - Lexmark C522 | Service Manual - Page 22
"120.01, 120.02, 120.08-120.10, 120.13-120.15-Fuser error service check" on page 2-28. 140.03-140.08 Autocomp Motor Error Tray 1 motor has failed. POR the printer. If the error message persists, see "140.xx-Autocomp (tray 1) motor error service check" on page 2-32. 142.09-142.18, 142.20-142.25 - Lexmark C522 | Service Manual - Page 23
page 2-37. POR the printer. If the error message persists, see "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 - Lexmark C522 | Service Manual - Page 24
flag • Damaged fuser autoconnect • Faulty fuser DC cable connection • Faulty fuser • Faulty system card Action • 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 - Lexmark C522 | Service Manual - Page 25
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 drive assembly top cartridge) error service check" on page 2-34 and then "144.xx-Motor (EP drive assembly bottom cartridge) error service check" on page 2-35 - Lexmark C522 | Service Manual - Page 26
causes: • Faulty cable/connector • Faulty fuser motor • 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 "142.xx and 906.01-906.04-Motor (fuser) error service check" on page 2-33. During duplex - Lexmark C522 | Service Manual - Page 27
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 page 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 - Lexmark C522 | Service Manual - Page 28
. • If the previous actions do not fix the problem, go to "140.xx-Autocomp (tray 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 - Lexmark C522 | Service Manual - Page 29
, and stack it flat in the 500-sheet tray (tray 2). • If the previous actions do not fix the problem, go to "147.xx, 149.xx-Motor (500-sheet/550sheet option tray 2 motor) error service check" on page 2-37. • Ensure proper media is set for the type of paper used. • Fan media, and stack it flat in - Lexmark C522 | Service Manual - Page 30
for the type of paper used. • Fan media, and stack it flat in the tray or MPF. • Replace the MPF swing arm assembly. "Multipurpose feeder (MPF) swing arm assembly removal-models C52x only" on page 4-67. • If the previous actions do not fix the problem, go to "148.xx-MPF motor error service check" on - Lexmark C522 | Service Manual - Page 31
(power on self test) error service check" on page 2-38. Tray 1 motor not connected. See "920.02-POST (power on self test) error service check" on page 2-38. Transfer belt not connected. See "920.03-POST (power on self test) error service check" on page 2-38. Fuser motor not connected. See "920 - Lexmark C522 | Service Manual - Page 32
has failed. 946.03 Transfer Roll Magenta transfer roll has failed. 946.04 Transfer Roll Black transfer roll has failed. 947.01 Transfer Roll Yellow transfer roll has failed. POR the printer. If the error message persists, see "945.xx, 946.xx, 947.xx-Transfer roll error service check" on page - Lexmark C522 | Service Manual - Page 33
removal" on page 4-79. POR the printer. If the error message persists, replace the system card. See "System card removal" on page 4-79. POR the printer. If the error message persists, replace the system card. See "System card removal" on page 4-79. Replace 500-sheet assembly. 2-18 Service Manual - Lexmark C522 | Service Manual - Page 34
If the problem still exists, replace the system card. See "System card removal" on page 4-79. • Check to see if the toner cartridge is a supported cartridge. Note: Once the cartridge shipped with the printer is exhausted, it must be replaced by a supply cartridge (refer to the User's Guide for part - Lexmark C522 | Service Manual - Page 35
"System card removal" on page 4-79. • The printer deleted some held jobs in order to process current jobs. • Press until Continue appears, and then press to clear the message. • If this does not fix the problem, replace the system card. See "System card removal" on page 4-79. 2-20 Service Manual - Lexmark C522 | Service Manual - Page 36
flash detected 54 Serial option error • The printer was unable to restore some or all current job. • Install additional printer memory. • If this does not fix the problem, replace the system card. memory before downloading any resources to flash. • If this does not fix the problem, replace the - Lexmark C522 | Service Manual - Page 37
removal" on page 4-79. 58 Too many trays attached 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 fix the problem, replace the system card. See "System - Lexmark C522 | Service Manual - Page 38
not possible, contact your next level of service. • Replace the waste toner box using the instruction sheet that comes with the replacement waste toner box. • Ensure that there is no interference between the waste toner box and the printer. • If the problem persists, open the front access door and - Lexmark C522 | Service Manual - Page 39
removal" on page 4-79. 84 Replace PC Unit • Replace the specified photoconductor unit using the instruction sheet that comes with the replacement specified photoconductor unit. • If the problem persists, replace the system card. See "System card removal" on page 4-79. 2-24 Service Manual - Lexmark C522 | Service Manual - Page 40
attendance messages (continued) Error code 84 PC Unit missing Action • Scroll down the operator panel to see if the printer is showing that all contact. • Insert or reinstall the specified photoconductor unit and see if problem clears. See "Photoconductor unit removal" on page 4-70. • - Lexmark C522 | Service Manual - Page 41
Pin 10 • If continuity is not present, replace the fuser cable. If the problem persists after replacing cable, replace the system card. See "System card removal" on page 4-79. 88 Cartridge low • Replace the specified toner cartridge. • Press until Continue appears, and then press to clear - Lexmark C522 | Service Manual - Page 42
page 4-74. Problem solved. No Go to step 2. Replace the system card. See "System card removal" on page 4-79. 111.xx, 112.xx, 113.xx, and 114.xx-Printhead error service check Step Questions / actions Yes 1 Is the front access door completely closed? Go to step 2. 2 Turn the printer off, and - Lexmark C522 | Service Manual - Page 43
and DC autoconnects on both the fuser and the printer for damage. Are the connectors damaged? Replace the fuser cable. Replace the LVPS cable. See "Low voltage power supply (LVPS) removal" on page 4-65. Replace the appropriate cable. Go to step 4. Go to step 5. Go to step 6. 2-28 Service Manual - Lexmark C522 | Service Manual - Page 44
1 Pin 2 Pin 3 AC autoconnect Pin 5 Pin 4 Pin 1 Is continuity present? 8 Replace the fuser. See "Fuser removal" on page 4-60. Does the error clear? Problem solved. 5022-xxx No Replace the DC fuser cable. Replace the AC fuser cable. Replace the system card. See "System card removal" on page 4-79 - Lexmark C522 | Service Manual - Page 45
removal" on page 4-60. Does the error clear? Problem solved. No Set the switch for proper the country voltage. Go to step 3. Go to step 4. Replace the system card. See "System card removal" on page 4-79. 120.04-120.07-Fuser error service check Step Questions / actions Yes 1 Check the input - Lexmark C522 | Service Manual - Page 46
Pin 1 Is continuity present? 6 Reinstall the fuser. See "Fuser removal" on page 4-60. Does the error clear? 7 Replace the fuser. See "Fuser removal" on page 4-60. Does the error clear? Problem solved. Problem solved. 5022-xxx No Replace the DC fuser cable. Replace the AC fuser cable. Go to step - Lexmark C522 | Service Manual - Page 47
(tray 1) motor error service check Step Questions / actions Yes No 1 Turn the printer off paper pick mechanism. See "Paper pick mechanism assembly removal" on page 4-68. Does the error clear? Problem solved. Replace the system card. See "System card removal" on page 4-79. 2-32 Service Manual - Lexmark C522 | Service Manual - Page 48
5022-xxx 142.xx and 906.01-906.04-Motor (fuser) error service check Step Questions / actions 1 Is the top access door completely closed? 2 Turn the printer off, and remove the fuser. Yes No Go to step 2. Close the top access door. Lift the top access door to its widest position, and put - Lexmark C522 | Service Manual - Page 49
5022-xxx 143.xx-Motor (EP drive assembly top cartridge) error service check Step Questions / actions Yes No 1 Turn the printer off, and remove the rear cover. Check the connector JCART1 for proper connection to the system card, the cable for pinch points, and the cable - Lexmark C522 | Service Manual - Page 50
144.xx-Motor (EP drive assembly bottom cartridge) error service check Step Questions / actions Yes 1 Turn the printer off, and step 3. Is either fuse blown? 3 Replace the EP drive assembly. See Problem solved. "Electrophotographic (EP) drive assembly removal-model C52x only" on page 4-48 - Lexmark C522 | Service Manual - Page 51
Does the error clear? Problem solved. Replace the system card. See "System card removal" on page 4-79. 146.xx-Motor (duplex) error service check Step Questions / actions Yes No 1 Is the top access door completely closed? Go to step 2. Close the top access door. 2 Turn the printer off, and - Lexmark C522 | Service Manual - Page 52
error clear? Replace the option cable. Problem solved. No Go to step 2. Replace the system card. See "System card removal" on page 4-79. 148.xx-MPF motor error service check Step Questions / actions Yes No 1 Turn the printer Replace the paper pick mechanism. See "Paper pick mechanism - Lexmark C522 | Service Manual - Page 53
motor. See "Bump aligner motor removal" on page 4-40. Does the error clear? Yes Problem solved. No Replace the system card. See "System card removal" on page 4-79. 920.02-POST (power on self test) error service check Step Questions / actions Yes 1 Replace the paper pick mechanism. See "Paper - Lexmark C522 | Service Manual - Page 54
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 the fuser. See "Fuser removal" on page 4-60. Does the error clear? Problem solved. 920.05-POST (power on self test) error service check - Lexmark C522 | Service Manual - Page 55
paper pick mechanism. See "Paper pick mechanism assembly removal" on page 4-68. Does the error clear? Problem solved. No Replace the system card. See "System card removal" on page 4-79. 920.07-POST (power on self test) error service check Step Questions / actions Yes No 1 Turn the printer - Lexmark C522 | Service Manual - Page 56
fuser. See "Fuser removal" on page 4-60. Does the error clear? Problem solved. 920.09-12-POST (power on self test) error service check Replace the system card. See "System card removal" on page 4-79. Step Questions / actions Yes No 1 Turn the printer Check all the toner level sensor cables - Lexmark C522 | Service Manual - Page 57
) 4X Negative lead Waste toner assembly Is there approximately 5 V dc on any of the pins? 5 Replace the HVPS. See "High voltage power supply (HVPS) removal" on page 4-62. Does the error clear? Problem solved. Replace the system card. See "System card removal" on page 4-79. 2-42 Service Manual - Lexmark C522 | Service Manual - Page 58
(power on self test) error service check Step Questions / actions Yes No 1 Turn the printer off, and remove the cartridge motors. Pin 3 Pin 2 Pin 1 JCART1 Pin 1 Pin 2 Pin 3 To cartridge motor connector Pin 1 Pin 2 Pin 3 Is continuity present? 3 Replace the EP drive assembly. See Problem - Lexmark C522 | Service Manual - Page 59
. See Problem solved. "Electrophotographic (EP) drive assembly removal-model C52x only" on page 4-48 or "Electrophotographic (EP) drive assembly removal-model C53x only" on page 4-51. Does the error clear? Replace the system card. See "System card removal" on page 4-79. 2-44 Service Manual - Lexmark C522 | Service Manual - Page 60
55. Go to step 2. 2 Replace the transfer belt assembly. See "Transfer belt removal" on page 4-91. Does the error clear? Problem solved. Replace the system card. See "System card removal" on page 4-79. Models C53x only Step Questions / actions 1 Turn the printer off, and remove the rear cover - Lexmark C522 | Service Manual - Page 61
-model C53x only" on page 4-32. Does the error clear? Problem solved. Replace the system card. See "System card removal" on page 4-79. 920.18-POST (power on self test) error service check Step Questions / actions Yes 1 Turn the printer off, and remove the rear cover. Check the connector - Lexmark C522 | Service Manual - Page 62
1 Turn the printer off, and remove error service check Step Questions / actions 1 Replace the top access cover assembly. See "Top access cover assembly removal- model C52x only" on page 4-28 or "Top access cover assembly removal-model C53x only" on page 4-32. Does the error clear? Yes Problem - Lexmark C522 | Service Manual - Page 63
