Lexmark 522n - C Color Laser Printer Service Manual Download Page 325

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Index

I-1

4520-xxx

Index

Acronyms

1-4

Adjustment Procedures

4-2

Duplex Motor Drive Belts

4-2

Fuser Solenoid

4-3

Gap Adjustment

4-3

Paper Alignment Assembly

4-5

Printhead Assembly

4-4

Base Sensor Test

3-16

Button Test

3-11

Connector Locations

Controller Board

5-10

Duplex Unit Board

5-18

Engine Board

5-4

Envelope Feeder Board

5-16

Fuser Board

5-12

High Voltage Power Supply

5-3

Interconnect Board

5-14

LVPS

5-1

Network Controller Board

5-11

Controller Board Connectors

5-10

Diagnostic Aids

3-1

Device Tests

3-2

Disk Test/Clean

3-3

Flash Test

3-4

Quick Disk Test

3-2

Diagnostic Mode

3-1

Duplex Tests

3-6

Duplex Feed 1 Test

3-9

Duplex Feed 2 Test

3-9

Duplex Motor Test

3-8

Duplex Quick Test

3-6

Duplex Sensor Test

3-7

Error Log

3-10

Clearing the Error Log

3-10

Viewing the Error Log

3-10

Hardware Tests

3-11

Button Test

3-11

LCD Test

3-11

Parallel Wrap Test

3-13

ROM Memory Test

3-13

SDRAM Memory Test

3-12

Serial Wrap Test

3-13

Input Tray Tests

3-15

Input Tray Feed Test

3-15

Paper Feed Tests

Base Sensor Test

3-16

Input Tray Sensor Test

3-15

Output Bin Test - Standard Bin

3-16

Print Registration

3-17

Print Tests

3-22

Printer Setup

3-18

Maintenance Page Count

3-19

Restore EP Factory Defaults

3-21

Setting Configuration ID

3-20

Setting the Page Count

3-18

Viewing the Permanent Page

Count

3-18

Diagnostic Mode

3-1

Disabling Download Emulations

3-5

Disk Test/Clean

3-3

Duplex Option Board Connectors

5-18

Duplex Tests

3-6

Engine Board Connectors

5-4

Envelope Option Board Connectors

5-16

Error Codes

Service Error Codes

2-2

User Error Messages

2-25

Error Log

3-10

ESD-Sensitive Parts

4-1

Flash Test

3-4

Summary of Contents for 522n - C Color Laser Printer

Page 1: ...exmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Di...

Page 2: ...S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can...

Page 3: ...rvice Check 2 42 Dead Machine Service Check 2 43 Duplex Unit Service Check 2 45 Envelope Feeder Service Check 2 48 Fuser Service Check 2 56 Fuser Solenoid Service Check 2 60 Input Sensor Service Check...

Page 4: ...st 3 11 SDRAM Memory Test 3 12 ROM Memory Test 3 13 Parallel Wrap Test 3 13 Serial Wrap Test 3 13 Input Tray Tests 3 15 Input Tray Feed Test 3 15 Input Tray Sensor Test 3 15 Output Bin Test Standard B...

Page 5: ...0 EMC Shields Removals 4 21 Engine Board Removal 4 23 Main Fan Removal 4 24 Frames Removals 4 25 Fuser Removal 4 28 Fuser Board Removal 4 29 Fuser Cover Removal 4 30 Fuser Detack Housing Assembly Remo...

Page 6: ...per Front Cover Interlock Switch Assembly Removal 4 60 Connector Locations 5 1 Low Voltage Power Supply 5 1 High Voltage Power Supply 5 3 Engine Board 5 4 Engine Board 5 9 Controller Board Non Network...

Page 7: ...embly 17 Electronics IV 7 38 Assembly 18 Electronics V 7 40 Assembly 19 Electronics VI 7 42 Assembly 20 250 Sheet Tray 7 44 Assembly 21 Integrated Paper Tray 250 Sheet 7 48 Assembly 22 500 Sheet Tray...

Page 8: ...viii Service Manual 4520 xxx...

Page 9: ...Notices and Safety Information ix 4520 xxx Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label...

Page 10: ...x Service Manual 4520 xxx Class 1 Laser Statement Label...

Page 11: ...escribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der...

Page 12: ...en par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe I Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere...

Page 13: ...superior al nivel de la Clase I durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E...

Page 14: ...ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermedd...

Page 15: ...taessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Lase...

Page 16: ...r foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe I 1 i...

Page 17: ...Notices and Safety Information xvii 4520 xxx Japanese Laser Notice Chinese Laser Notice...

Page 18: ...not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is n...

Page 19: ...lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Norme di sicurezza Il prodotto stato progettato testato e approvato in conformit a severi standard di sicur...

Page 20: ...ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende Vorsichtsma nahmen treffen Pautas de Seguridad Este producto se ha dise...

Page 21: ...deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Informaci de Seguretat Aquest producte est dissenyat comprovat i aprovat per tal d acom...

Page 22: ...xxii Service Manual 4520 xxx Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas...

Page 23: ...sed to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Printer operation information is provided to enhance...

Page 24: ...xxiv Service Manual 4520 xxx...

Page 25: ...printers designed to attach to IBM compatible personal computers and to most computer networks The Lexmark T laser printers are available in the following models Model Name Type Lexmark T522 4520 210...

Page 26: ...apter IR Adapter IPDS Card Assembly PRESCRIBE Card Assembly Image QuickCard Assembly Bar code Card Assembly Parallel Interface Card SES for SCS USB Parallel Port Marknet Print Servers 250 and 500 shee...

Page 27: ...the printer problem and repair the failure After you complete the repair perform tests as needed to verify the repair Tools Required for Service Flat blade screwdriver 1 Phillips screwdriver 2 Phillip...

Page 28: ...plification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MROM Masked Read Only Memory NVRAM Nonvolatile Random Access Memory OE...

Page 29: ...odes on page 2 2 User status messages provide the user with information on the current status of the printer Ready is displayed on the first line of the display unless Power Saver is invoked and then...

Page 30: ...Replace the engine board 902 General Engine Software These errors indicate an unrecoverable engine software error Replace the engine board 903 Paperport Link Driver Error 904 Interface Violation by t...

Page 31: ...6 923 Fuser Error Fuser is too hot during printing or when printer is idle Go to the Fuser Service Check on page 2 56 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit...

Page 32: ...Check on page 2 77 936 Main Drive Motor initial lock failure 937 Main Drive Motor lost lock 939 Controller Engine Communications Error The controller board and the engine board cannot communicate wit...

Page 33: ...replacing the controller board 941 Controller Font CRC Replace the controller board 943 Controller Font Version Indicates that the controller code and FONT ROM are incompatible 944 Controller Board Fa...

Page 34: ...the problem replace the controller board 963 RAM in slot 3 is Bad Replace the card in slot 3 If this does not fix the problem replace the controller board 964 Emulation Error Indicates a failure with...

Page 35: ...device Note Service Errors 980 thru 984 device can be one of the following engine board duplex tray x 1 2 3 4 or 5 envelope feeder or output bin 990 device Indicates an equipment check condition has o...

Page 36: ...eshooting a paper path problem especially paper jams in the base printer envelope feeder and duplex unit When a 9XX or 2XX error displays 1 Press and hold Return and press Select to enter for sub erro...

Page 37: ...B5 x 4 A4 x 5 Executive x 6 A5 x 7 Custom x 9 73 4 Env A 9 Env B 10 Env C 8 661 Env D C5 Env E B5 Env F Legal Env First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 84 xx 00 x1 x2...

Page 38: ...le causes for this error are Paper might be pre staged in the paper source tray Paper is picking too fast A defective input sensor 84 00 06 A paper jam has been declared by a smart device Immediate st...

