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Lexmark T52 Series, Service Manual

The Lexmark T52 Series product offers high-quality printing with reliable performance. For easy troubleshooting and maintenance, the Service Manual is available for download, absolutely free. Access this comprehensive manual on manualshive.com to efficiently resolve any issues and optimize the usage of your Lexmark T52 Series printer.

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Index

I-7

4520-xxx

99A1130

   

7-55

99A1131

   

7-55

99A1133

   

7-55

99A1134

   

7-55

99A1164

   

7-59

99A1182

   

7-76

99A1280

   

7-59

99A1290

   

7-59

99A1502

   

7-3

99A1506

   

7-3

99A1508

   

7-3

99A1509

   

7-3

99A1510

   

7-3

99A1511

   

7-3

99A1512

   

7-3

99A1517

   

7-5

99A1518

   

7-5

99A1520

   

7-25

99A1524

   

7-7

99A1525

   

7-5

99A1531

   

7-13

99A1536

   

7-47

, 

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

   

7-19

, 

7-51

99A1583

   

7-19

, 

7-51

99A1587

   

7-3

99A1593

   

7-39

99A1594

   

7-3

99A1596

   

7-7

99A1601

   

7-19

, 

7-47

, 

7-49

, 

7-51

99A1602

   

7-51

99A1605

   

7-77

99A1609

   

7-11

99A1611

   

7-35

99A1612

   

7-39

99A1613

   

7-5

99A1616

   

7-11

99A1633

   

7-78

99A1634

   

7-59

99A1636

   

7-51

99A1638

   

7-45

99A1643

   

7-5

99A1644

   

7-17

99A1645

   

7-53

99A1646

   

7-73

99A1647

   

7-75

, 

7-77

99A1649

   

7-25

99A1651

   

7-25

, 

7-41

, 

7-43

99A1654

   

7-77

99A1658

   

7-25

99A1664

   

7-53

99A1665

   

7-53

99A1666

   

7-45

, 

7-51

, 

7-57

, 

7-61

, 

7-71

99A1667

   

7-53

99A1668

   

7-55

99A1669

   

7-57

99A1672

   

7-59

99A1673

   

7-55

99A1674

   

7-55

99A1675

   

7-55

99A1676

   

7-59

99A1677

   

7-55

99A1679

   

7-59

99A1680

   

7-55

99A1682

   

7-55

99A1683

   

7-77

99A1684

   

7-77

99A1685

   

7-77

99A1686

   

7-77

99A1691

   

7-59

99A1692

   

7-59

99A1693

   

7-55

99A1694

   

7-61

99A1695

   

7-59

99A1696

   

7-61

99A1697

   

7-61

99A1698

   

7-61

99A1699

   

7-61

99A1700

   

7-61

99A1702

   

7-53

99A1704

   

7-73

, 

7-75

99A1705

   

7-73

, 

7-75

Summary of Contents for T52 Series

Page 1: ...Lexmark 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 Diagnostics Manuals Menu ...

Page 2: ...U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark and Lexmark with diamond design and MarkNet are ...

Page 3: ...ervice 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 2 61 Input Tray s Service Check 2 62 High Capacity Feeder Input Tray Service Check 2 66 Main Drive Service Check 2 77 Operator Panel Service Check 2 79 Options Service Check 2 81 Output Bin Sensor S...

Page 4: ...est 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 Bin 3 16 Base Sensor Test 3 16 Print Registration 3 17 Printer Setup 3 18 Setting the Page Count 3 18 Viewing the Permanent Page Count 3 18 Maintenance Page Count 3 19 Setting Configuration ID 3 20 Re...

Page 5: ...20 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 Removal 4 32 Fuser Transfer Plate Removal 4 32 Fuser Envelope Conditioner Solenoid Removal 4 33 Fuser Narrow Media Sensor Flag Assembly Removal 4 34 Fuser Exit Sensor Flag Assembly Removal 4 34 Fuser Lam...