.03 945.04, 946.04, 957.04 Color JHVPS1 cable to: HVPS System card Yellow Pin 19 Pin 19 Pin 20 Pin 20 Cyan Pin 15 Pin 15 Pin 16 Pin 16 Magenta Pin 17 Pin 17 Pin 18 Pin 18 Black Pin 23 Pin 23 Pin 24 Pin 24 Is continuity present? 2-48 Service Manual - Lexmark C522 | Service Manual - Page 64
contact assembly. See "Transfer contact assembly removal" on page 4-92. yellow2 cyan2 magenta2 black2 yellow1 cyan1 magenta1 black1 Is continuity present? 4 Replace the HVPS. See "High voltage power Problem solved. supply (HVPS) removal" on page 4-62. Does the error clear? Replace the system - Lexmark C522 | Service Manual - Page 65
a method of troubleshooting components. Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer. This error code indicates a previously installed system card. See "System card removal" on page 4-79. 2-50 Service Manual - Lexmark C522 | Service Manual - Page 66
printer service check A dead printer is a condition where the display is blank, the LED on the operator panel is off, no fans turn, no motors turn, and the fuser to perform the task. Remove any input and output paper handling options from the printer. Step Questions / actions 1 Check the AC line - Lexmark C522 | Service Manual - Page 67
and turn the printer off before any feature or option cards are removed or replaced. Is a failing part found? Replace the faulty part. Exit sensor service check No Contact your next level of support. Step Questions / actions Yes 1 Verify the paper is loaded properly in the manual feed slot - Lexmark C522 | Service Manual - Page 68
a method of troubleshooting components. Once a component has been installed in a printer, it cannot be used in another printer. It must Operator panel display blank, five beeps, and LED off Service tip: The printer has detected a problem with the system card, the operator panel assembly cable ( - Lexmark C522 | Service Manual - Page 69
Service tip: The printer has detected a problem with the system card, the operator panel assembly cable (part of the top cover access assembly), or the operator panel assembly if POST does not complete. The printer Replace the system card. See "System card removal" on page 4-79. 2-54 Service Manual - Lexmark C522 | Service Manual - Page 70
Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photoconductor unit. Service tip: Before troubleshooting any print quality problems, do the following: 1. Print - Lexmark C522 | Service Manual - Page 71
, press and hold and , turn on the printer, and release the buttons when the clock graphic displays), and run the appropriate cartridge drive motor test for the missing color. See "General motor tests" on page 3-8. Did the motor run? Go to step 5. 2-56 Service Manual Go to step 5. Go to step - Lexmark C522 | Service Manual - Page 72
6. to the photoconductor charge roll. Ensure the assembly. See "Transfer contact springs are properly mounted and that contact assembly the charge roll contact spring is making good removal" on page 4-92. contact with the HVPS spring that runs through the left printer frame. See "Transfer contact - Lexmark C522 | Service Manual - Page 73
usually caused by a problem in the EP drive assembly or in the transfer belt assembly. Check the EP drive assembly and transfer belt assembly for correct operation. Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, or duplex paper path. Check the - Lexmark C522 | Service Manual - Page 74
belt? Yes No Replace the photoconductor unit. See "Photoconductor unit removal" on page 4-70. Replace the print cartridge. Go to step 2. Go to step 3. Replace the transfer belt. See "Transfer belt removal" on page 4-91. Contact your next level of support. Print quality-residual image Service - Lexmark C522 | Service Manual - Page 75
5022-xxx Print quality-solid color page Service tip: A solid color page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum. Step Questions / actions Yes No 1 Replace - Lexmark C522 | Service Manual - Page 76
4 Replace the HVPS. See "High voltage power supply (HVPS) removal" on page 4-62. Did this solve the problem? Problem solved. Print quality-vertical banding Replace the developer cartridge. 5022-xxx No Replace the system card. See "System card removal" on page 4-79. Diagnostic information 2-61 - Lexmark C522 | Service Manual - Page 77
5022-xxx 2-62 Service Manual - Lexmark C522 | Service Manual - Page 78
that can be accessed during POR to identify problems with the printer. Diagnostics menu 1. Turn off the printer. 2. Press and hold and . The Diagnostics menu group contains the settings and operations used while manufacturing and servicing the printer. See "Diagnostics menu" on page 3-2 for more - Lexmark C522 | Service Manual - Page 79
Motor Calibration Synchronizes the bump aligner and fuser motor speeds with the transfer belt speed to ensure that output is printed correctly. See "Motor Calibration" on page 3-9. Servo Laser Test Tests servo laser located in the printhead. See "Servo Laser Test" on page 3-9. 3-2 Service Manual - Lexmark C522 | Service Manual - Page 80
Test See "Motor Test (duplex)" on page 3-14. INPUT TRAY TESTS (if Tray 2 is installed) Tray 2 See "Input Tray Tests" on page 3-14. BASE SENSOR TEST Bin Full Test See "Bin Full Test" on page 3-15. Sensor Test See "Sensor Test" on page 3-15. PRINTER SETUP Defaults See "Defaults" on page - Lexmark C522 | Service Manual - Page 81
5022-xxx Registration Print registration makes sure the black printing is properly aligned on the page. This is one of the steps in aligning a new printhead. See "Printhead negative value causes the right end of the scan line to move up the page. The left end stays fixed. 3-4 Service Manual - Lexmark C522 | Service Manual - Page 82
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 Formatted Size = Tray 1 = xxxxxx Lexmark C52X Quick Test Printer - Lexmark C522 | Service Manual - Page 83
top and bottom • Horizontal lines to check for skew • General printer information, including current page count, installed memory, serial number, and Test page: Note: Print the Quick Test Page on letter or A4 paper. 1. Select REGISTRATION from DIAGNOSTICS. 2. Press until the appears next to Quick - Lexmark C522 | Service Manual - Page 84
adjusting the printhead and the color planes to the black plane and to each other. Before you start, perform the black alignment (Registration). See , and enter the best number for the top adjustment in the T space. Transfer this number over to the computation area for Z. 5. On the operator panel, - Lexmark C522 | Service Manual - Page 85
the printer as directed in the following table: Motor test Setup requirements Top access cover Front access door Align Motor Test Closed Fuser Closed Tray 1 Not applicable Tray 2 Not applicable Closed Closed Not applicable Not applicable Bottom cartridge Top cartridge Transfer Closed - Lexmark C522 | Service Manual - Page 86
test is run to match the fuser motor speed to the belt motor speed. 1. Select MOTOR TESTS from DIAGNOSTICS. 2. Select Motor Calibration. The printer generates eight pages as part of this test. To stop the test, press Stop ( ). Servo Laser Test 1. Select MOTOR TESTS from DIAGNOSTICS. 2. Select Servo - Lexmark C522 | Service Manual - Page 87
Print Test Page always prints on one side of the paper, regardless of the duplex setting. 4. Press Back ( The test prints on the media in the default tray. This test may be printed from either Configuration be canceled. When the test pages print, the printer returns to the original screen. To run the - Lexmark C522 | Service Manual - Page 88
each button one at a time, and an X appears in the box that represents that button. When you press Back ( ) or Stop in progress. Note: Turn off the printer to exit the test before the test is the memory test has failed and finished with errors. Initially, 00000 displays with the maximum fail - Lexmark C522 | Service Manual - Page 89
times the CACHE test has failed, finished with errors. Initially, 000000 is displayed. The maximum fall count is 999,999. 2. To exit the test, turn the printer off. Duplex Tests Quick Test (duplex) This test , be sure to set the registration. See "Registration" on page 3-4. 3-12 Service Manual - Lexmark C522 | Service Manual - Page 90
provides service personnel with a way to verify the function of the printer's paper you choose to print the page on should be either Letter or A4. To run the Print Test (duplex): 1. Select Print Test from DUPLEX TESTS. The printer executes a continuous print test that generates a duplexed, color - Lexmark C522 | Service Manual - Page 91
duplex unit paper feed drive system is working correctly. 1. Select Motor Test from DUPLEX TESTS. The duplex motor runs continuously until stopped. The message Motor Running displays. 2. To stop the test, press Back ( ) or Stop ( ). Input Tray Tests If tray 2 is installed, the INPUT TRAY TESTS menu - Lexmark C522 | Service Manual - Page 92
the transfer belt. The sensor should change state. Remove the cyan toner cartridge. Shine a flashlight on the toner level sensor. The sensor should change state. Remove the black toner cartridge. Shine a flashlight on the toner level sensor. The sensor should change state. Remove the magenta toner - Lexmark C522 | Service Manual - Page 93
paper size, envelope size, PCL symbol set, code pages, and units of measure. Warning: Changing this setting resets the printer the Prt Color Pg Count, the Prt Mono Pg Count, or the Perm Page Count: 1. Select PRINTER SETUP from when the printer is manufactured. However, the servicer may need to - Lexmark C522 | Service Manual - Page 94
used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media. The fuser temperature can be adjusted to: Low, Normal, High. The default is Normal. DC Charge Adjust, Dev Bias Adj, Transfer Adjust Each of these three settings enables - Lexmark C522 | Service Manual - Page 95
includes: • Detailed printer information, including code versions • Time and date stamps • Page counts for most errors • Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. 3-18 Service Manual - Lexmark C522 | Service Manual - Page 96
YES is selected, Deleting EVENT LOG displays on the screen. Press Back ( ) to return to EVENT LOG. EXIT DIAGNOSTICS Press Select to exit DIAGNOSTICS. The printer performs a power-on reset and returns to normal mode. Diagnostic aids 3-19 - Lexmark C522 | Service Manual - Page 97
C52x. Configuration menu Reset Fuser Cnt See "Reset Fuser Cnt" on page 3-21. Color Lock Out See "Color Lock Out" on page 3-21. (For models C52x: Black Only Mode) Prt Quality Menu, and Resetting the Printer displays. The printer performs a POR and returns to normal mode. 3-20 Service Manual - Lexmark C522 | Service Manual - Page 98
Motor Calibration. See "Motor Calibration" on page 3-24. To cancel a reset, press Back. Color Lock Out Called Black Only Mode in C52x models. Select On when printing for extended periods with only black toner. This saves the toner cartridges (cyan, magenta, and yellow) and photoconductor units - Lexmark C522 | Service Manual - Page 99
printer problem. When factory default settings are restored: • All downloaded resources (fonts, macros, symbol sets) in the printer printer models that have integrated network support. Restoring Factory Defaults appears on the operator panel while factory defaults are restored. 3-22 Service Manual - Lexmark C522 | Service Manual - Page 100
the transfer belt. It then uses these to calculate the appropriate amount of adjustment, if necessary. When an event initiates a TPS operation, the printer performs a toner density calibration, an alignment calibration, or both of the calibrations. Selections are On (default) and Off. Auto Color Adj - Lexmark C522 | Service Manual - Page 101
Order Lets the system support person set whether the color order of the cartridges inside the printer is enforced and if messages appear. From top to bottom, as indicated by the color labels in the printer, the enforced toner cartridges order is yellow, cyan, magenta, and black. When On is selected - Lexmark C522 | Service Manual - Page 102
was MP Feeder, then when the printer restarts, the printer automatically changes the Env Prompt setting to Manual Env. Load Manual overrides that would result in a change paper message are disabled for Paper or Env prompts that are set to Manual, Manual Paper, or Manual Env. Jobs on Disk Lets the - Lexmark C522 | Service Manual - Page 103