Page 39: ...s from the feeder and check the envelope feeder for correct operation 84 xx 18 There is media over the Tray 2 pass thru sensor during warm up Check for media over the sensor If no media is present che...

Page 40: ...r during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 6 and see if Tray 6 is feeding paper correc...

Page 41: ...r before the printer EP was ready x1 Leading Edge of Media State x2 Trailing Edge of Media State 84 xx 23 x1 x2 The transfer servo never started x1 Media Size x2 Leading Edge of Media State 84 xx 25 T...

Page 42: ...ly This failure can be caused by a broken fuser exit sensor flag This may also be caused by erratic operation of exit sensor flag or exit sensor or a defective piece of media 89 xx 04 x1 The fuser exi...

Page 43: ...t being activated by a page that was known to have been picked by a source other than the duplex option Ensure the correct source has been selected and the media is feeding from that source 8E xx 06 x...

Page 44: ...to feed a sheet of media 8E xx 11 It took too long for the DC auto compensator motor to come up to speed 8E xx 13 x1 x2 Late feeding from a paper source interfered with the next pick retry x 1 Media S...

Page 45: ...zz 01 The Hot Roll fell too far below the desired temperature while printing zz 02 The Hot Roll was too cool while the system was doing some checking zz 03 The Hot Roll was too cool when heating to t...

Page 46: ...expected 03 The Hot Roll timed out trying to reach the final lamp detection temperature 04 After Hot Roll lamp detection did not reach steady state control in time 05 The Hot Roll did not reach opera...

Page 47: ...anytime an incorrect lamp is detected xx 00 Lamp detection performed and found an error 01 It took long to do lamp detection and NVRAM detected a previous wrong lamp detected yy Actual Temperature zz...

Page 48: ...sor test Check the envelope pass thru sensor to ensure it is operating correctly If the sensor test fails go to the Envelope Feeder Service Check on page 2 48 If the test passes look for anything that...

Page 49: ...of the paper path between the input sensor and the exit sensor 05 The duplex logic thinks a sheet of paper is feeding to the duplex unit due to a sensor malfunction in the paper path when in fact the...

Page 50: ...values Press Menu until Reset Printer is on the second line of the display Press Select to Reset the printer Busy The printer is busy receiving or processing data or printing data Note The printer ind...

Page 51: ...alues Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Printing Directory List A directory of the flash and disk contents is processing or printing...

Page 52: ...Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Resetting Printer The pr...

Page 53: ...Ready message No button actions are possible while this message is displayed Activating Menu Changes The printer is reset to activate a printer setting changed in the menus No button actions are possi...

Page 54: ...ccess the jammed pages Insert Cartridge or Close Door This message displays when the printer front door is open or the print cartridge is missing If this message cannot be cleared go to Cover Open Swi...

Page 55: ...re the Paper Size setting is correct for the size paper that is being used 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error This...

Page 56: ...6 Standard Serial Disabled This error is displayed when data is sent to the printer across the standard serial port but the port has been disabled 56 Parallel Port Disabled This error is displayed whe...

Page 57: ...Maintenance The operator panel displays this message at each 250K page count interval It is necessary to replace the fuser assembly transfer roller and charge roll at this interval to maintain the pri...

Page 58: ...No more data is processed from the host computer Press Go to return the printer to the Ready state User Message Explanation Toner Low If the toner cartridge is low then Toner Low displays The Toner Lo...

Page 59: ...s if any displays Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder Tray X Low If any of the input trays are low then Tray X Low displays where X designates w...

Page 60: ...wing table User Message Explanation Parallel Standard Parallel Port if available Serial Standard Serial Port if available Serial X Serial Port where X 1 2 3 is attached to PCI connector X Network X Ne...

Page 61: ...ncing a communications problem not fully connected or having a hardware failure If the device is temporarily removed or not connected properly then reattach it When the option is recognized the printe...

Page 62: ...ack on again Data loss results if print jobs are active when the printer is power cycled If a print job is active then remove the option and finish the job The printer automatically clears the message...

Page 63: ...l displays one square block of pels that turn on one at a time until all sixteen blocks display and then they all turn off 6 Performing Self Test appears on the display The high capacity option elevat...

Page 64: ...2 79 Paper feed problems Base printer or Integrated 500 Paper Tray Go to the Paper Feed Service Check on page 2 84 Paper jams at exit of Redrive Assembly No Duplex Unit installed Go to the Paper Feed...

Page 65: ...Go to the Print Quality Toner on backside of printed page on page 2 99 Print quality Vertical black bands on edge of copy Go to the Print Quality Black bands on outer edges of the page on page 2 96 U...

Page 66: ...y option to the next higher mounted option Go to the Input Tray s Service Check on page 2 62 Symptom Action Paper feed problem with Duplex Paper jams at Paper Removal Tray Paper skews in the Duplex Un...

Page 67: ...ck the printer error log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option Paper feed problems with error message Use the Sub Error Cod...

Page 68: ...ully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing 3 Remove the charge roll from the left side cha...

Page 69: ...ink assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check for continuity of the...

Page 70: ...switch for proper mechanical operation If incorrect repair as necessary Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4 3 It measures approximately 5 V...

Page 71: ...assembly FRU Action 1 Line Voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 AC Line Cord Check the line cord for any signs of damage If correct check the contin...

Page 72: ...utions before applying AC power Measure the voltage on LVPS output connector CN3 Pin 1 2 10 or 11 The voltage measures 5 V dc If incorrect replace the LVPS 9 Engine Board Turn the printer off and disc...

Page 73: ...een the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly If no...

Page 74: ...t Sensor Flag Run the Duplex Sensor Test from the diagnostics menu If the test fails check the input sensor cable at J5 on the system board for correct installation If no problem is found replace the...

Page 75: ...he system board Check for any shorts between each pin of the motor cable and the motor housing If shorts are found replace the motor Check the resistance of the stepper motor between J3 1 Stpmtr A to...

Page 76: ...ay that is recognized Note If a 260 Paper Jam Check Envelope message displays check the Sub Error Codes for 9XX and 2XX Error Codes on page 2 8 Printer does not recognize the envelope feeder as an att...

Page 77: ...ce the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 measures 2...

Page 78: ...or flag Note It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for any s...

Page 79: ...and operation If incorrect repair or replace the flag 2 Envelope Out Hopper Input Sensor Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the envel...

Page 80: ...re the voltage at J4 6 The voltage measures approximately 5 V dc If incorrect disconnect J4 and measure the voltage again If incorrect replace the envelope feeder system board If correct replace the D...

Page 81: ...nt may be too narrow 2 Weight Assembly Check the weight assembly to make sure it moves up and down freely without any binds Also check to make sure the weight assembly rests on all the rear kick rolle...

Page 82: ...ope feeder 2 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of the env...

Page 83: ...Fan to Engine Board Cable Check the continuity of the cable If incorrect replace the cable 3 Error Code 927 Fan runs Check the voltage at J1 1 on the engine board The voltage measures 5 V dc static 0...

Page 84: ...m may be due to the following The fuser may have reached standby temperature too quickly The line voltage may be above the maximum rating for the printer Note A 920 921 or 922 fuser error may be cause...

Page 85: ...ect replace the fuser top cover assembly 3 LVPS LVPS to Fuser AC Cable Caution When taking measurements for AC power observe all safety precautions Measure the AC line voltage between the two connecto...

Page 86: ...he thermistor assembly If damage is found replace the fuser top cover assembly If no damage is found check the resistance of the thermistor between pins J6 1 and J6 2 on the cable HOT 2 5K ohms COLD 1...

Page 87: ...lace the engine board If correct go to step 5 5 Fuser Hot Roll Fuser Hot Roll Bearings Fuser Backup Roll Bearings Fuser Backup Roll Fuser Mechanical Parts Examine the fuser assembly for signs of overh...