Page 6: ...pper 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 5 10 Controller Board Network 5 11 Fuser Board 5 12 Interconnect Board 5 14 Envelope Feeder Board 5 16 Duplex Unit Board 5 18 Preventive Maintenance 6 1 Safety Inspection Guide 6 1 Lubrication Speci...

Page 7: ...sembly 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 7 50 Assembly 23 Duplex Unit 7 54 Assembly 24 Envelope Feeder 7 60 Assembly 25 High Capacity Feeder 7 62 Assembly 26 Kiosk Vertical Paper Adapter 7 72 Assembly 27 Kiosk Horizontal Paper Adapter 7 74 ...

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: ...cribed service condition Laser Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J für Laserprodukte der Klasse I 1 In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I der die Anforderungen der IEC International Electrotechnical Commission 60825 gemäß amtlicher Bestätigung erfüllt Laserpro...

Page 12: ...n par l utilisateur ou de révision l exposition à des rayonnements laser supérieurs à des rayonnements de Classe I Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 608...

Page 13: ...perior al nivel de la Clase I durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico Declaração sobre Laser A impressora está certificada nos E U A em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I 1 de produtos laser Em outros locais está certificada como um produto laser da Classe I em conformidad...

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 Lasermeddelelse Printeren er godkendt som et Klasse I laserprodukt i overenstemmelse med kravene i IEC 60825 Klasse I laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b l...

Page 15: ...ttaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle Älä katso säteeseen VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad Betrakta ej strålen Laser notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J för laserprodukter av Klass I 1 I andra länder uppfyller skrivaren kraven för laserprodukter av Klas...

Page 16: ... foreskrevne serviceoperasjoner Avís sobre el Làser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes làser de classe I 1 i segons ha estat certificat en altres llocs és un producte làser de classe I que compleix els requisits d IEC 60825 Els productes làser de classe I no es consideren perillosos Aquesta impressora conté ...

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 not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand...

Page 19: ...s électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires Norme di sicurezza Il prodotto è stato progettato testato e approvato in conformità a severi standard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non è responsabile per l utilizzo di par...

Page 20: ... ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen Pautas de Seguridad Este producto se ha diseñado verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark Puede que las características de seguridad de algunas piezas no s...

Page 21: ...ão deste produto Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários Informació de Seguretat Aquest producte està dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark Les característiques de seguretat d algunes peces pot ser que no sempre siguin òbvies Lexmar...

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: ...used 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 the tests and checks Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components ...

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

Page 25: ...e 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 Non network Lexmark T522n 4520 220 Network Lexmark T520 4520 001 Non network Lexmark T520n 4520 002 Network ...

Page 26: ...dapter 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 sheet paper trays of A5 letter and legal size 250 Sheet UAT Universally Adjustable Tray 400 Sheet UAT Universally Adjustable Tray 2000 Sheet High Capacity Feeder Envelope Feeder Duplex Unit 250 Sheet For...

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 Phillips screwdriver T10 Torx screwdriver 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug...

Page 28: ...mplification 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 OEM Original Equipment Manufacturer PC Photoconductor POR Power On Reset POST Power On Self Test RIP Raster Imaging Processor ROM Read Only Memory SDRAM Synchronous Dual Random Access Memory SRAM Stati...

Page 29: ...Codes 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 Power Saver is displayed If a user status message is displayed go to the User Status Messages on page 2 22 User error messages are indicated by a two or three digit error code that provides the user ...

Page 30: ...d 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 the controller software 905 Interface Violation by Paperport Device 906 Controller Engine Link Driver Error 910 DC Pick Motor DC Pick Motor Stall Error Codes 910 911 912 913 and 914 are indications th...

Page 31: ...56 923 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 Go to the Fuser Service Check on page 2 56 925 Fuser Error Wrong fuser lamp installed Check the fuser lamp for the correct type of lamp that should be installed If the correct fuser lamp is installed...

Page 32: ...e 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 with one another The controller board engine board or interconnect board is defective Check each board for correct installation and secure ground If no problem is found replace the FRUs in the following...

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 Failure Replace the controller board 945 Controller Board Failure ASIC Failure Replace the controller board 946 Controller Board Failure SRAM Failure Replace the controller board 947 PQET Error Replace...