by 1, press the right arrow; to decrease the value by 1, press the left arrow. Exit Config Menu Press Select to exit the CONFIG MENU. The printer performs a power-on reset and returns to normal mode. 3-26 Service Manual - Lexmark C522 | Service Manual - Page 104
jams. 202 Paper Jam fuser / exit sensor 203 Paper Jam exit sensor retract when duplexing 230 Paper Jam exit sensor to input sensor when duplexing 230 Paper Jam exit sensor to input sensor when duplexing 242 Paper Jam tray 2 242 Paper Jam tray 1 250 Paper Jam MPF feeder 200 Paper Jam input - Lexmark C522 | Service Manual - Page 105
appears. 1. Pull the paper down and out. 2. Open the top access cover, and close it. 3. Load the paper, and push the paper in until it stops. The printer should pull it in farther. Note: Maintain pressure on the paper or envelope until the printer takes the paper from your hand. 3-28 Service Manual - Lexmark C522 | Service Manual - Page 106
Jam messages appear. In either case, push the paper farther into the manual feeder. If the paper does not feed: 1. Remove the paper or envelope. 2. Open the top access cover, and close it. 3. Load the paper, and push the paper in until it stops. The printer should pull it in farther. Note: Maintain - Lexmark C522 | Service Manual - Page 107
5022-xxx Theory of operation Paper path Paper exit flag Fuser Transfer belt System card Bump roller align Input flag Paper pick mechanism Duplex MPF pick 3-30 Service Manual - Lexmark C522 | Service Manual - Page 108
5022-xxx Diagnostic aids 3-31 - Lexmark C522 | Service Manual - Page 109
as it comes out of the paper trays or MPF. Transfer belt The transfer rolls (located inside the transfer belt unit) are an integral part of the electrophotographic process, and the transfer belt advances the print media through the printer. Fuser The fuser bonds toner to the print media and advances - Lexmark C522 | Service Manual - Page 110
It does not matter where the media comes from (Tray 1, Tray 2, or, the MPF); it will enter the electrophotographic process at the bump aligner drive. The bump aligner motor drives the bump aligner roll which feeds the paper to the transfer belt. 500-sheet assembly pick tire Bump aligner roll Pick - Lexmark C522 | Service Manual - Page 111
5022-xxx Once the paper is fed onto the transfer belt, the photoconductor drums in conjunction with the transfer belt pull the print media through the paper path. Photoconductor drums Transfer belt 3-34 Service Manual - Lexmark C522 | Service Manual - Page 112
5022-xxx Once the print media exits the transfer belt, it enters the fuser where heat and pressure are applied to bond the toner permanently to the media. The fuser rollers continue to turn and pull the print media through the paper path until it reaches the exit drive roll. The exit drive roll - Lexmark C522 | Service Manual - Page 113
the media when it is exiting the printer to the output bin and also serves as a one-way gate when the media is entering back into the printer for a duplex print. In other words, it diverts the print media's path, directing it to either the output bin or the duplex paper path. 3-36 Service Manual - Lexmark C522 | Service Manual - Page 114
the rollers discussed previously. The drives for these components are illustrated and discussed in the following paragraphs. Paper pick mechanism drive When printing from Tray 1 or Tray 2, the paper pick motor drives the paper pick gears which causes the pick roller to turn. During an MPF print, the - Lexmark C522 | Service Manual - Page 115
of bump aligner gears which causes the bump aligner roll to turn. Bump aligner roll Bump aligner gears Bump aligner gears Bump aligner motor Note: If this motor is stalling or causing waste toner box full messages, the vertical auger mechanism might be causing the problem. 3-38 Service Manual - Lexmark C522 | Service Manual - Page 116
drive assembly motors. The top cartridge motor 1 on the EP drive assembly provides drive to the top two photoconductor units and toner cartridges (yellow and cyan). Likewise, the bottom cartridge motor 2 drives the two bottom photoconductor units and toner cartridges. When the printer's top access - Lexmark C522 | Service Manual - Page 117
a motor located on the EP drive assembly. When the top access door is open, the coupler for the transfer belt disengages. Outside Inside Transfer belt motor Coupler Fuser drive The fuser drive (motor) is built into the fuser assembly and drives the fuser rollers to turn. 3-40 Service Manual - Lexmark C522 | Service Manual - Page 118
mounted on the front door assembly. Drive is provided to three drive shafts in the duplex unit by a belt that is driven by the motor. The drive shafts move the print media through the duplex unit during printing. Duplex motor Drive shafts Bottom view Belt of motor and gear Diagnostic aids 3-41 - Lexmark C522 | Service Manual - Page 119
sensor that detects if: 1) tray 1 is present, 2) narrow media is being used, and 3) the media is a transparency. The sensor works for tray 1, tray 2 (500-sheet option), and the MPF. Paper pick sensor Paper pick mechanism Multifunction transparency sensor Input sensor 3-42 Service Manual - Lexmark C522 | Service Manual - Page 120
paper exits the fuser and as it is retracted from the exit tray back into the duplex path. Each sheet must be driven past the fuser exit paper exit flag for too long, or the print media doesn't reach the paper exit flag within a given time, a paper jam error will be posted. There is a similar paper - Lexmark C522 | Service Manual - Page 121
5022-xxx Electrophotographic (EP) process Main components High voltage power supply Fuser Printhead Developer (toner) cartridge Transfer belt Photoconductor belt System card The system card is the brain of the printer. During the print process, an image is sent from a computer to the system card - Lexmark C522 | Service Manual - Page 122
doctor blade located in the toner cartridge • The four transfer rolls located in the transfer belt Printhead assembly The printhead receives control and image data from the system card (RIP). Through the use of a laser unit, the printhead irradiates the photoconductor drum with light and creates an - Lexmark C522 | Service Manual - Page 123
current to flow from the HVPS to the photoconductor drum contact on the photoconductor unit. It is essential that the contact springs are properly touching to provide a good flow. If not, print quality problems will occur. High voltage power supply High voltage contact path 3-46 Service Manual - Lexmark C522 | Service Manual - Page 124
toner cartridge contains three parts that are provided high voltage from the HVPS. These three parts are: the doctor blade, the developer roll, and the toner adder roll (TAR). It is essential that the contact springs are properly touching to provide a good flow. If not, print quality problems will - Lexmark C522 | Service Manual - Page 125
5022-xxx Transfer belt The transfer belt houses four transfer rollers that provide image transfer from the photoconductor drum to the print media. The transfer belt receives its high voltage charge through spring contacts located on the transfer contact assembly as shown in the following - Lexmark C522 | Service Manual - Page 126
card, the printhead and the photoconductor unit. The following illustration depicts a typical data path for a single color exposure. Data is received from printhead laser into light energy data that is directed to the light sensitive photoconductor unit. System card Printhead Photoconductor unit - Lexmark C522 | Service Manual - Page 127
roll with help from the doctor blade and is introduced to the electrostatic image on the photoconductor drum. The toner then transfers to the photoconductor drum. Photoconductor unit Developer cartridge Photoconductor drum Developer roll Toner add roll (TAR) Paddles 3-50 Service Manual - Lexmark C522 | Service Manual - Page 128
the print media. The print media is advanced in the paper path onto the transfer belt and is carried along the belt underneath each photoconductor unit. The charged transfer roll(s) located inside the transfer belt pulls the image from the photoconductor drum to the print media. This is a direct - Lexmark C522 | Service Manual - Page 129
Fusing After the image has been transferred onto the print media, it is ready for fusing. The print media is transported into the fuser where the hot roll and backup roll use a combination of high heat and pressure to melt and press the toner to the media. Backup roll Hot roll 3-52 Service Manual - Lexmark C522 | Service Manual - Page 130
collected in the waste toner container located next to the belt inside the transfer belt unit. The photoconductor drum is cleaned by the cleaning blade. Photoconductor drum cleaning blade Transfer belt cleaning blade Transfer belt waste toner container Transfer belt cleaning shaft Diagnostic - Lexmark C522 | Service Manual - Page 131
5022-xxx Electrical interlock 5 V interlock switch An interlock switch triggered by the front access door disables the +5 V output to the printhead which turns off the laser. Gearbox shield removed 5V interlock switch 3-54 Service Manual - Lexmark C522 | Service Manual - Page 132
of the switch is activated which signals the system card to disable a +24 V power supply output, turning off all high voltage supplies, the bump/align motor, the duplex motor and the fuser motor for safety considerations. Diagnostic aids 3-55 - Lexmark C522 | Service Manual - Page 133
5022-xxx 3-56 Service Manual - Lexmark C522 | Service Manual - Page 134
service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer the fuser carefully as it remains hot for a while after the printer stops to ESD-sensitive parts, follow the instructions below in addition to all the usual - Lexmark C522 | Service Manual - Page 135
solvent, fingerprints, and other foreign matter. • Do not scratch the surface of the optical photoconductor roller. Parts not to be touched Any part where the mounting screws are used to meet a printer alignment set at the factory must not be removed, disassembled, or adjusted. 4-2 Service Manual - Lexmark C522 | Service Manual - Page 136
. There is one printhead that houses the four color planes. The black plane is aligned to the printer, and the color planes are internally aligned to black. Electrical alignment is done to fine tune the alignment of the color planes to the black plane once the printhead is installed. The first - Lexmark C522 | Service Manual - Page 137
5022-xxx 2. Remove the paper exit tray for access to the printhead alignment screw (B). 3. Enter Diagnostic mode (turn off the printer, press and hold buttons when the clock graphic displays). 4. Select REGISTRATION. 5. Select Skew. 6. Adjust this setting to zero, and press Select ( ). 7. Press - Lexmark C522 | Service Manual - Page 138
Test Printer Information Page 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 Formatted Size = Tray - Lexmark C522 | Service Manual - Page 139
= 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 Formatted Size = Tray 1 = xxxxxx LexmarkC52X Quick Test Printer - Lexmark C522 | Service Manual - Page 140
5022-xxx Registration (black) Top Margin 1. Select Quick Test (REGISTRATION in the bottom margin until the points of the bottom margin alignment marks are visible and touching the edge of the paper. • Increasing the value (right arrow) moves the alignment marks up on the page. • Decreasing - Lexmark C522 | Service Manual - Page 141
check the results. Repeat if necessary. 5. When the registration is complete, proceed to the color alignments. Alignment (cyan, yellow, and magenta) 1. Press Back ( ) on the operator panel until you reach the top menu, It is important to set all the values to zero before starting. 4-8 Service Manual - Lexmark C522 | Service Manual - Page 142
5022-xxx 5. Select Quick Test in the Cyan menu, and press Select. Two pages print. You may have to print these pages several times until you get T and Z aligned. Do not go to step 2 until T and Z are aligned. The first page is similar to the following: Repair information 4-9 - Lexmark C522 | Service Manual - Page 143
the right and left arrows, and press Select to save the value. 9. Reprint the Quick Test, and evaluate whether you are at zero changes. 4-10 Service Manual - Lexmark C522 | Service Manual - Page 144
5022-xxx 10. Repeat this process for skew (Z). Don't forget to add the T value and the current cyan Z value to obtain the new skew (Z) value. An example is shown below: -18 -18 -18 -14 -32 Repair information 4-11 - Lexmark C522 | Service Manual - Page 145