Page 88: ...nce of the solenoid between J4 1 and J4 2 on the fuser control board The resistance measures between 5 ohms and 10 ohms If incorrect replace the solenoid assembly 2 LVPS Check the voltage at CN3 18 on...

Page 89: ...ved A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly FRU Action 1 Input Sensor Flag Check the input sensor flag for damage and proper operati...

Page 90: ...tray that has a problem or needs service FRU Action 1 Tray X Option System Board or Compensator Assembly or Autoconnect Cable Check the autoconect cables and connectors for any signs of damage Replace...

Page 91: ...ls check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tr...

Page 92: ...mooth and correct operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector J5...

Page 93: ...bles Tray X System Board Check the autoconnect from the printer or option above tray x Check for signs of cuts pinched wiring or damage to the contacts in the connector Check the autoconnect cable s f...

Page 94: ...operating correctly The base printer indicates a dead machine condition when the high capacity input tray is installed FRU Action 1 AC Line Cord AC Jumper HCIT to Printer AC input and Output Receptacl...

Page 95: ...roperly connected to the high capacity feeder tray option board assembly 2 Base Printer or option mounted above Check the option or base printer autoconnect for signs of damage Repair the high capacit...

Page 96: ...rnal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to e...

Page 97: ...ils check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the t...

Page 98: ...the paper low switch cable from J3 on the high capacity system board Short pins 1 and 2 together while observing the sensor test on the display If the display does not change replace the high capacity...

Page 99: ...imit switch If incorrect replace the switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High Capacity Feeder Con...

Page 100: ...lace as required It is advisable to replace all four wear strips at the same time FRU Action 1 DC Drive Motor High Capacity Feeder Option System Board Be sure the motor cable is correctly installed at...

Page 101: ...J1 1 Brown approximately 0 V dc J1 2 yellow approximately 0 V dc Motor Running Forward J1 1 Brown Approximately 0 V dc J1 2 Yellow Approximately 24 V dc Motor Running Reverse J1 1 Brown Approximately...

Page 102: ...osition does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board FRU Action...

Page 103: ...ensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feed...

Page 104: ...for any signs of damage or contamination 3 Drive Pulley Check the drive pulley for any signs of wear binds or damage to the pulley or pulley shaft Make sure the pulley turns freely on the pulley shaft...

Page 105: ...rive Assembly Excessive noise or vibration Remove the controller board and run a Diagnostic Print Test in the continuous mode Check the main drive assembly for any excessive noise or vibration Determi...

Page 106: ...in drive motor running J12 7 5 V dc static 0 V dc when main drive motor running J12 6 5 V dc static 2 5 V dc when main drive motor running J12 5 5 V dc static 0 V dc when main drive motor running J12...

Page 107: ...ual cable on some printers and a combination cable assembly with the cover switch cable on later models Note If the operator panel is operating properly except for a Pel or a few Pels missing or broke...

Page 108: ...ce the operator panel assembly 3 Operator Panel Display blank 5 beeps LED On Check for ground between J13 4 and ground If correct replace the operator panel assembly If incorrect replace the engine bo...

Page 109: ...r damaged then run the Flash Test on page 3 4 If the test fails replace the Flash card If the problem continues replace the controller board DRAM Memory Option s This service check is the same as the...

Page 110: ...ion This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network Card Option Note The network is installed on the controller board...

Page 111: ...nless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message is not displayed FRU Action 1 Engine Board Printer fails to display Remove Paper Standard Bin message...

Page 112: ...rs or binds Replace the alignment assembly if any problem is found 2 Inner Deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly replace...

Page 113: ...tact the paper Also the autocompensator motor may be failing If this problems continues replace the autocompensator assembly Double Feeding Paper Note If double feeding paper occurs mostly from the bo...

Page 114: ...heck to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Parallel Port Service Check Run the Parallel Wrap Test on page 3 13 Note The Pa...

Page 115: ...the engine board If incorrect replace the defective cable The voltage at J8 1 measures approximately 5 V dc If incorrect replace the engine board The voltage at J3 7 measures approximately 24 V dc If...

Page 116: ...lain paper 20 lb Select the following menu settings as indicated Be sure and note the original settings so you can return the printer to the original customer printer setup Print Resolution Set to 300...

Page 117: ...curely and are not pitted contaminated or damaged If incorrect replace the contact with one from the HV contact kit Screws are included to attach the contacts to the right side frame in the HV contact...

Page 118: ...f damage or contamination 3 HVPS Check the fuse on the HVPS If open replace the HVPS Check the voltages at J10 on the engine board Measure the following voltages from connector J10 to printer ground P...

Page 119: ...t can also be caused by incorrect feeding from one of the input paper sources paper trays duplex unit or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged...

Page 120: ...spaced 38 26 mm 1 506 inch apart This can be caused by defective gear s in the main drive gearbox Replace the FRUs in the following order 1 Main drive gearbox 2 Reference edge 4 Lines spaced 44 64 mm...

Page 121: ...Us in the following order 1 Alignment assembly 2 Main drive gearbox assembly 11 Lines spaced 95 66 mm 3 766 inch apart Replace the FRUs in the following order 1 Toner cartridge 2 Main drive gearbox as...

Page 122: ...ters cannot be cleaned Try another printhead if all other attempts fail to correct a background problem 2 Transfer Roll Assembly Check the high voltage contact from the HVPS to the transfer roll Check...

Page 123: ...ne If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 2 voltage is incorrect or if the vol...

Page 124: ...s print quality problem appears as vertical black bands on one or both sides of the copy and can be wide narrow light or dark FRU Action 1 Charge Roll Counterbalance Springs If the problem is just on...

Page 125: ...uity of line J10 8 in the front cable harness If there is no continuity replace the cable harness If there is continuity replace the HVPS If this does not correct the problem replace the engine board...

Page 126: ...eck the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 Right Side Transfer Roll Arm Assembly HVPS Check the right side transfer roll a...

Page 127: ...t on the backside of the media This problem is generally caused by a toner buildup on the fuser hotroll or backup roll Check the fuser hotroll and backup roll for any noticeable buildup of toner Repai...

Page 128: ...tween the smart chip on the cartridge and the smart contact assembly Service Tip An intermittent 32 Unsupported Cartridge User Error Message can be caused by poor contact between the smart cartridge c...

Page 129: ...esigned to check the serial port hardware by using a wrap plug P N 1329048 and invoking the Serial Post Diagnostic Test The test helps isolate the printer from the serial cable and host The test provi...

Page 130: ...e front harness cable to make sure it is properly seated into the toner sensor If correct at both the sensor and engine board J10 check the continuity of the cable If incorrect replace the cable 3 Ton...

Page 131: ...ently CAUTION Make sure the printer is powered off before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer FRU Action 1 Transfer Roll...

Page 132: ...to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact If correct go to Print Quality Background on page 2 94 4 HVPS 917 Er...

Page 133: ...stic Mode 1 Turn the printer off 2 Press and hold the Go and Return buttons 3 Turn the printer on 4 Release the buttons when Performing Self Test displays on the operator panel The tests display on th...

Page 134: ...If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select the Quick Disk Test from the Device Tests menu The power indicator blinks while the test is in progr...

Page 135: ...est Clean BAD 000000 00 message displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 3 The power indicator blinks during the test The...

Page 136: ...ted at the end of the test To run the Flash Test 1 Select Flash Test from the Device Tests menu The power indicator blinks while the test is running Flash Test Test Passed message displays if the test...

Page 137: ...following steps are necessary to instruct the printer to POR without activating any download emulations To Disable the Download Emulation 1 Turn the printer off 2 Press and hold the Go and Menu butto...

Page 138: ...o print the Quick Test Page from the default paper source If the default paper source only supports envelopes then the page is printed from Tray 1 Check the Quick Test Page for the correct offset betw...

Page 139: ...ensors and switches are working correctly Select Sensor Test from the Duplex Tests menu Manually actuate each of the duplex sensors When the sensor switch is closed CL closed displays when the sensor...