Page 34: ...he controller board 961 RAM in Slot 1 is Bad Replace the card in Slot 1 If this does not fix the problem replace the controller board 962 RAM in Slot 2 is Bad Replace the card in Slot 2 If this does not fix 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 failur...

Page 35: ...pecified device 981 device The engine protocol violation detected by the specified device 982 device Comm Communications error detected by the specified device 983 device Invalid command received by the specified device 984 device Invalid command parameter received by the specified 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 en...

Page 36: ...leshooting 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 error codes 2 The first screen of information is displayed Write down the information 3 Continue pressing Return and Select until each screen of information is obtained 4 When the last screen displays th...

Page 37: ...3 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 This code indicates that the input sensor in the printer is still actuated from the first sheet and the second sheet is ready to arrive at the sensor x1 media size x2 media source Check the printer ...

Page 38: ...ble 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 stop homing not allowed 84 00 07 A paper jam has been declared by a smart device Homing was allowed before the stop 84 xx 0B x1 x2 x3 The option tray pass thru sensor was never actuated by a piece of m...

Page 39: ...es 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 check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 2 and see if Tray 2 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper...

Page 40: ...or 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 correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 1D The envelope feeder pass thru sensor never deactivated The d...

Page 41: ...or 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 This code indicates that the media has activated the input sensor before the printhead has locked Enough time has elapsed since printhead start to expect a lock One of the following may be failing Pri...

Page 42: ...bly 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 exit sensor never actuated from the sheet going through the fuser before the next page begins feeding x 1 Media Size 89 xx 07 The narrow media sensor in the fuser was covered by a sheet of paper when no...

Page 43: ...ot 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 x1 The second pick failed from a paper source when paper was in the source and the only sheet in the paper path 8E xx 07 x1 The second pick failed from a paper source when paper was in the source Othe...

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 Size x 2 Media Source First 6 Bytes Sub Error Code Data Note xx can be any value Explanation ...

Page 45: ...p 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 the desired temperature 921 Service Fuser Error Fuser under temperature while at standby EN 41 xx yy 1 EN zz 2 xx Actual Fuser Temperature yy The temperature that the fuser wants to reach zz 00 The fu...

Page 46: ...n 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 operating temperature in time 923 Service Fuser Error Fuser over temperature EN 12 xx yy 1 EN 2 This sub error code is displayed anytime that the Hot Roll has reached a higher than desired temperature xx ...

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 The temperature that the fuser was trying to reach First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 84 xx 17 There is an envelope in the feeder during POST First 6 Bytes Sub Err...

Page 48: ...nsor 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 might cause the envelope to stop over the sensor 84 xx 1E x1 x2 An envelope never activated the envelope feeder pass thru sensor or the sensor never sensed the presence of an envelope x1 Media Size ...

Page 49: ...h 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 printer has not sent a command to send a sheet of paper to the duplex unit 06 The exit sensor detected a sheet of paper too early 07 The sheet of paper trailing edge did not clear the exit sensor in...

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 indicator light blinks while the printer is processing data Press Stop to take the printer out of Busy The Not Ready message is displayed No more data is processed but the printer processes all paper cu...

Page 51: ...values 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 because Print Directory is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper current...

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 printer is deleting any print jobs in process and restoring all settings to user defaults No button actions are possible while this message is displayed Formatting Flash Do Not Power Off The flash memo...

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 possible while this message is displayed User Error Message Explanation 200 Paper Jam Remove Cartridge Paper is jammed at the printer Input Sensor Open the printer upper front door and remove the print ca...

Page 54: ...access 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 Switch Cable Service Check on page 2 42 31 Defective Print Cartridge Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected It may take the printer 10 ...

Page 55: ...ure 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 message can only occur if the Resolution Reduction setting is turned on Note 1200 dpi pages are not resolution reduced If a 1200 dpi job runs out of memory a Memory Full error is displayed 37 Insuff...

Page 56: ...56 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 when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or ...