(T), the Skew (Z), and on the second page of the Quick Test page, the Left Margin (L), Right Margin (R), and Bow (P). 12. Repeat steps 2 through 11 for yellow and magenta. Note: Start each color group by setting the Top Margin, Left Margin, Right Margin, Bottom Margin, Skew, and Bow to zero. 4-12 - Lexmark C522 | Service Manual - Page 146
. 1. Turn the printer power off and unplug the power cable from the outlet prior to starting removals or checks. 2. Prior to starting any repairs, read and understand the warnings in this manual. • High temperature • High voltage • Laser radiation 3. Confirm the direction of all parts and screw - Lexmark C522 | Service Manual - Page 147
5022-xxx Cover removals 4-14 Service Manual - Lexmark C522 | Service Manual - Page 148
Exit tray cover removal See "Exit tray cover, C52x" on page 7-3 for the part number. Grasp the exit tray, and lift away from printer. 5022-xxx Repair information 4-15 - Lexmark C522 | Service Manual - Page 149
7-3. 1. Remove the paper tray. 2. Remove the right cover. See "Right cover removal" on page 4-26. 3. Disconnect the transfer belt cable (A). 4. Press the two tabs (B) on either side of the transfer belt assembly, and lift out the transfer belt assembly. Note: Leave the photoconductor units on the - Lexmark C522 | Service Manual - Page 150
5022-xxx 5. Looking down at the keyed end of the restraint (C), twist the end clockwise, slide the restraint upward through the slit (D), and slip the end of the restraint through the keyed hole (E). Repeat for the other side. C E D 6. Close the front access door. Repair information 4-17 - Lexmark C522 | Service Manual - Page 151
5022-xxx 7. Remove the four screws (F) that attach the pivot pin to the front access door cover. 8. Remove the front access cover assembly. 4-18 Service Manual - Lexmark C522 | Service Manual - Page 152
5022-xxx Gearbox shield removal Not a FRU. 1. Remove the paper tray. 2. Remove the right cover. See "Right cover removal" on page 4-26. 3. Remove the four screws (A). 4. Remove the gearbox shield (B). There is a locking tab on the - Lexmark C522 | Service Manual - Page 153
on page 7-3 for the part number. 1. Place the printer on the table with the left side edge hanging over slightly. 2. Remove the waste toner assembly. See "Waste toner assembly removal" on page 4-93. 3. Open the top Be careful not to damage the two small locking tabs (C). A C B 4-20 Service Manual - Lexmark C522 | Service Manual - Page 154
5022-xxx Operator panel outer bezel removal See "Outer bezel, C52x" on page 7-3 for the part number for the C52x models. See the same page for the specific models for the bezels for the C53x models. 1. Using a flathead screwdriver or similar tool, unsnap the locking tabs (A) on the upper left and - Lexmark C522 | Service Manual - Page 155
4-21. 2. Press the top of the inner bezel to release the inner bezel (A) from the outer bezel. 3. Gently twist to free the lower tabs (B). A B 4-22 Service Manual - Lexmark C522 | Service Manual - Page 156
component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. 1. Remove the outer bezel. See "Operator panel outer bezel removal" on page 4-21. 2. Remove the screw - Lexmark C522 | Service Manual - Page 157
(A). The upper right screw can be accessed through a hole in the frame (B). 6. Remove the paper tray dust cover assembly. A B 7. Lift the dust cover bracket (C), and disconnect the dust cover spring (D). C D 8. Set the dust cover bracket aside to reuse with the new FRU. 4-24 Service Manual - Lexmark C522 | Service Manual - Page 158
Rear cover removal See "Rear cover" on page 7-3 for the part number. 1. Loosen the eight screws (A). Note: Do not remove the screws. 2. Lift up on the rear cover, and slide to the right to remove from the back of the printer. 5022-xxx A Repair information 4-25 - Lexmark C522 | Service Manual - Page 159
5022-xxx Right cover removal See "Right cover" on page 7-3 for the part number. 1. Make sure the power cord is removed. 2. Place the printer on the table with the right side edge hanging over slightly. 3. Open the top access door. 4. Open the front access door. 5. Remove the three screws (A). B 6. - Lexmark C522 | Service Manual - Page 160
Installation note: Be sure the tab (B) is fully engaged. 5022-xxx B Repair information 4-27 - Lexmark C522 | Service Manual - Page 161
network), C520n/C522n/ fuser. See "Fuser removal" on page 4-60. 4. Remove the four screws (A) exposed after removing the fuser. A 5. Remove the operator panel. See "Operator panel assembly removal" on page 4-23. 6. Remove the exit tray. See "Exit tray cover removal" on page 4-15. 4-28 Service Manual - Lexmark C522 | Service Manual - Page 162
the exit tray. B 5022-xxx 8. If the top access door is open, close it. Warning: Ensure that the top access door is closed before removing the linkage screw. Failing to close the door leaves the linkage under a load, which may result in the linkage screw being catapulted away from the printer when - Lexmark C522 | Service Manual - Page 163
5022-xxx 9. Remove the linkage screw (C). C 4-30 Service Manual - Lexmark C522 | Service Manual - Page 164
fan at JFAN1 (E), the operator panel at JOPP1 (F), the high voltage power supply connector at JHVPS1 (G), and the bin full sensor at JBIN1(H) (for network printers only) from the system card. 12. On the left side, unplug the connector (J) from CN1 on the high voltage power supply (HVPS). Rear Left - Lexmark C522 | Service Manual - Page 165
4-25. 4. Remove the fuser. See "Fuser removal" on page 4-60. 5. Remove the four screws (A) exposed after removing the fuser. A 6. Remove the operator panel. See "Operator panel assembly removal" on page 4-23. 7. Remove the exit tray. See "Exit tray cover removal" on page 4-15. 4-32 Service Manual - Lexmark C522 | Service Manual - Page 166
the exit tray. B 5022-xxx 9. If the top access door is open, close it. Warning: Ensure that top access door is closed before removing the linkage screw. Failing to close the door leaves the linkage under a load, which may result in the linkage screw being catapulted away from the printer when - Lexmark C522 | Service Manual - Page 167
5022-xxx 10. Remove the linkage screw (C). C 4-34 Service Manual - Lexmark C522 | Service Manual - Page 168
5022-xxx 11. Disconnect the cables for the fan at JFAN1 (D), the operator panel at JOPP1 (E), the high voltage power supply connector at JHVPS1 (F), and the bin full sensor at JBIN1(G), and USB at J1 (H) (model C534 only) from the system card. 12. Unplug the connector (I) from CN1 on the high - Lexmark C522 | Service Manual - Page 169
5022-xxx 13. Disconnect the ground cable (J). J 14. Lift and remove the top access cover assembly. 4-36 Service Manual - Lexmark C522 | Service Manual - Page 170
5022-xxx Bin full sensor removal-models C52x See "Bin full sensor with cable, C520n/C522n/C524n/C524dn" on page 7-3 for the part number. 1. Open the top access door. 2. Remove the fuser. See "Fuser removal" on page 4-60. 3. Disconnect the spring (A). 4. Remove the seven screws (B) securing the inner - Lexmark C522 | Service Manual - Page 171
, and press the side of the bin full sensor (B) to snap it loose from the cable cover. 4. Remove the bin full sensor and cable. 4-38 Service Manual - Lexmark C522 | Service Manual - Page 172
5022-xxx Bump aligner gear removal See the Bump aligner gear kit on page 7-5 for the part number. 1. Remove the paper pick mechanism assembly. See "Paper pick mechanism assembly removal" on page 4-68. 2. Close the front access door for better access to the gears. 3. Remove the three e-clips and - Lexmark C522 | Service Manual - Page 173
5022-xxx Bump aligner motor removal See "Bump aligner motor" on page 7-7 for the part number. 1. Remove the right side cover. 2. Remove the bump aligner gears. See "Bump aligner gear removal" on page 4-39. 3. Remove the two bump aligner motor mounting screws (A). A 4-40 Service Manual - Lexmark C522 | Service Manual - Page 174
4. Disconnect the JBUMP1 connector (B) from the system card. 5022-xxx B 5. Remove the bump aligner motor from the printer. Repair information 4-41 - Lexmark C522 | Service Manual - Page 175
5022-xxx Bump aligner rollers and springs removal-models C53x See "Bump aligner roller and spring" on page 7-5 for the part number. 1. Remove the paper tray. 2. Push up and back to relase the bump aligner spring. 3. Lower the bump aligner spring to remove it. 4-42 Service Manual - Lexmark C522 | Service Manual - Page 176
4. Remove the bump aligner roller. 5022-xxx Installation note: Make sure to support the bump aligner roller in the arms of the bump aligner spring. Repair information 4-43 - Lexmark C522 | Service Manual - Page 177
5022-xxx Contact springs removal See "Contact springs" on page 7-17 for the part number. 1. Remove all the toner cartridges. 2. Remove the screw (A) and the spring cap (B) of the appropriate contact spring. A B 3. Press the lower half (C, D) of the springs and remove the springs. C D 4-44 - Lexmark C522 | Service Manual - Page 178
5022-xxx Installation notes: When installing, make sure the top half (E) of the spring is under the straight spring (F). This is typical for both types of springs. Also make sure the bottom half (D,G) of both springs are compressed and locked by the appropriate locking tabs (H, I). F E H G I D - Lexmark C522 | Service Manual - Page 179
screwdriver between the deflector assembly and the right side frame, and lever the deflector away from the frame. 4. Pivot the deflector out, and remove. 4-46 Service Manual - Lexmark C522 | Service Manual - Page 180
Installation notes: 1. Align the two studs (A) to the two alignment holes (B) in the left side frame. 5022-xxx 2. Align the stud (C) with the alignment hole (D) on the right frame. 3. Snap into place. 4. Replace the screw on the right side. Repair information 4-47 - Lexmark C522 | Service Manual - Page 181
Low voltage power supply (LVPS) removal" on page 4-65. 2. Open the top access door. 3. Open the front access door. 4. Remove all the toner cartridges. 5. Disconnect the JTRANS2 connector (A) from the system card. 6. Disconnect JCART1 (B) and JCART2 (C) connectors from the drive assembly. B C 4-48 - Lexmark C522 | Service Manual - Page 182
7. Remove the six inner screws (D). 5022-xxx 8. Remove the nine outer screws (E). Note: Access the top two screws through the top cover. E E E 9. Remove the EP drive assembly from the printer. Repair information 4-49 - Lexmark C522 | Service Manual - Page 183
plates (G) will be fully forward. If not, slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers. 4-50 Service Manual - Lexmark C522 | Service Manual - Page 184
. See "Right cover removal" on page 4-26. 2. Open the top access door. 3. Open the front access door. 4. Remove all the toner cartridges. 5. Remove the six inner screws (A). 5022-xxx 6. Disconnect JCART1 (B), JCART2 (C), and JTRANS2 (D) connectors from the drive assembly. Repair information 4-51 - Lexmark C522 | Service Manual - Page 185
5022-xxx 7. Remove the nine outer screws (E). Note: Access the top two screws through the top cover. E E E 8. Remove the EP drive assembly from the printer. 4-52 Service Manual - Lexmark C522 | Service Manual - Page 186
5022-xxx Installation note: Ensure that the top access door is open and the EP drive is retracted when installing the new EP drive assembly. Note: When retracted, upper (F) and lower retraction plates (G) will be fully forward. If not, slide the upper retraction plate forward until the EP drive - Lexmark C522 | Service Manual - Page 187
access door. 4. Remove the gearbox shield. See "Gearbox shield removal" on page 4-19. 5. Remove the interlock switch mounting screw (B) from the right side of the printer. B 6. Remove the cable from cable guide, and remove the 5 V interlock switch. 4-54 Service Manual - Lexmark C522 | Service Manual - Page 188
5022-xxx Front door assembly removal See the part number for the Front door assembly for the specific model you need on page 7-5. 1. Remove the front access cover assembly. See "Front access door cover assembly removal" on page 4-16. 2. Remove the rear cover. See "Rear cover removal" on page 4-25. - Lexmark C522 | Service Manual - Page 189
front door assembly. 7. Release the left and right front door assembly cable restraint springs (E) from the front door assembly. E 8. Open the front door assembly. 4-56 Service Manual - Lexmark C522 | Service Manual - Page 190
9. Unwrap and remove the cable from the left and right pulleys (F). 5022-xxx 10. Remove the mounting screw (G) and the cap (H). G H Repair information 4-57 - Lexmark C522 | Service Manual - Page 191