Page 140: ...pass the test the following results must display AA 00 BB in the range of 20 through 3F inclusively hex CC in the range of 3A through 5D inclusively hex DD in the range of 11 through 1F inclusively h...

Page 141: ...r Paper message displays when the paper reaches paper stop position 1 and the power indicator turns on solid Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop position...

Page 142: ...in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log menu The Error log displays on...

Page 143: ...o run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test continually executes the LCD display test 2 Press Return Stop to cancel the test Button Test To run the Button Test 1 Select...

Page 144: ...top to exit the test P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F represents the number o...

Page 145: ...ower indicator on solid The results appear on the screen Parallel Wrap Test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested To run th...

Page 146: ...indicator blinks indicating the test is running 3 This test runs continuously unless canceled by pressing Return Stop Each time the test finishes the screen updates with the result If the test passes...

Page 147: ...Continuous continues feeding media from the selected source until Return Stop is pressed 4 Press Return Stop to exit test Input Tray Sensor Test This test is used to determine if the input tray sensor...

Page 148: ...splay indicates OP open when the flag is out of the sensor and CL closed when the flag is in the sensor 4 Press Return Stop to exit the test Base Sensor Test This test is used to determine if the sens...

Page 149: ...select the margin value to be changed press Select until the margin value pair you want to change is blinking 4 To change the margin value press Menu When the value you want is displayed press Select...

Page 150: ...ating it is the first digit to be changed 2 Press either Menu until the value you want displays 3 Press Select to move to the next digit press Menu until the value you want displays Continue with each...

Page 151: ...ance Page Count 1 Select Maintenance Count Value from the Diagnostic menu 2 Press Return to go to the previous menu To reset the Maintenance Page Count to zero Select Reset Maintenance Count Pressing...

Page 152: ...he Configuration ID is on a label located inside the printer The label is attached to the top front cover hinge assembly and is visible when the top front cover is open The leftmost digit blinks indic...

Page 153: ...papers and or problems with letterheads on some types of media The fuser temperature can be adjusted as follows NORMAL LOWER LOWEST Warm Up Time You can change the amount of time the printer warms up...

Page 154: ...p is pressed The contents of the Print Test Page varies depending on the media installed in the selected input source Note The Print Test Page always prints on one side of the paper regardless of the...

Page 155: ...ne class ID matching the machine class ID stored in NVRAM Some diagnostic information may be printed on the pages when printing from this menu To run the Print Quality Test Pages 1 Turn the printer of...

Page 156: ...Print Test displays The test is continuous 5 Press Select once again to stop the test Printing Menu Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Set...

Page 157: ...like the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness High normal force is one of the most signifi...

Page 158: ...erial interface transmit signal serial interface receive signal and two ground pins The duplex unit receives the 24 V dc from the base printer for the duplex motors and also converts the voltage to 5...

Page 159: ...ncreases The thermistor is connected to the fuser control board connector J2 1 and J2 2 and from J2 to J1 2 and J1 3 on the fuser control board to J16 2 and J16 3 on the engine board J16 2 THERMGND an...

Page 160: ...per is jammed between the printer input and exit sensors This condition can be caused by the paper exiting the input sensor too late or jamming in the fuser assembly prior to activating the exit senso...

Page 161: ...pose feeder and has not reached the base machine input sensor or has not reached the input sensor in time Error Message 260 Paper Jam Check Envelope Feeder An envelope is jammed in the envelope feeder...

Page 162: ...3 30 Service Manual 4520 xxx...

Page 163: ...tricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ES...

Page 164: ...page 4 19 to access the drive belt idler pulley 2 Loosen the idler pulley mounting screw and position the idler to provide 3 mm 5 mm drive belt deflection 3 Tighten the idler pulley mounting screw bei...

Page 165: ...s they are fed through the printer This adjustment does not reduce the printer overall performance such as pages per minute but can help in reducing the amount of curl of some printed medias thus impr...

Page 166: ...lf Test displays 4 Select Registration from the menu 5 Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamonds...

Page 167: ...egistration on page 3 17 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the...

Page 168: ...range specified in Print Registration on page 3 17 The reference screw can be adjusted without loosening the locknut Turn the screw a few turns and print a copy of the Quick Test Page as you check th...

Page 169: ...correct screw type in each location during reassembly Reference Number Screw Type Location Purpose Qty M3 5x8 mm Thread Cutting right side frame to center pan attach 1 toner level sensor mounting 1 ch...

Page 170: ...side frame attach 2 M3 5x12 mm Thread Cutting engine board shield to left frame attach 1 paper alignment assembly mounting 2 toner cartridge guide track mounting 2 left side frame to center pan attach...

Page 171: ...round attach 2 controller board to inner shield mounting 2 controller board back mounting 2 engine board to interconnect shield ground attach 1 lower stacker duct mounting 1 ground cables to ground ce...

Page 172: ...bottom hole attach 1 M3x6 mm Taptite Panhead stacker duct mounting 1 controller to shield mounting 2 controller board mounting 2 in pan mounting 2 shield ground attach 1 LVPS mounting 2 fuser cover mo...

Page 173: ...Thread Forming right side cover mounting 1 right side frame to pan attach 3 left side frame to pan attach 1 M3x6 mm SEMS Machine Screw with washer fuser board ground cable mounting 1 M3 5x12 mm Plast...

Page 174: ...ter Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avo...

Page 175: ...Repair Information 4 13 4520 xxx Right Cover Removal 1 Open the upper and bottom front covers 2 Release the cover latch A and remove the right cover mounting screw B...

Page 176: ...4 14 Service Manual 4520 xxx 3 Remove the redrive assembly 4 Remove the right side cover mounting screw B 5 Remove the right side cover...

Page 177: ...nt cover 2 Remove the upper front cover mounting screws A 3 Rotate the cover upward to allow the rear cover hinges to clear the mounting slots and remove the cover Note When removing the cover hold th...

Page 178: ...Remove the rear paper deflector 4 Press the fuser wiper cover latch and remove the cover 5 Remove the paper full sensor flag assembly from the mounting bracket 6 Remove the mounting screws A and remo...

Page 179: ...inner EMC shield 2 Remove the controller board mounting screws A 3 Remove the controller board parallel port mounting screws if installed 4 Remove the USB port mounting screws C if present 5 Remove th...

Page 180: ...moval 1 Remove the inner EMC shield 2 Remove the developer drive assembly mounting screws A 3 Remove the developer drive assembly Note Be sure the developer drive assembly wheel aligns with the hub on...

Page 181: ...2 Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6 3 Position the duplex assembly on its side 4 Gently release the three front cove...

Page 182: ...ly 5 Position the duplex assembly on its side 6 Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly 7 Remove the center drive deflector asse...

Page 183: ...ovals Inner EMC Shield Removal 1 Remove the left door 2 Remove the outer EMC shield 3 Remove all option boards from the connector board slots 4 Remove the inner EMC shield mounting screws A 5 Remove t...

Page 184: ...4 22 Service Manual 4520 xxx Outer EMC Shield Removal 1 Remove the left door 2 Loosen the outer EMC shield mounting screws A and remove the shield...

Page 185: ...gine board 3 Remove the engine board mounting screws A 4 Remove the engine board shield mounting screw B from the main drive motor assembly 5 Remove the engine board Note Anytime the engine board is r...

Page 186: ...oval 1 Remove the top rear cover 2 Remove the inner EMC shield 3 Note the routing of the main fan cable A and disconnect the cable from the engine board at connector J1 4 Release the four latches B an...

Page 187: ...frames 2 Remove the EP frame assembly Left Side Frame Removal 1 Remove the engine board 2 Remove the main drive assembly 3 Remove the upper front cover hinge assembly 4 Remove the multipurpose tray lo...