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 print quality and reliability of the printer The parts are available as a maintenance kit For more information go to Scheduled Maintenance on page 6 2 81 Engine Code CRC Failure This error displays when...

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 Low condition clears whenever the upper front door is opened and Toner Low displays again if the condition exists after the upper front door is closed Tray X Missing If any of the input trays are missi...

Page 59: ...us 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 which tray 1 through 5 displays If multiple trays are low they are prioritized in the following order Tray 5 4 3 2 1 Note Tray X Low clears whenever Tray X goes empty or Tray X is removed When Tray X ...

Page 60: ...owing 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 Network card X X 1 2 3 is attached to PCI connector X LocalTalk X LocalTalk Card X X 1 2 3 is attached to PCI connector X Infrared Standard Infrared port if available Infrared X Infrared Port X X 1 2 3...

Page 61: ...encing 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 printer automatically clears the error and continues If the option is experiencing a hardware problem turn the printer off and back on If the error occurs again turn the printer off remove the option and c...

Page 62: ...back 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 once the option is removed Once the job is complete turn off the printer and attach the option again Insert Duplex Front Cover This message displays when the duplex front access cover is not install...

Page 63: ...el 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 elevator tray moves to the uppermost position if installed The duplex unit is checked if installed 7 Busy appears on the display 8 The fuser lamp turns on The fuser takes longer to warm up from a cold star...

Page 64: ...e 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 Service Check on page 2 84 Paper jams at exit of Redrive Assembly Duplex Unit installed Go to the Duplex Unit Service Check on page 2 45 Fuser Solenoid fails to operate Go to the Fuser Solenoid Serv...

Page 65: ...e 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 Unable to clear a 32 Unsupported Print Cartridge User Error Message Go to the Smart Contact Assembly Service Check on page 2 100 Symptom Action The printer does not recognize the high capacity feeder ...

Page 66: ...ay 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 Unit Paper fails to pass from lower option thru the Duplex Unit Go to the Duplex Unit Service Check on page 2 45 Symptom Action Envelopes do not feed from the envelope feeder Envelopes do not feed prop...

Page 67: ...eck 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 Codes for 9XX and 2XX Error Codes on page 2 8 to help diagnose the problem Print quality problems Go to Print Quality Test Pages on page 3 23 and print a test page to help diagnose problems before chang...

Page 68: ...fully 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 charge roll bearing and remove the roll from the printer Leave the paper wrapped around the charge roll until it is reinstalled FRU Action 1 Charge Roll Assembly Check the charge roll for correct instal...

Page 69: ...link 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 right link assembly from the bearing to the charge roll high voltage contact on the right side frame If incorrect replace the link assembly Make sure the charge roll bushing is installed and operatin...

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 dc If the voltage is incorrect replace the engine board If the voltage is correct check the voltage at J4 1 If the voltage measures greater than 1 0 V dc replace the engine board If the voltage is c...

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 continuity of the line cord and replace if necessary 3 5 V dc at any Option Connector Check for 5 V dc on any of the option connectors The easiest to access is the envelope feeder connector located behind ...

Page 72: ...autions 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 disconnect all the cables from the engine board Check for 5 V dc at the engine board test point If incorrect replace the FRUs in the following order 1 Engine board 2 Interconnect board If correct turn th...

Page 73: ...ween 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 short is found replace the system board 2 Autoconnect Cables Connectors Check the autoconnect cables for damage to the cables or the pins in the connectors If damaged replace the cable s If no damage...

Page 74: ...ut 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 FRUs in the following order 1 Input sensor assembly 2 Duplex unit system board 3 Paper Exit Sensor and Flag Check the duplex exit sensor for correct installation and free movement of the sensor flag ...

Page 75: ...the 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 J3 2 Stpmtr A The resistance measures approximately 10 ohms The resistance between J3 3 Stpmtr B to J3 4 Stpmtr B measures approximately 10 ohms If the resistance is incorrect replace the stepper mot...

Page 76: ...ray 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 attached input option FRU Action 1 Envelope Feeder Check to make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer 2 Front Autoconnect on Printer C...