5022-xxx 11. Open the front door assembly, slide it to the right, and remove. You need to press firmly to slide the front door assembly to the right. Installation note: See "Front door assembly front cable removal" on page 4-59 for proper installation of the cable restraints. 4-58 Service Manual - Lexmark C522 | Service Manual - Page 192
access cover is closed. 4. Remove the end of the cable (E) from the frame. Installation note: The shortest cable installs on the right side of the printer. Repair information 4-59 - Lexmark C522 | Service Manual - Page 193
for the Reset value. Resetting Fuser Count Value appears. 3. Press to select Motor Calibration from the CONFIG MENU. Calibrating displays, and the printer prints several blank pages and then returns to the CONFIG MENU. 4. Select Exit Config Menu. See "Page Counts" on page 3-16. 4-60 Service Manual - Lexmark C522 | Service Manual - Page 194
parts packet (P/N 40X1430), C52x" on page 7-5 or "Fuser cable cover, included in parts packet (P/N 40X3598), C53x" on page 7-5 for the part number. 1. Open the top access door. 2. Open the front access door. 3. Remove the yellow and cyan toner cartridges. 4. Pull the locking tab (A) down on the left - Lexmark C522 | Service Manual - Page 195
panel outer bezel removal" on page 4-21. 2. Remove the six mounting screws (A). A 3. Release the locking tab (B) from the front, lower corner of the HVPS. B 4-62 Service Manual - Lexmark C522 | Service Manual - Page 196
4. Disconnect the five connectors (C) from the HVPS. 5022-xxx Installation notes: Be sure to replace the spring when replacing the HVPS. See the illustration for proper orientation. Repair information 4-63 - Lexmark C522 | Service Manual - Page 197
5022-xxx Left bellcrank removal See "Left bellcrank assembly" on page 7-5 for the part number. 1. Remove the left cover. See "Left cover removal" on page 4-20. 2. Remove the C-clip (A). 3. Remove the left bellcrank. 4-64 Service Manual - Lexmark C522 | Service Manual - Page 198
connector (A) from the system card. 5022-xxx A 4. Remove the five LVPS mounting screws (B). 5. Disconnect the cable from the LVPS (C). B C 6. Remove the cable from the cable guide, and remove the LVPS. Repair information 4-65 - Lexmark C522 | Service Manual - Page 199
5022-xxx Installation note: When installing the new LVPS, make sure the voltage switch (D) is set for the proper value (115 V or 230 V), depending on the country. D 4-66 Service Manual - Lexmark C522 | Service Manual - Page 200
5022-xxx Multipurpose feeder (MPF) swing arm assembly removal-models C52x only See "MPF swing arm assembly, C52x" on page 7-5 for the part number. 1. Open the top access door. 2. Open the front access door. 3. Remove the three mounting screws (A). A 4. Remove the swing arm assembly from the frame. - Lexmark C522 | Service Manual - Page 201
rear cover. See "Rear cover removal" on page 4-25. 2. Disconnect the JTRAY1 (A) and JTRAY2 (B) connectors from the system card. 3. Remove all toner cartridges. 4. For models C52x only: If installed, remove the MPF swing arm assembly. See "Multipurpose feeder (MPF) swing arm assembly removal-models - Lexmark C522 | Service Manual - Page 202
mounting screws (C). 6. Release the front locking tabs (D). 7. Slide the paper pick mechanism forward until the rear locking tabs (E) release. E 5022-xxx C D 8. Lower the paper pick mechanism, and remove through the front of the printer. Note: Make sure the JTRAY1 and JTRAY2 connectors do not - Lexmark C522 | Service Manual - Page 203
. 2. Select Supplies Menu, and press . 3. Press to select Replace Supply. 4. Select Cyan PC Unit, Magenta PC Unit, Yellow PC Unit, or Black PC Unit based on the photoconductor unit that was just replaced, and then press . PC Unit Replaced displays. Press to select Yes. 4-70 Service Manual - Lexmark C522 | Service Manual - Page 204
you are having problems with media picking, replace these tires also. Always replace the pick tires in pairs. The tires come in a package of two. Warning: Remove only the rubber tires and not the pick tire assembly to avoid losing small parts. 1. Remove the paper tray. 2. Pull the autocompensator - Lexmark C522 | Service Manual - Page 205
with the surface texture (D) turning in the direction as shown. Note: Feel the rubber surface to verify it turns properly in the direction shown. 4-72 Service Manual - Lexmark C522 | Service Manual - Page 206
containing the damaged pad over the corner of the table. 2. Pull the pad (A) from the bottom of the printer. B A Installation Note: When installing the new pad, remove the appropriate side cover that corresponds to the damaged pad. It is necessary to remove the corresponding - Lexmark C522 | Service Manual - Page 207
Remove the toner cartridges. 2. Remove the exit tray cover. See "Exit tray cover removal" on page 4-15. 3. Disconnect the transfer belt cable (A). 4. Press the two tabs (B) on either side of the transfer belt assembly, and lift out the transfer belt assembly. Note: Leave the photoconductor units on - Lexmark C522 | Service Manual - Page 208
: Secure the printhead when removing the printhead alignment screw. Failure to do this allows the printhead to fall out of the printer, potentially damaging the printhead. C 8. Close the top access cover and remove the printhead alignment screw (D), and remove the printhead. D Repair information - Lexmark C522 | Service Manual - Page 209
be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw. Once the black skew is adjusted, the mounting screws will be fully . C 2. Align the printhead. See "Printhead alignment" on page 4-3. 4-76 Service Manual - Lexmark C522 | Service Manual - Page 210
Right bellcrank removal See "Right bellcrank assembly" on page 7-5 for the part number. 1. Open the front access cover. 2. Remove the gearbox/switch shield. See "Gearbox shield removal" on page 4-19. 3. Remove the C-clip (A). 5022-xxx A 4. Remove the right bellcrank. Repair information 4-77 - Lexmark C522 | Service Manual - Page 211
will be rendered inoperable. 1. Remove the system card support shield. See "System card support shield removal" on page 4-81. 2. From the outside right of the printer, disconnect the five connectors (A). 3. Remove the two mounting screws (B), and remove the smart chip card. A B 4-78 Service Manual - Lexmark C522 | Service Manual - Page 212
at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Warning: Be careful not to damage the printhead cable when removing the system card. 1. Remove the rear cover - Lexmark C522 | Service Manual - Page 213
screws (C) from the parallel connector. Network system card Non-network system card B B C 5. Remove the eight screws (D) from the system card. 6. Remove the system card. 4-80 Service Manual - Lexmark C522 | Service Manual - Page 214
shield. 7. Pull the cables through the access holes on the right side of the printer. 8. For network printers-Remove the two screws (D) attaching the parallel connector support plate. For non-network printers-Remove the INA mounting plate screw (E) and the INA mounting plate. Repair information 4-81 - Lexmark C522 | Service Manual - Page 215
(D) from the top and bottom of the support shield. Note: Only the printhead cables come through the access holes in the system card support shield. D 10. Lower and remove the support shield. Be careful not to damage the cables that route through the top frame of the printer. 4-82 Service Manual - Lexmark C522 | Service Manual - Page 216
part number. Note the locations of the toner sensors. Yellow 5022-xxx Cyan Magenta Black 1. Remove the HVPS. See "High voltage power supply (HVPS) removal" on page 4-62. 2. For yellow and cyan only: Remove the transfer contact assembly. See "Transfer contact assembly removal" on page 4-92. Note - Lexmark C522 | Service Manual - Page 217
5022-xxx 3. For all colors: It is difficult to press both locking tabs at the same time. Using a spring hook, press the locking tab (A), and disengage the sensor on that side. Press the other locking tab (B), and remove the sensor. A B 4-84 Service Manual - Lexmark C522 | Service Manual - Page 218
5022-xxx Top access door 24 V interlock switch removal See "Top access door 24 V interlock switch" on page 7-13 for the part number. 1. Remove the top access cover assembly. See "Top access cover assembly removal-model C52x only" on page 4-28. 2. Disconnect the JCVR1 connector (A) from the system - Lexmark C522 | Service Manual - Page 219
careful not to damage or remove the spring that mounts over the screw. 8. Remove the rear mounting screws (H). 9. Remove the top cover camshaft assembly. A D E F H H G C B B 4-86 Service Manual - Lexmark C522 | Service Manual - Page 220
assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed, or the printer will not work correctly. 1. Ensure the EP drive assembly is engaged by sliding the upper retraction plate (A) fully to the rear. A 2. Remove the - Lexmark C522 | Service Manual - Page 221
sure the cam (H) engages the waste toner shutter (G). Also make sure the drive pinion (I) engages the upper retraction plate (J). 8. Install the rear mounting screws (K). 9. Slide the spring (L) and the lever arm (M) onto the shaft. 10. Install the e-clip (N). G I H L K J M N 4-88 Service Manual - Lexmark C522 | Service Manual - Page 222
5022-xxx 11. Rotate the lever arm (O) all the way up as if the top access door were open. 12. While still holding the lever arm (O) up, flip the right lock (P) up and install the front mounting screws (Q). Warning: Failure to place the camshaft assembly in the open position prevents the front access - Lexmark C522 | Service Manual - Page 223
5022-xxx Note: If the left side of the camshaft assembly becomes disassembled, use the following illustration: 4-90 Service Manual - Lexmark C522 | Service Manual - Page 224
notes: When you installed the new transfer belt and moved all the photoconductor units from the used one to the new one, the alignment of the toner cartridges and photoconductor units may have changed. For better color quality, perform the Color Alignment procedure in the Configuration Menu - Lexmark C522 | Service Manual - Page 225
. 4. Remove the eight springs (B) for reuse during installation. Note: The top spring may fall away from the transfer contact assembly during removal. Installation note: For ease of installation, put the transfer contact assembly on before installing the springs. B B A A B 4-92 Service Manual - Lexmark C522 | Service Manual - Page 226
Waste toner assembly removal Not a FRU. 1. Press release latch (A). 2. Swing front of waste toner away from printer and remove. 5022-xxx A Repair information 4-93 - Lexmark C522 | Service Manual - Page 227
5022-xxx 4-94 Service Manual - Lexmark C522 | Service Manual - Page 228
service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer the fuser carefully as it remains hot for a while after the printer stops to ESD-sensitive parts, follow the instructions below in addition to all the usual - Lexmark C522 | Service Manual - Page 229
solvent, fingerprints, and other foreign matter. • Do not scratch the surface of the optical photoconductor roller. Parts not to be touched Any part where the mounting screws are used to meet a printer alignment set at the factory must not be removed, disassembled, or adjusted. 4-2 Service Manual - Lexmark C522 | Service Manual - Page 230
. There is one printhead that houses the four color planes. The black plane is aligned to the printer, and the color planes are internally aligned to black. Electrical alignment is done to fine tune the alignment of the color planes to the black plane once the printhead is installed. The first - Lexmark C522 | Service Manual - Page 231
5022-xxx 2. Remove the paper exit tray for access to the printhead alignment screw (B). 3. Enter Diagnostic mode (turn off the printer, press and hold buttons when the clock graphic displays). 4. Select REGISTRATION. 5. Select Skew. 6. Adjust this setting to zero, and press Select ( ). 7. Press - Lexmark C522 | Service Manual - Page 232
Test Printer Information Page 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 Formatted Size = Tray - Lexmark C522 | Service Manual - Page 233
= 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 Formatted Size = Tray 1 = xxxxxx LexmarkC52X Quick Test Printer - Lexmark C522 | Service Manual - Page 234
5022-xxx Registration (black) Top Margin 1. Select Quick Test (REGISTRATION in the bottom margin until the points of the bottom margin alignment marks are visible and touching the edge of the paper. • Increasing the value (right arrow) moves the alignment marks up on the page. • Decreasing - Lexmark C522 | Service Manual - Page 235