Page 188: ...4 26 Service Manual 4520 xxx 7 Place the printer on its back and remove the left side frame mounting screws A 8 Remove the left side frame...

Page 189: ...ator arm bias spring from the right side frame 5 Remove the toner sensor mounting screw A disconnect the sensor cable and remove the toner sensor 6 Remove the right side frame mounting screws B and re...

Page 190: ...r Removal 1 Remove the redrive assembly 2 Remove the ground screw B 3 Remove the fuser mounting screws A 4 Disconnect the AC fuser lamp connector from the LVPS 5 Disconnect the DC fuser cable from the...

Page 191: ...formation 4 29 4520 xxx Fuser Board Removal 1 Remove the fuser assembly 2 Disconnect the cables A from the fuser board 3 Remove the fuser board mounting screws B 4 Lift the fuser board from the fuser...

Page 192: ...e fuser board 3 Disconnect the AC fuser lamp cable from the top left side of the fuser cover 4 Remove the two screws A from the right side fuser lamp contact cover 5 Remove screw B that attaches the f...

Page 193: ...Repair Information 4 31 4520 xxx CAUTION Take care when removing the screw as the lamp is under pressure When the contact is released damage to the lamp or contact may occur...

Page 194: ...free the fuser frame walls 5 Gently apply outward pressure on the left and right fuser side frames to release the detack housing assembly Fuser Transfer Plate Removal 1 Remove the upper paper deflecto...

Page 195: ...the fuser assembly 2 Disconnect the solenoid cable from the fuser board 3 Remove the solenoid mounting screw A 4 Disconnect the solenoid link B 5 Remove the solenoid from the fuser assembly Note Perf...

Page 196: ...ure the sensor operates correctly 6 Replace the cable tie on the cable bundle Fuser Exit Sensor Flag Assembly Removal 1 Cut the cable tie from the fuser board cable bundle 2 Disconnect the exit sensor...

Page 197: ...mp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp Use the following table to identify and insta...

Page 198: ...right side cover 4 Disconnect the HVPS cable from the HVPS at connector C 5 Disconnect the transfer roll cable from the HVPS board Warning Use care when disconnecting the cable from the transformer on...

Page 199: ...the printer on its side 6 Locate the integrated tray compensator assembly B on the bottom of the printer and disconnect the compensator arm bias spring from the frame 7 Remove the C clip that rests ag...

Page 200: ...ick Roll Assembly Removal 1 Remove the paper tray 2 Place the printer on its side 3 Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer 4 Un...

Page 201: ...ove the engine board and shield 3 Remove the LVPS 4 Disconnect all cables from the interconnect board Go to Interconnect Board on page 5 14 to identify the correct jumper locations for your printer 5...

Page 202: ...rvice Manual 4520 xxx Low Voltage Power Supply Removal 1 Remove the right cover 2 Remove the LVPS mounting screws A from the rear of the bottom pan 3 Pull the LVPS assembly from the right side of the...

Page 203: ...Repair Information 4 41 4520 xxx 4 Press the release latch on the fuser lamp cable connector B and disconnect from the LVPS 5 Remove the fuser assembly...

Page 204: ...4 42 Service Manual 4520 xxx 6 Disconnect the interconnect card cable from the LVPS C 7 Remove the LVPS...

Page 205: ...rom the cable clamps B on the main drive assembly 6 Remove the ground screw C and remove the engine board shield 7 Remove the main drive assembly mounting screws D 8 Remove the link from the rear of t...

Page 206: ...4 44 Service Manual 4520 xxx Main Drive Motor Removal 1 Remove the main drive assembly 2 Remove the main drive motor mounting screws A 3 Remove the main drive motor...

Page 207: ...bly Removal 1 Open the multipurpose tray to a position that allows the left and right tray hinge slots A to align with the rectangular mounting posts B Pull upward on each tray hinge to remove the tra...

Page 208: ...anual 4520 xxx 2 Remove the upper deflector 3 Remove the solenoid mounting screw 4 Remove the screws A mounting the multipurpose tray lower deflector assembly 5 Remove the multipurpose tray lower defl...

Page 209: ...4 47 4520 xxx Operator Panel Assembly Removal 1 Remove the upper front cover 2 Gently press the operator panel lens tab A to loosen the operator panel 3 Disconnect the operator panel cable and remove...

Page 210: ...the operator panel Pull the cables through the rectangular hole in the hinge pivot arm 4 Plug the new operator panel cable into the operator panel and snap the new cover open switch cable into the br...

Page 211: ...embly 2 Release the paper pass thru sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly Paper Tray Board Removal...

Page 212: ...Assembly Removal 1 Remove the upper paper deflector assembly 2 Remove the inner paper deflector assembly 3 Release the input paper sensor from its mounting and remove 4 Remove the left door 5 Remove t...

Page 213: ...cate the paper alignment assembly reference adjustment screw B through the left frame and remove the screw 7 Remove the paper alignment assembly Note Do the Paper Alignment Assembly Adjustment on page...

Page 214: ...sembly 5 Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector Upper Paper Deflector Assembly Removal 1 Open the m...

Page 215: ...e the input paper sensor from its mounting and remove Paper Size Sensing Board Removal 1 Disconnect the paper size sensing board cable from the board 2 Remove the two paper size sensing board mounting...

Page 216: ...cover 2 Disconnect the printhead cables A from the printhead assembly 3 Remove the printhead mounting screws B and remove the printhead Note Do the Printhead Assembly Adjustment on page 4 4 whenever...

Page 217: ...0 xxx Redrive Assembly Removal 1 Remove the redrive door assembly 2 Remove the redrive exit cover 3 Remove the redrive assembly mounting screws A 4 Release the redrive assembly mounting latches B and...

Page 218: ...Disconnect smart cartridge cable 2 Remove print cartridge 3 Remove transfer plate 4 Unlatch smart cartridge contact assembly A from the right frame assembly 5 Remove smart cartridge contact B 6 Discon...

Page 219: ...Repair Information 4 57 4520 xxx Toner Sensor Removal 1 Remove the right side cover 2 Remove the toner sensor mounting screw A Disconnect the toner sensor cable and remove the toner sensor...

Page 220: ...eft pivot arm 3 Lift the transfer roll assembly toward the left and remove it from the printer Upper Paper Deflector Assembly Removal 1 Open the multipurpose tray and remove the tray from the two moun...

Page 221: ...on the inside of each hinge 4 Detach the two springs B from the upper front cover hinges 5 Disconnect the operator panel cable from the operator panel assembly 6 Raise the upper front cover hinge ass...

Page 222: ...embly Removal 1 Remove the upper front cover 2 Remove the operator panel 3 Remove the inner EMC shield 4 Remove the mounting screw A and remove the switch assembly 5 Note the routing of the interlock...

Page 223: ...ons Low Voltage Power Supply Connector Pin No Signal CN3 Interconnect Board 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground...

Page 224: ...5 2 Service Manual 4520 xxx...

Page 225: ...nnector Locations 5 3 4520 xxx High Voltage Power Supply Connector Pin No Signal CN1 Engine Board 1 Developer PWM 2 24 V dc Return 3 Charge PWM 4 24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OU...

Page 226: ...n Stall 2 Ground 3 Main Fan J3 Printhead Mirror Motor 1 24 V dc Return 2 24 V dc Return 3 ReFREQ 4 LOCKn 5 Start 6 24 V dc Return 7 24 V dc J4 Cover Closed Switch 1 Cover Closed 2 Ground 3 5 V dc J5 P...

Page 227: ...5 V dc 2 HsyncID 3 Hsyncin 4 Ground J10 Cartridge Sensor Input Sensor HVPS 1 AT Servo HVPS 2 Servo OutT HVPS 3 TXENABLE HVPS 4 Transfer HVPS 5 24 V dc HVPS 6 Charge HVPS 7 Ground HVPS 8 Developer HVPS...