Page 77: ...ace 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 24 V dc If any of the voltages are incorrect replace the autoconnect cable connector If the voltages are correct replace the envelope system board FRU Action ...

Page 78: ...sor 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 signs of damage or binds If incorrect replace the flag If the flag is operating correctly check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the envelope system b...

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 envelope system board If correct perform the Envelope Feed Sensor Test to check both the sensor and flag If the test fails remove any envelopes in the hopper turn the printer off and disconnect J3 from th...

Page 80: ...ure 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 C motor assembly FRU Action 1 Main Drive Belt Check the belt for correct installation and for signs of damage Replace as necessary 2 Gears Check all the gears for correct installation and for signs ...

Page 81: ...ent 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 rollers when the hopper is empty Replace the weight assembly if it is damaged or does not operate properly 3 Envelope Edge Guide Check the envelope edge guide to make sure it is not warped or set too clos...

Page 82: ...lope 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 envelopes being stuck together or signs of glue Check to make sure the flaps are not interleaved 2 Deflector Check the deflector gap adjustment The adjustment may be too wide 3 Restraint Roll Bias Sprin...

Page 83: ...n 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 V dc fan running If incorrect replace the main fan If this does not fix the problem replace the engine board 4 Error Code 927 Fan not running Check the voltage at J1 3 on the engine board The voltag...

Page 84: ...em 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 caused by an incorrectly mounted thermistor Service Tip Set the Fuser Temperature to NORMAL before starting this service check FRU Action 1 Fuser Lamp Incorrect Lamp 925 Service Error Install the correct ...

Page 85: ...rect 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 connectors on the fuser end of the LVPS to fuser AC cable If the voltage is incorrect turn the power off and remove the LVPS Measure the AC line voltage between pins CN1 1 and CN1 3 on the board If correct c...

Page 86: ...the 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 150K ohms to 260K ohms If the resistance is incorrect replace the fuser top cover assembly If the resistance is correct check each pin of J6 to ground If there is continuity replace the fuser cover as...

Page 87: ...place 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 overheating or damage Check the hot roll and backup roll for signs of excessive toner label glue labels or other contaminants If problems are found with the hot roll or backup roll replace the failing rol...

Page 88: ...ance 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 the LVPS The voltage measures approximately 42 V dc If incorrect replace the LVPS 3 DC Fuser to Engine Board Cable Check the continuity of the DC fuser to engine board cable If incorrect replace the...

Page 89: ...oved 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 operation If a problem is found repair as necessary 2 Engine Board Check for approximately 5 V dc at J10 10 on the engine board If incorrect replace the engine board 3 Input Sensor Cable Check the continuit...

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 if necessary Check the cables for continuity If incorrect replace the compensator assembly cable If the cables connectors and connections are good replace the FRUs in the following order 1 Autocompe...

Page 91: ...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 tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Spring Bevel Gear Feedroll Gear Drive Roll Assembly Wear Plate Drive Shaft Bearings and Skewed Backup Roller Check these parts for sign...

Page 92: ...smooth 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 on the system board If no problem is found replace the paper low sensor assembly If this does not correct the problem replace the option system board FRU Action 1 Paper Out Sensor Flag Check the pape...

Page 93: ...ables 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 for correct installation at the tray x system board If correct check the continuity of the autoconnect cable s If correct replace the tray x system board If incorrect replace the cable FRU Action 1 Au...

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 Receptacles AC Wiring Harness If the base printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT check the AC jumper cord If defective r...

Page 95: ...properly 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 capacity option autoconnect as necessary 3 LVPS Option System Board Check the voltages at J11 2 and J11 4 The voltage measures 24 V dc If the voltage is correct replace the high capacity system board assemb...

Page 96: ...ernal 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 each pin on the motor connector If you find a short between any pin and the motor housing replace the motor assembly If no shorts are found replace the high capacity feeder option control board Check ...

Page 97: ...ails 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 tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Spring Bevel Gear Feedroll Gear Drive Roll Assembly Wear Plate Drive Shaft Bearings and Skewed Backup Roller Check these parts for sig...