check the results. Repeat if necessary. 5. When the registration is complete, proceed to the color alignments. Alignment (cyan, yellow, and magenta) 1. Press Back ( ) on the operator panel until you reach the top menu, It is important to set all the values to zero before starting. 4-8 Service Manual - Lexmark C522 | Service Manual - Page 236
5022-xxx 5. Select Quick Test in the Cyan menu, and press Select. Two pages print. You may have to print these pages several times until you get T and Z aligned. Do not go to step 2 until T and Z are aligned. The first page is similar to the following: Repair information 4-9 - Lexmark C522 | Service Manual - Page 237
the right and left arrows, and press Select to save the value. 9. Reprint the Quick Test, and evaluate whether you are at zero changes. 4-10 Service Manual - Lexmark C522 | Service Manual - Page 238
5022-xxx 10. Repeat this process for skew (Z). Don't forget to add the T value and the current cyan Z value to obtain the new skew (Z) value. An example is shown below: -18 -18 -18 -14 -32 Repair information 4-11 - Lexmark C522 | Service Manual - Page 239
(T), the Skew (Z), and on the second page of the Quick Test page, the Left Margin (L), Right Margin (R), and Bow (P). 12. Repeat steps 2 through 11 for yellow and magenta. Note: Start each color group by setting the Top Margin, Left Margin, Right Margin, Bottom Margin, Skew, and Bow to zero. 4-12 - Lexmark C522 | Service Manual - Page 240
. 1. Turn the printer power off and unplug the power cable from the outlet prior to starting removals or checks. 2. Prior to starting any repairs, read and understand the warnings in this manual. • High temperature • High voltage • Laser radiation 3. Confirm the direction of all parts and screw - Lexmark C522 | Service Manual - Page 241
5022-xxx Cover removals 4-14 Service Manual - Lexmark C522 | Service Manual - Page 242
Exit tray cover removal See "Exit tray cover, C52x" on page 7-3 for the part number. Grasp the exit tray, and lift away from printer. 5022-xxx Repair information 4-15 - Lexmark C522 | Service Manual - Page 243
7-3. 1. Remove the paper tray. 2. Remove the right cover. See "Right cover removal" on page 4-26. 3. Disconnect the transfer belt cable (A). 4. Press the two tabs (B) on either side of the transfer belt assembly, and lift out the transfer belt assembly. Note: Leave the photoconductor units on the - Lexmark C522 | Service Manual - Page 244
5022-xxx 5. Looking down at the keyed end of the restraint (C), twist the end clockwise, slide the restraint upward through the slit (D), and slip the end of the restraint through the keyed hole (E). Repeat for the other side. C E D 6. Close the front access door. Repair information 4-17 - Lexmark C522 | Service Manual - Page 245
5022-xxx 7. Remove the four screws (F) that attach the pivot pin to the front access door cover. 8. Remove the front access cover assembly. 4-18 Service Manual - Lexmark C522 | Service Manual - Page 246
5022-xxx Gearbox shield removal Not a FRU. 1. Remove the paper tray. 2. Remove the right cover. See "Right cover removal" on page 4-26. 3. Remove the four screws (A). 4. Remove the gearbox shield (B). There is a locking tab on the - Lexmark C522 | Service Manual - Page 247
on page 7-3 for the part number. 1. Place the printer on the table with the left side edge hanging over slightly. 2. Remove the waste toner assembly. See "Waste toner assembly removal" on page 4-93. 3. Open the top Be careful not to damage the two small locking tabs (C). A C B 4-20 Service Manual - Lexmark C522 | Service Manual - Page 248
5022-xxx Operator panel outer bezel removal See "Outer bezel, C52x" on page 7-3 for the part number for the C52x models. See the same page for the specific models for the bezels for the C53x models. 1. Using a flathead screwdriver or similar tool, unsnap the locking tabs (A) on the upper left and - Lexmark C522 | Service Manual - Page 249
4-21. 2. Press the top of the inner bezel to release the inner bezel (A) from the outer bezel. 3. Gently twist to free the lower tabs (B). A B 4-22 Service Manual - Lexmark C522 | Service Manual - Page 250
component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. 1. Remove the outer bezel. See "Operator panel outer bezel removal" on page 4-21. 2. Remove the screw - Lexmark C522 | Service Manual - Page 251
(A). The upper right screw can be accessed through a hole in the frame (B). 6. Remove the paper tray dust cover assembly. A B 7. Lift the dust cover bracket (C), and disconnect the dust cover spring (D). C D 8. Set the dust cover bracket aside to reuse with the new FRU. 4-24 Service Manual - Lexmark C522 | Service Manual - Page 252
Rear cover removal See "Rear cover" on page 7-3 for the part number. 1. Loosen the eight screws (A). Note: Do not remove the screws. 2. Lift up on the rear cover, and slide to the right to remove from the back of the printer. 5022-xxx A Repair information 4-25 - Lexmark C522 | Service Manual - Page 253
5022-xxx Right cover removal See "Right cover" on page 7-3 for the part number. 1. Make sure the power cord is removed. 2. Place the printer on the table with the right side edge hanging over slightly. 3. Open the top access door. 4. Open the front access door. 5. Remove the three screws (A). B 6. - Lexmark C522 | Service Manual - Page 254
Installation note: Be sure the tab (B) is fully engaged. 5022-xxx B Repair information 4-27 - Lexmark C522 | Service Manual - Page 255
network), C520n/C522n/ fuser. See "Fuser removal" on page 4-60. 4. Remove the four screws (A) exposed after removing the fuser. A 5. Remove the operator panel. See "Operator panel assembly removal" on page 4-23. 6. Remove the exit tray. See "Exit tray cover removal" on page 4-15. 4-28 Service Manual - Lexmark C522 | Service Manual - Page 256
the exit tray. B 5022-xxx 8. If the top access door is open, close it. Warning: Ensure that the top access door is closed before removing the linkage screw. Failing to close the door leaves the linkage under a load, which may result in the linkage screw being catapulted away from the printer when - Lexmark C522 | Service Manual - Page 257
5022-xxx 9. Remove the linkage screw (C). C 4-30 Service Manual - Lexmark C522 | Service Manual - Page 258
fan at JFAN1 (E), the operator panel at JOPP1 (F), the high voltage power supply connector at JHVPS1 (G), and the bin full sensor at JBIN1(H) (for network printers only) from the system card. 12. On the left side, unplug the connector (J) from CN1 on the high voltage power supply (HVPS). Rear Left - Lexmark C522 | Service Manual - Page 259
4-25. 4. Remove the fuser. See "Fuser removal" on page 4-60. 5. Remove the four screws (A) exposed after removing the fuser. A 6. Remove the operator panel. See "Operator panel assembly removal" on page 4-23. 7. Remove the exit tray. See "Exit tray cover removal" on page 4-15. 4-32 Service Manual - Lexmark C522 | Service Manual - Page 260
the exit tray. B 5022-xxx 9. If the top access door is open, close it. Warning: Ensure that top access door is closed before removing the linkage screw. Failing to close the door leaves the linkage under a load, which may result in the linkage screw being catapulted away from the printer when - Lexmark C522 | Service Manual - Page 261
5022-xxx 10. Remove the linkage screw (C). C 4-34 Service Manual - Lexmark C522 | Service Manual - Page 262
5022-xxx 11. Disconnect the cables for the fan at JFAN1 (D), the operator panel at JOPP1 (E), the high voltage power supply connector at JHVPS1 (F), and the bin full sensor at JBIN1(G), and USB at J1 (H) (model C534 only) from the system card. 12. Unplug the connector (I) from CN1 on the high - Lexmark C522 | Service Manual - Page 263
5022-xxx 13. Disconnect the ground cable (J). J 14. Lift and remove the top access cover assembly. 4-36 Service Manual - Lexmark C522 | Service Manual - Page 264
5022-xxx Bin full sensor removal-models C52x See "Bin full sensor with cable, C520n/C522n/C524n/C524dn" on page 7-3 for the part number. 1. Open the top access door. 2. Remove the fuser. See "Fuser removal" on page 4-60. 3. Disconnect the spring (A). 4. Remove the seven screws (B) securing the inner - Lexmark C522 | Service Manual - Page 265
, and press the side of the bin full sensor (B) to snap it loose from the cable cover. 4. Remove the bin full sensor and cable. 4-38 Service Manual - Lexmark C522 | Service Manual - Page 266
5022-xxx Bump aligner gear removal See the Bump aligner gear kit on page 7-5 for the part number. 1. Remove the paper pick mechanism assembly. See "Paper pick mechanism assembly removal" on page 4-68. 2. Close the front access door for better access to the gears. 3. Remove the three e-clips and - Lexmark C522 | Service Manual - Page 267
5022-xxx Bump aligner motor removal See "Bump aligner motor" on page 7-7 for the part number. 1. Remove the right side cover. 2. Remove the bump aligner gears. See "Bump aligner gear removal" on page 4-39. 3. Remove the two bump aligner motor mounting screws (A). A 4-40 Service Manual - Lexmark C522 | Service Manual - Page 268
4. Disconnect the JBUMP1 connector (B) from the system card. 5022-xxx B 5. Remove the bump aligner motor from the printer. Repair information 4-41 - Lexmark C522 | Service Manual - Page 269
5022-xxx Bump aligner rollers and springs removal-models C53x See "Bump aligner roller and spring" on page 7-5 for the part number. 1. Remove the paper tray. 2. Push up and back to relase the bump aligner spring. 3. Lower the bump aligner spring to remove it. 4-42 Service Manual - Lexmark C522 | Service Manual - Page 270
4. Remove the bump aligner roller. 5022-xxx Installation note: Make sure to support the bump aligner roller in the arms of the bump aligner spring. Repair information 4-43 - Lexmark C522 | Service Manual - Page 271
5022-xxx Contact springs removal See "Contact springs" on page 7-17 for the part number. 1. Remove all the toner cartridges. 2. Remove the screw (A) and the spring cap (B) of the appropriate contact spring. A B 3. Press the lower half (C, D) of the springs and remove the springs. C D 4-44 - Lexmark C522 | Service Manual - Page 272
5022-xxx Installation notes: When installing, make sure the top half (E) of the spring is under the straight spring (F). This is typical for both types of springs. Also make sure the bottom half (D,G) of both springs are compressed and locked by the appropriate locking tabs (H, I). F E H G I D - Lexmark C522 | Service Manual - Page 273
screwdriver between the deflector assembly and the right side frame, and lever the deflector away from the frame. 4. Pivot the deflector out, and remove. 4-46 Service Manual - Lexmark C522 | Service Manual - Page 274
Installation notes: 1. Align the two studs (A) to the two alignment holes (B) in the left side frame. 5022-xxx 2. Align the stud (C) with the alignment hole (D) on the right frame. 3. Snap into place. 4. Replace the screw on the right side. Repair information 4-47 - Lexmark C522 | Service Manual - Page 275
Low voltage power supply (LVPS) removal" on page 4-65. 2. Open the top access door. 3. Open the front access door. 4. Remove all the toner cartridges. 5. Disconnect the JTRANS2 connector (A) from the system card. 6. Disconnect JCART1 (B) and JCART2 (C) connectors from the drive assembly. B C 4-48 - Lexmark C522 | Service Manual - Page 276
7. Remove the six inner screws (D). 5022-xxx 8. Remove the nine outer screws (E). Note: Access the top two screws through the top cover. E E E 9. Remove the EP drive assembly from the printer. Repair information 4-49 - Lexmark C522 | Service Manual - Page 277
plates (G) will be fully forward. If not, slide the upper retraction plate forward until the EP drive retracts and is disengaged from the developers. 4-50 Service Manual - Lexmark C522 | Service Manual - Page 278
. See "Right cover removal" on page 4-26. 2. Open the top access door. 3. Open the front access door. 4. Remove all the toner cartridges. 5. Remove the six inner screws (A). 5022-xxx 6. Disconnect JCART1 (B), JCART2 (C), and JTRANS2 (D) connectors from the drive assembly. Repair information 4-51 - Lexmark C522 | Service Manual - Page 279
5022-xxx 7. Remove the nine outer screws (E). Note: Access the top two screws through the top cover. E E E 8. Remove the EP drive assembly from the printer. 4-52 Service Manual - Lexmark C522 | Service Manual - Page 280
5022-xxx Installation note: Ensure that the top access door is open and the EP drive is retracted when installing the new EP drive assembly. Note: When retracted, upper (F) and lower retraction plates (G) will be fully forward. If not, slide the upper retraction plate forward until the EP drive - Lexmark C522 | Service Manual - Page 281