Page 228: ...Panel 1 FPIRQ 2 Ground 3 I2CCLK 4 5 V dc 5 I2CDATA J12 Transport Motor 1 ON OFF 2 Ground 4 5 V dc 5 MTR1 6 Dir 7 MTR4 8 MTR3 9 24 V RET 10 24 V RET 11 24 V dc J14 Autoconnect Options 1 RXDIN 2 Ground...

Page 229: ...IZE1 5 24 V dc 6 Ground 7 POUT 8 5 V dc 9 Paper Low 10 5 V dc J16 Fuser 1 Narmedia 2 Thermgnd 3 Therm 4 Ground 5 Thumpdrv 6 5 V dc 7 Thumpret 8 Exit Sensor R J17 MPT Pick 1 MPT Pick 2 24 V dc J18A Aut...

Page 230: ...5 8 Service Manual 4520 xxx J19 MPT Paper Out 1 MPFSENSE 2 Ground 3 MPFLED J22 Smart Contact 1 Scart 5 V 2 Ground 3 Ground Connector Pin No Signal...

Page 231: ...Connector Locations 5 9 4520 xxx Engine Board...

Page 232: ...5 10 Service Manual 4520 xxx Controller Board Non Network...

Page 233: ...Connector Locations 5 11 4520 xxx Controller Board Network...

Page 234: ...Signal J1 Engine Board 1 NarMedia 2 ThermGnd 3 HRTherm 4 Ground 5 ThumpA 6 5 V dc 7 ThumpB 8 ExitSns J2 Thermistor 1 ThermGnd 2 HRTherm J3 Thumper 1 Ground 2 42 V dc J4 Thumper Solenoid 1 ThumpB 2 Th...

Page 235: ...Connector Locations 5 13 4520 xxx...

Page 236: ...2 Heaton 3 Xeroxing 4 24 V dc 5 24 V dc 6 24 V dc 7 Ground 8 Ground 9 Ground 10 Ground J3 LVPS 1 Ground 2 Ground 3 Ground 4 Ground 5 5 V dc 6 5 V dc 7 5 V dc 8 5 V dc J5 Autoconnect BTM FNT 1 24 V dc...

Page 237: ...Connector Locations 5 15 4520 xxx 210 220 001 002...

Page 238: ...Board Connector Pin No Signal J1 1 N A 2 Ground 3 Tx EOC 4 Ground 5 Rx EOC 6 24 V dc Return 7 24 V dc J2 1 Ground 2 Paper Present 3 5 V dc J3 1 Ground 2 Paper Present 3 5 V dc J4 1 Motor Phase B 2 Mo...

Page 239: ...Connector Locations 5 17 4520 xxx...

Page 240: ...1 Motor 2 Motor J2 DC Motor Sensor Encoder Board 1 5 V dc Sensor 2 Tach 3 Ground J3 Stepper Motor 1 STPMOTA 2 STPMOTA 3 STPMOTB 4 STPMOTB J4 Fan 1 24 V dc 2 Fan On J5 Paper Input Sensor 1 5 V dc Senso...

Page 241: ...connect Option Below 1 Ground 2 PrtxDout 3 Ground 4 PrtRxd J10 Autoconnect Option Below 1 24 V dc 2 Ground J11 Printer Autoconnect 1 24 V dc 2 Ground J12 Printer Autoconnect 1 N A 2 Ground 3 PrtxDin 4...

Page 242: ...5 20 Service Manual 4520 xxx...

Page 243: ...tered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposu...

Page 244: ...roller and charge roll at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 115 V 630 W Maintenanc...

Page 245: ...ajority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by descr...

Page 246: ...7 2 Service Manual 4520 xxx Assembly 1 Covers...

Page 247: ...nk 9 99A1502 1 Latch Upper Cover 10 99A0004 1 Spring Latch 11 99A1511 1 Cover Assembly Lower Front 12 99A2014 1 Operator Panel Assembly 110V 12 99A2015 1 Operator Panel Assembly 220V 13 99A2060 1 Swit...

Page 248: ...7 4 Service Manual 4520 xxx Assembly 2 Frame...

Page 249: ...A2022 1 Right Sideframe 15 99A1518 1 Frame Extension Right 210 220 16 99A0028 1 Spring Tray Bias 17 99A0585 1 Parts Packet Contact Kit Contact Dr Blade TAR Developer Roll 3 Contact PC Drum 1 Contact C...

Page 250: ...7 6 Service Manual 4520 xxx Assembly 2 Frame continued...

Page 251: ...896 1 Guard Gear 33 99A2078 1 Pan Motor Drip 34 99A0567 1 Link Gear Release 35 99A0556 1 Spring Counterbalance NS 99A0263 17 Parts Packet Screw NS 99A1524 1 Spring Cartridge Load NS 99A1546 1 Shield G...

Page 252: ...7 8 Service Manual 4520 xxx Assembly 3 Printhead...

Page 253: ...Parts Catalog 7 9 4520 xxx Asm Index Part Number Units Description 3 1 99A2026 1 Printhead Assembly NS 99A0263 3 Parts Packet Screw Printhead Mounting...

Page 254: ...7 10 Service Manual 4520 xxx Assembly 4 Paper Feed Autocompensator...

Page 255: ...y 2 99A2079 1 Pick Arm Assembly 500 210 220 2 99A2157 1 Pick Arm Assembly 250 001 002 3 99A0070 2 Pick Rolls 4 99A1616 1 Flag Paper Out 500 Tray 4 99A1609 1 Flag Paper Out 250 Tray 001 002 5 99A1927 1...

Page 256: ...7 12 Service Manual 4520 xxx Assembly 5 Paper Feed Multipurpose Unit...

Page 257: ...eflector Assembly MPT 7 99A1531 1 Deflector Lower 8 99A0263 2 Parts Packet Screw Lower Deflector Mounting 8 mm 8 99A0263 2 Parts Packet Screw Lower Deflector Mounting 12 mm 9 99A0084 1 Flag MPT Paper...

Page 258: ...7 14 Service Manual 4520 xxx Assembly 6 Paper Feed Alignment...

Page 259: ...gnment Assembly Paper Feed 2 99A0263 3 Parts Packet Screw Paper Feed 3 99A2066 1 Clip Reference Ground 4 99A0492 1 Screw Paper Reference Adjustment 5 99A0565 1 Washer Reference Adjustment 6 99A0566 1...

Page 260: ...7 16 Service Manual 4520 xxx Assembly 7 Paper Feed Output...

Page 261: ...cription 7 1 99A2029 1 Redrive Assembly Inner 250 210 220 1 99A2151 1 Redrive Assembly Inner 250 001 002 2 99A1644 1 Door Assembly Redrive 250 NS 99A0104 1 Spring Upper Diverter NS 99A1857 1 Deflector...

Page 262: ...7 18 Service Manual 4520 xxx Assembly 8 Integrated Paper Tray 500 Sheet...

Page 263: ...int 2 99A1576 1 Tray Assembly 500 Sheet 3 99A1895 1 Restraint Side 4 99A0292 4 Strip Wear 5 99A1812 1 Label Tray Option Number 6 99A1583 1 Plate 500 Tray Wear 7 99A0126 3 Finger Autosize 8 99A0124 1 P...

Page 264: ...7 20 Service Manual 4520 xxx Assembly 9 Main Drive...

Page 265: ...rbox w Motor 2 99A0134 1 Shaft Power Takeoff 250 2 99A1569 1 Shaft Power Takeoff 500 3 99A0275 1 Spring Power Takeoff Shaft 4 99A2080 1 Gear Bevel with Grease Packet NS 99A0263 4 Parts Packet Screw Ge...

Page 266: ...7 22 Service Manual 4520 xxx Assembly 10 Developer Drive...

Page 267: ...g 7 23 4520 xxx Asm Index Part Number Units Description 10 1 99A1544 1 Developer Drive Assembly 2 99A2081 1 Parts Packet Developer Drive Shaft Coupler Gear 55 3 99A0263 3 Parts Packet Screw Developer...

Page 268: ...7 24 Service Manual 4520 xxx Assembly 11 Hot Roll Fuser...

Page 269: ...er Assembly 4 Hanger 7 5 99A1520 1 Gear Upper Redrive 6 99A2035 1 Housing Detack Assembly 7 99A2036 1 Hot Roll 8 99A2038 1 Backup Roll 9 99A2067 1 Envelop Conditioner Solenoid Assembly 10 99A2039 1 Fu...

Page 270: ...7 26 Service Manual 4520 xxx Assembly 12 Transfer...

Page 271: ...1 99A1015 1 Transfer Roll Assembly 2 99A0349 1 Arm Transfer Roll Assembly Right 3 99A0184 1 Spring Transfer Roll Right 4 99A0185 1 Shaft Transfer Pivot 5 99A0181 1 Spring Transfer Roll Left 6 99A1578...

Page 272: ...7 28 Service Manual 4520 xxx Assembly 13 Charging...

Page 273: ...Index Part Number Units Description 13 1 99A0512 1 Link Assembly Charge Left Kit 2 99A0513 1 Link Assembly Charge Right Kit 3 99A1017 1 Roll Assembly Charge 4 99A1555 1 Bushing Charge Roll NS 99A0263...

Page 274: ...7 30 Service Manual 4520 xxx Assembly 14 Electronics 1...

Page 275: ...Ireland 1 1339539 1 Power Cord Set 6 ft Israel Germany 1 1339540 1 Power Cord Set 6 ft Switzerland 1 1339541 1 Power Cord Set 6 ft South Africa 1 1339546 1 Power Cord Set 6 ft Two Prong Argentina HV 1...

Page 276: ...7 32 Service Manual 4520 xxx Assembly 14 Electronics I continued...

Page 277: ...6 1 Interconnect Board Assembly 2 slot 210 220 6 99A2152 1 Interconnect Board Assembly 1 slot 001 002 7 99A2042 1 Engine Board Assembly 210 220 7 99A2155 1 Engine Board Assembly 001 002 8 99A2486 1 Ca...

Page 278: ...7 34 Service Manual 4520 xxx Assembly 15 Electronics II...

Page 279: ...embly 2 Slot 210 220 3 99A2156 1 Shield Inner Assembly 1 Slot 001 002 4 99A2094 1 Shield Outer 2 Slot 210 220 4 99A2095 1 Shield Outer 1 Slot 001 002 5 99A0263 4 Parts Packet Screw Outer Shield Mounti...

Page 280: ...7 36 Service Manual 4520 xxx Assembly 16 Electronics III...

Page 281: ...Main 2 99A2030 1 Gearbox w Motor 3 99A0128 1 Board Input Tray ITC 4 99A2053 1 Cable Auto Connect Bottom 5 99A2046 1 Interconnect Board Assembly 6 99A2052 1 Cable Integrated Tray 7 99A2054 1 Cable Mai...

Page 282: ...7 38 Service Manual 4520 xxx Assembly 17 Electronics IV...

Page 283: ...t 4 99A2079 1 Pick Arm Assembly 500 210 220 4 99A2157 1 Pick Arm Assembly 250 001 002 5 99A2071 1 Sensor MPT Paper Out 6 99A2079 1 Pick Arm Assembly 500 210 220 6 99A2157 1 Pick Arm Assembly 250 001 0...

Page 284: ...7 40 Service Manual 4520 xxx Assembly 18 Electronics V...

Page 285: ...y 4 99A2046 1 Interconnect Board Assembly 5 99A2067 1 Solenoid Assembly Envelope Conditioner 6 99A2039 1 Fuser Board Assembly 7 99A1551 1 Sensor Exit 8 99A2033 1 Cover Fuser Assembly with Thermistor 9...

Page 286: ...7 42 Service Manual 4520 xxx Assembly 19 Electronics VI...

Page 287: ...y 4 99A2046 1 Interconnect Board Assembly 5 99A2067 1 Solenoid Assembly Envelope Conditioner 6 99A2039 1 Fuser Board Assembly 7 99A1551 1 Sensor Exit 8 99A2033 1 Cover Fuser Assembly with Thermistor 9...

Page 288: ...7 44 Service Manual 4520 xxx Assembly 20 250 Sheet Tray...

Page 289: ...sembly Drive 500 Dual 13 99A0451 1 Roller Skewed Backup 14 99A0282 1 Cable 250 Tray Option 15 99A0450 1 Retainer Roller 16 99A0350 1 Sensor Paper Low 17 99A0679 2 Bracket 250 Frame Retention 18 99A067...

Page 290: ...7 46 Service Manual 4520 xxx Assembly 20 250 Sheet Tray continued...

Page 291: ...19 4 Wear Strips 39 99A1829 1 Label Tray Option Number 40 99A0121 1 Clip 250 Tray Wear 41 99A0126 4 Finger Autosize 42 99A0124 1 Plate Snap In 43 99A1952 1 Label Paper Size 44 99A1537 1 Knob Paper Siz...

Page 292: ...7 48 Service Manual 4520 xxx Assembly 21 Integrated Paper Tray 250 Sheet...

Page 293: ...60 1 Restraint Back 250 Sheet Tray 3 99A1894 1 Restraint Side 250 Sheet Tray 4 99A0119 4 Wear Strips 5 99A1812 1 Label Tray Option Number 6 99A0121 1 Clip 250 Tray Wear 7 99A0126 4 Finger Autosize 8 9...

Page 294: ...7 50 Service Manual 4520 xxx Assembly 22 500 Sheet Tray...

Page 295: ...1 Sensor Option Pass Thru 10 99A0895 1 Restraint Side 500 Sheet Tray 11 99A0292 4 Wear Strips 12 99A1829 1 Label Tray Option Number 13 99A1583 1 Plate 500 Tray Wear 14 99A0126 4 Finger Autosize 15 99...

Page 296: ...7 52 Service Manual 4520 xxx Assembly 22 500 Sheet Tray continued...

Page 297: ...w Board Mounting 35 99A0267 1 Parts Packet Retainer Aligner Assembly 36 99A0280 1 Bearing Drive Shaft Low 37 99A0446 1 Aligner Assembly Paper 38 99A0274 1 Gear Feed Roll 39 99A0063 1 Spring Switch Act...

Page 298: ...7 54 Service Manual 4520 xxx Assembly 23 Duplex Unit...

Page 299: ...embly Deflector 15 99A0413 2 Parts Packet Screw Actuator Mtg 16 99A1130 1 Guide Return RH Upper 250 Duplex 17 99A0413 2 Parts Packet Screw Guide Mounting 18 99A0340 1 Guide Return RH Lower 250 Duplex...

Page 300: ...7 56 Service Manual 4520 xxx Assembly 23 Duplex Unit continued...

Page 301: ...99A0317 1 Gear Duplex Bevel 35 99A0434 1 Pan Engine Board Drip 36 99A0279 1 Bearing Drive Shaft 37 99A0191 1 Fuse 8A SB 38 99A1669 1 Board System with Jumper 250 500 Duplex 39 99A1666 1 Label Options...

Page 302: ...7 58 Service Manual 4520 xxx Assembly 23 Duplex Unit continued...

Page 303: ...99A0413 3 Parts Packet Screw Outer Frame 52 99A0330 1 Guide Assembly Center Drive 53 99A0269 1 Parts Packet Fan Mounting Kit 54 99A0308 1 Fan Cooling Duplex 55 99A0404 2 Parts Packet Retainer 5 mm Mai...

Page 304: ...7 60 Service Manual 4520 xxx Assembly 24 Envelope Feeder...