access door. 4. Remove the gearbox shield. See "Gearbox shield removal" on page 4-19. 5. Remove the interlock switch mounting screw (B) from the right side of the printer. B 6. Remove the cable from cable guide, and remove the 5 V interlock switch. 4-54 Service Manual - Lexmark C522 | Service Manual - Page 282
5022-xxx Front door assembly removal See the part number for the Front door assembly for the specific model you need on page 7-5. 1. Remove the front access cover assembly. See "Front access door cover assembly removal" on page 4-16. 2. Remove the rear cover. See "Rear cover removal" on page 4-25. - Lexmark C522 | Service Manual - Page 283
front door assembly. 7. Release the left and right front door assembly cable restraint springs (E) from the front door assembly. E 8. Open the front door assembly. 4-56 Service Manual - Lexmark C522 | Service Manual - Page 284
9. Unwrap and remove the cable from the left and right pulleys (F). 5022-xxx 10. Remove the mounting screw (G) and the cap (H). G H Repair information 4-57 - Lexmark C522 | Service Manual - Page 285
5022-xxx 11. Open the front door assembly, slide it to the right, and remove. You need to press firmly to slide the front door assembly to the right. Installation note: See "Front door assembly front cable removal" on page 4-59 for proper installation of the cable restraints. 4-58 Service Manual - Lexmark C522 | Service Manual - Page 286
access cover is closed. 4. Remove the end of the cable (E) from the frame. Installation note: The shortest cable installs on the right side of the printer. Repair information 4-59 - Lexmark C522 | Service Manual - Page 287
for the Reset value. Resetting Fuser Count Value appears. 3. Press to select Motor Calibration from the CONFIG MENU. Calibrating displays, and the printer prints several blank pages and then returns to the CONFIG MENU. 4. Select Exit Config Menu. See "Page Counts" on page 3-16. 4-60 Service Manual - Lexmark C522 | Service Manual - Page 288
parts packet (P/N 40X1430), C52x" on page 7-5 or "Fuser cable cover, included in parts packet (P/N 40X3598), C53x" on page 7-5 for the part number. 1. Open the top access door. 2. Open the front access door. 3. Remove the yellow and cyan toner cartridges. 4. Pull the locking tab (A) down on the left - Lexmark C522 | Service Manual - Page 289
panel outer bezel removal" on page 4-21. 2. Remove the six mounting screws (A). A 3. Release the locking tab (B) from the front, lower corner of the HVPS. B 4-62 Service Manual - Lexmark C522 | Service Manual - Page 290
4. Disconnect the five connectors (C) from the HVPS. 5022-xxx Installation notes: Be sure to replace the spring when replacing the HVPS. See the illustration for proper orientation. Repair information 4-63 - Lexmark C522 | Service Manual - Page 291
5022-xxx Left bellcrank removal See "Left bellcrank assembly" on page 7-5 for the part number. 1. Remove the left cover. See "Left cover removal" on page 4-20. 2. Remove the C-clip (A). 3. Remove the left bellcrank. 4-64 Service Manual - Lexmark C522 | Service Manual - Page 292
connector (A) from the system card. 5022-xxx A 4. Remove the five LVPS mounting screws (B). 5. Disconnect the cable from the LVPS (C). B C 6. Remove the cable from the cable guide, and remove the LVPS. Repair information 4-65 - Lexmark C522 | Service Manual - Page 293
5022-xxx Installation note: When installing the new LVPS, make sure the voltage switch (D) is set for the proper value (115 V or 230 V), depending on the country. D 4-66 Service Manual - Lexmark C522 | Service Manual - Page 294
5022-xxx Multipurpose feeder (MPF) swing arm assembly removal-models C52x only See "MPF swing arm assembly, C52x" on page 7-5 for the part number. 1. Open the top access door. 2. Open the front access door. 3. Remove the three mounting screws (A). A 4. Remove the swing arm assembly from the frame. - Lexmark C522 | Service Manual - Page 295
rear cover. See "Rear cover removal" on page 4-25. 2. Disconnect the JTRAY1 (A) and JTRAY2 (B) connectors from the system card. 3. Remove all toner cartridges. 4. For models C52x only: If installed, remove the MPF swing arm assembly. See "Multipurpose feeder (MPF) swing arm assembly removal-models - Lexmark C522 | Service Manual - Page 296
mounting screws (C). 6. Release the front locking tabs (D). 7. Slide the paper pick mechanism forward until the rear locking tabs (E) release. E 5022-xxx C D 8. Lower the paper pick mechanism, and remove through the front of the printer. Note: Make sure the JTRAY1 and JTRAY2 connectors do not - Lexmark C522 | Service Manual - Page 297
. 2. Select Supplies Menu, and press . 3. Press to select Replace Supply. 4. Select Cyan PC Unit, Magenta PC Unit, Yellow PC Unit, or Black PC Unit based on the photoconductor unit that was just replaced, and then press . PC Unit Replaced displays. Press to select Yes. 4-70 Service Manual - Lexmark C522 | Service Manual - Page 298
you are having problems with media picking, replace these tires also. Always replace the pick tires in pairs. The tires come in a package of two. Warning: Remove only the rubber tires and not the pick tire assembly to avoid losing small parts. 1. Remove the paper tray. 2. Pull the autocompensator - Lexmark C522 | Service Manual - Page 299
with the surface texture (D) turning in the direction as shown. Note: Feel the rubber surface to verify it turns properly in the direction shown. 4-72 Service Manual - Lexmark C522 | Service Manual - Page 300
containing the damaged pad over the corner of the table. 2. Pull the pad (A) from the bottom of the printer. B A Installation Note: When installing the new pad, remove the appropriate side cover that corresponds to the damaged pad. It is necessary to remove the corresponding - Lexmark C522 | Service Manual - Page 301
Remove the toner cartridges. 2. Remove the exit tray cover. See "Exit tray cover removal" on page 4-15. 3. Disconnect the transfer belt cable (A). 4. Press the two tabs (B) on either side of the transfer belt assembly, and lift out the transfer belt assembly. Note: Leave the photoconductor units on - Lexmark C522 | Service Manual - Page 302
: Secure the printhead when removing the printhead alignment screw. Failure to do this allows the printhead to fall out of the printer, potentially damaging the printhead. C 8. Close the top access cover and remove the printhead alignment screw (D), and remove the printhead. D Repair information - Lexmark C522 | Service Manual - Page 303
be printed that will be used to align the black plane to the printer frame and also allows skew adjustment with the printhead alignment screw. Once the black skew is adjusted, the mounting screws will be fully . C 2. Align the printhead. See "Printhead alignment" on page 4-3. 4-76 Service Manual - Lexmark C522 | Service Manual - Page 304
Right bellcrank removal See "Right bellcrank assembly" on page 7-5 for the part number. 1. Open the front access cover. 2. Remove the gearbox/switch shield. See "Gearbox shield removal" on page 4-19. 3. Remove the C-clip (A). 5022-xxx A 4. Remove the right bellcrank. Repair information 4-77 - Lexmark C522 | Service Manual - Page 305
will be rendered inoperable. 1. Remove the system card support shield. See "System card support shield removal" on page 4-81. 2. From the outside right of the printer, disconnect the five connectors (A). 3. Remove the two mounting screws (B), and remove the smart chip card. A B 4-78 Service Manual - Lexmark C522 | Service Manual - Page 306
at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Warning: Be careful not to damage the printhead cable when removing the system card. 1. Remove the rear cover - Lexmark C522 | Service Manual - Page 307
screws (C) from the parallel connector. Network system card Non-network system card B B C 5. Remove the eight screws (D) from the system card. 6. Remove the system card. 4-80 Service Manual - Lexmark C522 | Service Manual - Page 308
shield. 7. Pull the cables through the access holes on the right side of the printer. 8. For network printers-Remove the two screws (D) attaching the parallel connector support plate. For non-network printers-Remove the INA mounting plate screw (E) and the INA mounting plate. Repair information 4-81 - Lexmark C522 | Service Manual - Page 309
(D) from the top and bottom of the support shield. Note: Only the printhead cables come through the access holes in the system card support shield. D 10. Lower and remove the support shield. Be careful not to damage the cables that route through the top frame of the printer. 4-82 Service Manual - Lexmark C522 | Service Manual - Page 310
part number. Note the locations of the toner sensors. Yellow 5022-xxx Cyan Magenta Black 1. Remove the HVPS. See "High voltage power supply (HVPS) removal" on page 4-62. 2. For yellow and cyan only: Remove the transfer contact assembly. See "Transfer contact assembly removal" on page 4-92. Note - Lexmark C522 | Service Manual - Page 311
5022-xxx 3. For all colors: It is difficult to press both locking tabs at the same time. Using a spring hook, press the locking tab (A), and disengage the sensor on that side. Press the other locking tab (B), and remove the sensor. A B 4-84 Service Manual - Lexmark C522 | Service Manual - Page 312
5022-xxx Top access door 24 V interlock switch removal See "Top access door 24 V interlock switch" on page 7-13 for the part number. 1. Remove the top access cover assembly. See "Top access cover assembly removal-model C52x only" on page 4-28. 2. Disconnect the JCVR1 connector (A) from the system - Lexmark C522 | Service Manual - Page 313
careful not to damage or remove the spring that mounts over the screw. 8. Remove the rear mounting screws (H). 9. Remove the top cover camshaft assembly. A D E F H H G C B B 4-86 Service Manual - Lexmark C522 | Service Manual - Page 314
assembly and EP drive assembly must be set to the closed and engaged positions respectively before the camshaft assembly is installed, or the printer will not work correctly. 1. Ensure the EP drive assembly is engaged by sliding the upper retraction plate (A) fully to the rear. A 2. Remove the - Lexmark C522 | Service Manual - Page 315
sure the cam (H) engages the waste toner shutter (G). Also make sure the drive pinion (I) engages the upper retraction plate (J). 8. Install the rear mounting screws (K). 9. Slide the spring (L) and the lever arm (M) onto the shaft. 10. Install the e-clip (N). G I H L K J M N 4-88 Service Manual - Lexmark C522 | Service Manual - Page 316
5022-xxx 11. Rotate the lever arm (O) all the way up as if the top access door were open. 12. While still holding the lever arm (O) up, flip the right lock (P) up and install the front mounting screws (Q). Warning: Failure to place the camshaft assembly in the open position prevents the front access - Lexmark C522 | Service Manual - Page 317
5022-xxx Note: If the left side of the camshaft assembly becomes disassembled, use the following illustration: 4-90 Service Manual - Lexmark C522 | Service Manual - Page 318
notes: When you installed the new transfer belt and moved all the photoconductor units from the used one to the new one, the alignment of the toner cartridges and photoconductor units may have changed. For better color quality, perform the Color Alignment procedure in the Configuration Menu - Lexmark C522 | Service Manual - Page 319
. 4. Remove the eight springs (B) for reuse during installation. Note: The top spring may fall away from the transfer contact assembly during removal. Installation note: For ease of installation, put the transfer contact assembly on before installing the springs. B B A A B 4-92 Service Manual - Lexmark C522 | Service Manual - Page 320
Waste toner assembly removal Not a FRU. 1. Press release latch (A). 2. Swing front of waste toner away from printer and remove. 5022-xxx A Repair information 4-93 - Lexmark C522 | Service Manual - Page 321
5022-xxx 4-94 Service Manual - Lexmark C522 | Service Manual - Page 322
5. Locations and connectors Locations Covers 5022-xxx Locations and connectors 5-1 - Lexmark C522 | Service Manual - Page 323
pick mechanism assembly MPF swing arm assembly (models C52X only) Fuser cable cover Front door assembly Deflector assembly Front door cap Left front door assembly restraint cable Bellcrank assembly Printer pad Bump aligner gears Right front door assembly restraint cable 5-2 Service Manual - Lexmark C522 | Service Manual - Page 324
Right 5022-xxx EP drive assembly Bump aligner motor 5 V interlock switch Locations and connectors 5-3 - Lexmark C522 | Service Manual - Page 325
5022-xxx Rear 5-4 Service Manual - Lexmark C522 | Service Manual - Page 326
Left 5022-xxx High voltage power supply Toner level sensor Transfer contact assembly Locations and connectors 5-5 - Lexmark C522 | Service Manual - Page 327
5022-xxx Top Top cover camshaft assembly Top access door 24V interlock switch with cable 5-6 Service Manual - Lexmark C522 | Service Manual - Page 328
CRU and FRUs 5022-xxx Locations and connectors 5-7 - Lexmark C522 | Service Manual - Page 329
5022-xxx Sensors Toner level sensor Toner patch sensor (TPS) 5-8 Service Manual - Lexmark C522 | Service Manual - Page 330
Motors 5022-xxx Locations and connectors 5-9 - Lexmark C522 | Service Manual - Page 331
5022-xxx Printer cards 5-10 Service Manual - Lexmark C522 | Service Manual - Page 332
Connectors System card (network)-models C52x 5022-xxx Locations and connectors 5-11 - Lexmark C522 | Service Manual - Page 333
5022-xxx System card (non-network)-models C52x 5-12 Service Manual - Lexmark C522 | Service Manual - Page 334
5022-xxx Connector listing-models C52x (see "System card (network)-models C52x" on page 5-11 or "System card (non-network)-models C52x" on page 5-12) Connector Pin no. Signal Pin no. Signal JBIN1 JBUMP1 JCART1 JCART2 JCVR1 JDUPLX1 JFAN1 JFUSER1 1 V_BF (+5 SW) 2 S_BIN_FB 3 Ground 1 - Lexmark C522 | Service Manual - Page 335
22 HVPS_ID 24 XFER_SERV0-K 2 +5 V dc 4 +5 V dc 6 +24 V dc 8 +24 V dc 10 Ground 12 Ground 14 Ground 16 LVPS_HRON 2 OPTION_PWM 4 OPT_TYPE 6 Ground 8 OPT_PSIZE 10 OPT_PCTL 5-14 Service Manual - Lexmark C522 | Service Manual - Page 336
5022-xxx Connector listing-models C52x (see "System card (network)-models C52x" on page 5-11 or "System card (non-network)-models C52x" on page 5-12) (continued) Connector Pin no. Signal Pin no. Signal JOPP1 JPH1 1 I2C_DATA5_OP 2 V_PANEL+5V 3 I2C_CLK_OP 4 Ground 5 I2CIRQ5_R 6 +3.3 - Lexmark C522 | Service Manual - Page 337
V_TRANS_PHA+ 2 V_TRANS_PHA- 3 V_TRANS_PHB+ 4 V_TRANS_PHB- 1 VS_TRAY_INPT_LED (+5V) 2 S_TRAY_INPUT 3 Ground 4 VS_TRAY+5V_NMT 5 TRAY_NMT (+3.3v) 6 Ground 7 N/C 2 Ground 4 I2C_DATA_TB 6 TRANS_BELT_SNS 8 VS_5V_TPS 10 TPS_SNS 12 TPS_SNS_RTN 14 N/C 5-16 Service Manual - Lexmark C522 | Service Manual - Page 338
5022-xxx Connector listing-models C52x (see "System card (network)-models C52x" on page 5-11 or "System card (non-network)-models C52x" on page 5-12) (continued) Connector Pin no. Signal Pin no. Signal JTRAY2 1 VS_TRAY_ENC_LED 2 S_TRAY_ENC 3 Ground 4 V_TRAY_PICK_M- 5 V_TRAY_PICK_M+ - Lexmark C522 | Service Manual - Page 339
5022-xxx System card (network)-models C53x 5-18 Service Manual - Lexmark C522 | Service Manual - Page 340
5022-xxx Connector listing-models C53x (see "System card (network)-models C53x" on page 5-18) Connector Pin no. Signal J1 JBIN1 JBUMP1 JCART1 JCART2 JCVR1 JDUPLX1 JFAN1 1 V FHUSB_+5 2 JB_USB_RD- 3 JB_USB_RD+ 4 Ground 5 Ground 1 V_BF (+5 SW) 2 S_BIN_FB 3 Ground 1 VS_BUMP_LED 2 - Lexmark C522 | Service Manual - Page 341
Ground 13 Ground 15 LVPS_BRON 1 MM_REF 2 MM_LOCK 3 MM_START 4 Ground 5 +24 V dc 1 VS_JOPT-1 (+5V_SW) 3 S_OPT_ENC 5 Ground 7 +24VC 9 OPT_PLEV 5-20 Service Manual Pin no. 2 4 6 8 10 2 4 6 8 10 12 14 16 18 20 22 24 2 4 6 8 10 12 14 16 2 4 6 8 10 Signal V_FUSER_MS_FUSER_ENC - Lexmark C522 | Service Manual - Page 342
Connector listing-models C53x (see "System card (network)-models C53x" on page 5-18) (continued) Connector Pin no. Signal JOPP1 JPH1 1 I2C_DATA5_OP 2 V_PANEL+5V 3 I2C_CLK_OP 4 Ground 5 I2CIRQ5_R 6 +3.3 V dc 7 Ground 1 Ground 2 D_VDO_C- 3 D_VDO_C+ 4 Ground 5 D_VDO_Y- 6 - Lexmark C522 | Service Manual - Page 343
) 2 S_TRAY_INPUT 3 Ground 4 VS_TRAY+5V_NMT 5 TRAY_NMT (+3.3v) 6 Ground 7 N/C 1 VS_TRAY_ENC_LED 2 S_TRAY_ENC 3 Ground 4 V_TRAY_PICK_M- 5 V_TRAY_PICK_M+ Pin no. 2 4 6 8 10 12 Signal V_JTRANS-9 (+3.3V) TPS_PWM1 TPS_THERM_SNS I2C_CLK_TB V_TRANS-1 (+3.3V) N/C 5-22 Service Manual - Lexmark C522 | Service Manual - Page 344
5022-xxx Wiring diagrams Wiring diagrams are attached to the end of this document. Diagrams are designed for 11 x 17 in. or A3 paper. Print the individual wiring diagram pages separately on larger paper for best effect. Locations and connectors 5-23 - Lexmark C522 | Service Manual - Page 345
5022-xxx 5-24 Service Manual - Lexmark C522 | Service Manual - Page 346
the print quality and reliability of the printer. The following maintenance items are available for the customer: Maintenance items Description Fuser assembly, 115 V Fuser assembly, 230 V Fuser assembly, 100 V Transfer belt assembly, C52x Transfer belt assembly, C53x Part number 40X3569 40X3570 - Lexmark C522 | Service Manual - Page 347
5022-xxx 6-2 Service Manual - Lexmark C522 | Service Manual - Page 348
base printer or C520n Lexmark C522n Lexmark C524 Lexmark C524n Lexmark C524dn Lexmark C530dn Lexmark C532n Lexmark C532dn Lexmark C534n Lexmark C534dn/dtn Configuration Network Network Non-network Network Network Duplex, network Network Duplex, network Network Duplex, network (550-sheet tray - Lexmark C522 | Service Manual - Page 349
5022-xxx Assembly 1: Covers 1 4 2 5 3 6 7 9 8 10 15 11 12 14 13 7-2 Service Manual - Lexmark C522 | Service Manual - Page 350
(network), C530dn/C532dn/C534dn Exit tray cover, C52x Exit tray cover, C53x Rear cover Paper tray dust cover with dust cover spring, C53x Right cover Front access door cover assembly (duplex), C524dn only Front access door cover assembly (non-duplex), C520n/C522n/C524/ C524n Front access door - Lexmark C522 | Service Manual - Page 351
5022-xxx Assembly 2: Front 7-4 Service Manual - Lexmark C522 | Service Manual - Page 352
Fuser cable cover, included in parts packet (P/N 40X3598), C53x Printer pad, included in parts packet , screws (P/N 40X1431) Right bellcrank assembly Bump aligner gear kit assembly, C524dn Front door assembly, C520n/C522n/C524n Duplex front door assembly Paper pick mechanism assembly, C52x Paper pick - Lexmark C522 | Service Manual - Page 353
5022-xxx Assembly 3: Right 7-6 Service Manual - Lexmark C522 | Service Manual - Page 354
40X3574 40X1433 40X1436 40X1445 Units/ mach 1 1 1 1 1 1 Units/ FRU 1 1 1 1 1 1 Description EP drive assembly, C52x EP drive assembly, C53x Low voltage power supply, 115/230 V Bump aligner motor Front door 5 V interlock switch Ground contact plate, C52x only 5022-xxx Parts catalog 7-7 - Lexmark C522 | Service Manual - Page 355
5022-xxx Assembly 4: Rear 7-8 Service Manual - Lexmark C522 | Service Manual - Page 356
, C53x System card (network), C524n/C524dn System card (network), C520n/C522n System card, C524 System card (network), C530dn/C532n/C532dn System card (network), C534n System card (network), C534dn System card support shield, C52x System card support shield, C53x Smart chip card, C52x only 5022-xxx - Lexmark C522 | Service Manual - Page 357
5022-xxx Assembly 5: Left 1 2 3 7-10 Service Manual - Lexmark C522 | Service Manual - Page 358
Assembly 5: Left Index 5-1 2 3 3 P/N 40X1416 40X1428 40X1411 40X3579 Units/ mach 4 1 1 1 Units/ FRU 1 1 1 1 Description Toner level sensor Transfer contact assembly High voltage power supply, C52x High voltage power supply, C53x 5022-xxx Parts catalog 7-11 - Lexmark C522 | Service Manual - Page 359
5022-xxx Assembly 6: Top 1 2 7-12 Service Manual - Lexmark C522 | Service Manual - Page 360
Assembly 6: Top Index 6-1 2 P/N 40X3613 40X1437 Units/ mach 1 1 Units/ FRU 1 1 Description Top cover camshaft assembly Top access door 24 V interlock switch 5022-xxx Parts catalog 7-13 - Lexmark C522 | Service Manual - Page 361
5022-xxx Assembly 7: Customer replaceable units (CRUs) 1 6 5 2 3 2 4 7-14 Service Manual - Lexmark C522 | Service Manual - Page 362
/C532dn/C534n/C534dn MPF paper tray assembly, 250-sheet, C524/C524n/C524dn Paper tray assembly, single feeder, C520n/C522n MPF paper tray assembly, 250-sheet, C530dn/C532dn/C534dn Paper tray assembly, single feeder, C532n, C534n Transfer belt assembly, C52x Transfer belt assembly, C53x Power cord - Lexmark C522 | Service Manual - Page 363
5022-xxx Assembly 8: Contact springs 7-16 Service Manual - Lexmark C522 | Service Manual - Page 364
Assembly 8: Contact springs Index 8-1 P/N 40X1434 Units/ mach 1 Units/ FRU 1 Description Contact springs kit, including: • A-Torsion PCD contact spring (4) • B-Torsion CR contact spring (4) • C-Contact spring cap (4) • D-Charge roll contact spring (8) • E-HVPS TAR contact spring (4) • F-HVPS - Lexmark C522 | Service Manual - Page 365
5022-xxx Assembly 9: Cable parts packet 7-18 Service Manual - Lexmark C522 | Service Manual - Page 366
7-4 for part identification and location) • Duplex cable (1) Cables, C53x, including • A-Cartridge motor cable (1) • B-Fuser AC cable (1) • C-Fuser DC cable (1) • E-Option cable (1) • F-Transport motor cable (1) • Fuser cable cover (1) (see"Front" on page 7-4 for part identification and location - Lexmark C522 | Service Manual - Page 367
1 1 7377200 1 1 Description Parts packet, screw (contains one of each screw used in the printer, with the exception of the parts specifically called out.) 128 MB SDRAM, 100-pin 256 MB , C524n/C524dn/C534n/C534dn/C534dtn Printer relocation kit Options tray relocation kit 7-20 Service Manual - Lexmark C522 | Service Manual - Page 368
5-3 parts catalog 7-6 removal 4-54 theory 3-54 9xx service error codes 2-15-2-18 A accessing service menus 3-1 acronyms 1-14 adjustments 4-3 Align Motor Test 3-8 alignment diagnostics menu 3-7 printhead 4-3 Auto Align Adj 3-23 Auto Color Adj 3-23 B bellcrank left bellcrank 4-64 parts catalog - Lexmark C522 | Service Manual - Page 369
Test 3-11 Input Tray Tests 3-14 Motor Tests Align Motor Test 3-8 Bottom cartridge 3-8 Fuser 3-8 Mirror Motor Test 3-8 Motor Calibration 3-9 Servo Laser Test 3-9 Top cartridge 3-8 Transfer 3-8 Tray 1 3-8 Tray 2 3-8 Print Tests input source tests 3-9 Prt Quality Pgs 3-10 Printer Setup Configuration ID - Lexmark C522 | Service Manual - Page 370
38 duplex drive 3-41 fuser drive 3-40 paper pick mechanism drive 3-37 photoconductor unit/toner cartridge drive 3-39 transfer belt drive 3-40 media input and output capacities 1-12 selecting preprinted forms and letterhead 1-7 storing 1-10 supported media size 1-10 supported media weight 1-11 using - Lexmark C522 | Service Manual - Page 371
-C52x only 4-67 paper pick mechanism assembly 4-68 paper tray dust cover 4-24 photoconductor unit 4-70 pick roll rubber tires 4-71 precautions 4-13 printer pad 4-73 printhead 4-74 right bellcrank 4-77 smart chip card-C52x 4-78 system card 4-79 system card support shield 4-81 toner level sensor 4-83 - Lexmark C522 | Service Manual - Page 372
3-16 service checks 110.xx-Mirror motor 2-27 111.xx-114.xx-Printhead error 2-27 120.01, 120.02, 120.08-120.10, 120.13-120.15- Fuser error 2-28 120.03-Fuser error 2-30 120.04-120.07-Fuser error 2-30 140.xx-Autocomp motor error 2-32 142.xx-fuser motor error 2-33 143.xx-EP drive asm top cartridge motor - Lexmark C522 | Service Manual - Page 373
4-87 locations 5-6 parts catalog 7-12 removal 4-86 transfer belt locations 5-7 parts catalog 7-14 removal 4-91 transfer contact assembly locations 5-5 parts catalog 7-10 removal 4-92 Transfer Motor Test 3-8 transparencies using 1-8 W waste toner assembly locations 5-7 removal 4-93 I-6 Service Manual - Lexmark C522 | Service Manual - Page 374
7-15 Paper tray assembly, single feeder, C520n/C522n 7-15 Right cover 7-3 Left cover 7-3 Rear cover 7-3 Transfer contact assembly 7-11 System card support shield, C52x 7-9 Parts packet, C52x 7-5 Parts packet, cables, C52x 7-19 Parts packet, screws 7-5, 7-20 Bump aligner gear kit 7-5 Bump - Lexmark C522 | Service Manual - Page 375
card, C524/C524n/C524dn 7-20 Bar code card, C524/C524n/C524dn 7-20 Fuser assembly, 115 V 6-1, 7-15 Fuser assembly, 230 V 6-1, 7-15 Fuser assembly, 100 V 6-1, 7-15 Transfer belt assembly, C53x 6-1, 7-15 Paper pick mechanism assembly, C53x 7-5 Low voltage power supply, 115/230 V 7-7 System - Lexmark C522 | Service Manual - Page 376
15 Power cord-Taiwan 7-15 Power cord-Brazil 7-15 Paper tray dust cover with spring, C53x 7-3 Top cover camshaft assembly C520n/C522n 7-9 Bar code card, C534n/C534dn 7-20 Forms card, C534n/C534dn 7-20 PrintCryption card, C534n/C534dn 7-20 Printer relocation kit 7-20 Options tray relocation kit - Lexmark C522 | Service Manual - Page 377
5022-xxx I-10 Service Manual - Lexmark C522 | Service Manual - Page 378
- Lexmark C522 | Service Manual - Page 379
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 |
 |
Lexmark
™
C
520
, C
52
2
, C524, C530, C532, C534
5022-xxx
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.