Page 305: ...rts Packet Gear Kit 14 99A1698 1 Cover Left Side NS 99A0404 1 Parts Packet Retainer 4 mm PP NS 99A0404 3 Parts Packet Retainer Clip 5 mm Shaft NS 99A0404 2 Parts Packet Retainer 6 mm NS 99A0404 3 Part...

Page 306: ...7 62 Service Manual 4520 xxx Assembly 25 High Capacity Feeder...

Page 307: ...2 Transfer Lead Screw Assembly 13 99A0716 1 Bearing Leadscrew Bottom 14 99A0676 4 Parts Packet Nut 6 32 Hinge Mounting 15 99A0677 4 Parts Packet Washer Hinge Mounting Flat 16 99A0677 4 Parts Packet Wa...

Page 308: ...7 64 Service Manual 4520 xxx Assembly 25 High Capacity Feeder continued...

Page 309: ...0653 1 Switch Lower Limit Microswitch 42 99A0676 2 Parts Packet Nut Power Supply Ground 43 99A0677 4 Parts Packet Washer Motor Plate Mtg 44 99A1808 1 Cord AC External Jumper 45 99A0676 2 Parts Packet...

Page 310: ...7 66 Service Manual 4520 xxx Assembly 25 High Capacity Feeder continued...

Page 311: ...ptacle Upper AC 72 99A1803 1 Cover Top LVPS 73 99A1804 3 Nut w lock washer Top LVPS Cover Mounting 74 99A1804 1 Nut w lock washer Top LVPS Cover Mounting 75 99A1805 1 Grommet Top LVPS Cover 76 99A0281...

Page 312: ...7 68 Service Manual 4520 xxx Assembly 25 High Capacity Feeder continued...

Page 313: ...Release 93 99A1967 1 Card Assembly 2000 Tray Option 94 99A0263 3 Parts Packet Screw Tray Option Card Mtg NS 99A0675 10 Parts Packet Screw Door to Door Frame Mounting NS 99A0676 6 Parts Packet Nut Sup...

Page 314: ...7 70 Service Manual 4520 xxx Assembly 25 High Capacity Feeder continued...

Page 315: ...99A0263 1 Parts Packet Screw Deflector Mounting 100 99A0678 1 Deflector Base 101 99A0288 1 Sensor Pass Thru 102 99A1812 1 Label Tray Option Number 103 99A1666 1 Label Options 104 99A0677 4 Parts Packe...

Page 316: ...7 72 Service Manual 4520 xxx Assembly 26 Kiosk Vertical Paper Adapter...

Page 317: ...Idler 8 99A0197 1 Shaft Drive Rear 9 99A0079 1 Tray Assembly Backup Roller 10 99A0208 3 Parts Packet Pulley 11 99A0087 6 Spring Backup Roller 12 99A0086 6 Roller Backup 13 99A1706 1 Tray Assembly Dri...

Page 318: ...7 74 Service Manual 4520 xxx Assembly 27 Kiosk Horizontal Paper Adapter...

Page 319: ...99A1704 2 Gear Idler 8 99A0197 1 Shaft Drive Rear 9 99A0079 1 Tray Assembly Backup Roller 10 99A0208 3 Parts Packet Pulley 11 99A0087 6 Spring Backup Roller 12 99A0086 6 Roller Backup 13 99A1707 1 Tr...

Page 320: ...h DIMM 28 99A1774 1 Card Assembly 16MB Flash DIMM 28 99A2486 1 Card Assembly Bar Code 28 99A2487 1 Card Assembly Prescribe 5 4 2 Flash 28 99A2200 1 Card Assembly IPDS and SCS Tne 28 99A2488 1 Hard Dis...

Page 321: ...B or larger 28 99A1605 1 Kit Cap Stack Bails 500 28 99A1830 1 MarkNet N2001e 10 100 Ethernet 28 12G1696 1 MarkNet N2002e 10Base2 10Baset 28 12G1697 1 MarkNet N2000t 4 16 28 99A0560 1 Adapter Omnibus I...

Page 322: ...rings 29 99A0577 1 Parts Packet Cable Ties 10 each 29 99A0675 1 Parts Packet Screw High Capacity Feeder 29 99A0676 1 Parts Packet Nuts High Capacity Feeder 29 99A0677 1 Parts Packet Washers High Capac...

Page 323: ...rts Packet Pulley Kiosk 29 99A0234 1 Parts Packet Screw Kiosk 29 99A0394 1 Grease Packet Nyogel 744 29 99A0462 1 Grease Packet IBM 23 29 99A1852 1 Packaging 4069 250 250 printer 29 99A1853 1 Packaging...

Page 324: ...7 80 Service Manual 4520 xxx...

Page 325: ...x Sensor Test 3 7 Error Log 3 10 Clearing the Error Log 3 10 Viewing the Error Log 3 10 Hardware Tests 3 11 Button Test 3 11 LCD Test 3 11 Parallel Wrap Test 3 13 ROM Memory Test 3 13 SDRAM Memory Tes...

Page 326: ...13 Parts Catalog 7 1 Charging 7 28 Covers 7 2 Developer Drive 7 22 Duplex Unit 7 54 Electronics I 7 30 Electronics II 7 34 Electronics III 7 36 Electronics IV 7 38 Electronics VI 7 42 Envelope Feeder...

Page 327: ...mbly 4 49 Paper Alignment Assembly 4 50 Paper Deflectors 4 52 Inner Paper Deflector Assembly 4 52 Upper Paper Deflector Assembly 4 52 Paper Input Sensor 4 53 Paper Size Sensing Board 4 53 Pick Roll 4...

Page 328: ...97 7 77 13A0296 7 76 13A0297 7 76 13A0298 7 76 1339535 7 31 1339537 7 31 1339538 7 31 1339539 7 31 1339540 7 31 1339541 7 31 1339542 7 31 1339543 7 31 1339544 7 31 1339545 7 31 1339546 7 31 1342514 7...

Page 329: ...53 7 67 7 69 7 71 99A0267 7 13 7 25 7 27 7 53 7 67 7 69 7 78 99A0268 7 78 99A0269 7 59 7 78 99A0271 7 61 7 78 99A0272 7 45 7 67 99A0273 7 45 7 53 7 67 99A0274 7 45 7 53 7 57 7 69 99A0275 7 21 7 45 7...

Page 330: ...0545 7 76 99A0549 7 5 99A0556 7 7 99A0560 7 77 99A0565 7 15 99A0566 7 15 99A0567 7 7 99A0572 7 78 99A0577 7 3 7 78 99A0585 7 78 99A0627 7 45 7 57 99A0629 7 76 99A0650 7 63 99A0651 7 65 99A0653 7 65 99...

Page 331: ...7 49 99A1537 7 47 7 51 99A1538 7 7 99A1540 7 7 99A1541 7 7 99A1544 7 23 99A1546 7 7 99A1551 7 25 7 41 7 43 99A1553 7 43 99A1555 7 29 99A1569 7 21 99A1576 7 19 7 51 99A1578 7 27 99A1579 7 55 99A1582 7...

Page 332: ...800 7 67 99A1801 7 67 99A1802 7 67 99A1803 7 67 99A1804 7 67 99A1805 7 67 99A1806 7 63 99A1807 7 65 99A1808 7 65 99A1809 7 63 99A1812 7 19 7 49 7 71 99A1818 7 63 99A1819 7 73 7 75 99A1820 7 73 7 75 99...

Page 333: ...9A2066 7 15 99A2067 7 25 7 41 7 43 99A2070 7 11 99A2071 7 13 7 39 99A2075 7 3 99A2076 7 5 99A2077 7 5 99A2078 7 7 99A2079 7 11 99A2080 7 21 99A2081 7 23 99A2082 7 31 99A2083 7 31 99A2084 7 35 99A2087...

Page 334: ...I 10 Service Manual 4520 xxx...

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