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 feeder system board If the display changes check the continuity of the switch If incorrect replace the switch If correct replace the switch cable FRU Action 1 Paper Out Sensor Flag Check the paper o...

Page 99: ...limit 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 Control Board Disconnect the lower limit switch cable and check the voltage at J2 1 orange The voltage measures approximately 5 V dc If incorrect replace the high capacity feeder option control board FR...

Page 100: ...place 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 J1 on the board Check the cables damaged or loose wires Disconnect the motor Check for a short between each pin and the motor housing If a problem is found replace the motor assembly If no problem i...

Page 101: ...g 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 24 V dc J1 2 Yellow Approximately 0 V dc If any of the voltages are incorrect disconnect the motor and measure the resistance between J 1 and J 2 The resistance measures between 7 5 and 10 5 ohms If...

Page 102: ...position 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 1 High Capacity Feeder Option Control Board Check the voltages on the board at J4 1 red and J4 3 blue The voltages measure approximately 5 V dc If incorrect disconnect J4 from the board and measure t...

Page 103: ...Sensor 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 Feeder Option Control Board Run the sensor diagnostics for tray X X the number that represents the high capacity input tray If the test fails check the voltage at J3 1 gray The voltage measures approxima...

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 4 Motor Drive Belt Tray Drive Belt Check the DC motor drive belt for any signs of damage Check to make sure the belt is tracking correctly on the drive pulley idler pulley and motor pulley Check the...

Page 105: ...Drive 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 Determine if the noise is in the main drive toner cartridge fuser or main drive gearbox Look for any loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary 2 Mai...

Page 106: ...ain 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 4 5 V dc static 5 V dc when main drive motor running J12 1 5 V dc static 0 V dc when main drive motor running If the voltage is incorrect replace the FRUs in the following order 1 Main drive motor as...

Page 107: ...dual 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 broken run the LCD Test on page 3 11 from the hardware tests before continuing with this diagnostic service check FRU Action 1 Operator Panel Assembly If any button fails the Button Test replace the opera...

Page 108: ...ace 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 board 4 Operator Panel all diamonds No Beeps Check to make sure a card is not plugged in backward This condition causes the printer to fail POST displaying all diamonds on the operator panel with no be...

Page 109: ...or 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 flash memory option service check with the following exception Run the SDRAM Memory Test on page 3 12 from the menu if the SDRAM Memory card is correctly installed and not broken or damaged If the te...

Page 110: ...tion 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 on network model printers Error Code 976 Network Card X X Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly in...

Page 111: ...unless 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 Output Bin Sensor Test fails Check the voltage at J6 1 It measures 5 V dc when the flag is in the sensor and 0 V dc when the flag is out of the sensor If the voltage does not change replace the sens...

Page 112: ...ers 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 the deflector FRU Action 1 Pass Thru Sensor Check the pass thru sensor for correct installation and operation 2 Autocompensator Assembly The autocompensator pick roll shaft assembly is not providing...

Page 113: ...ntact 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 bottom of the stack check for missing or damaged restraint pads in the tray FRU Action 1 Paper Paper is usually the primary cause of a double feeding paper problem Flex the paper before placing the pap...

Page 114: ...Check 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 Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128 and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable...

Page 115: ...n 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 incorrect replace the engine board If correct replace the printhead assembly 2 Error Code 934 Mirror Motor Lost Lock Error Code 935 Mirror Motor unable to reach operating speed These error codes ind...

Page 116: ...plain 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 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF Fuser Temperature Set to NORMAL Test the printer usi...

Page 117: ...ecurely 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 kit 3 Charge Roll Conductive Bushing Check to make sure the charge roll bushing is correctly installed in the right charge roll arm 2 HVPS Check the voltages on J10 1 thru J10 8 If incorrect replace...

Page 118: ...of 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 Printer Idle J10 5 measures 24 V dc Printer Printing J10 5 measures 24 V dc If the voltages at J10 5 are incorrect replace the engine board 4 Front Cable Harness HVPS Section Check the front cable har...

Page 119: ...nt 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 Replace as necessary 5 Printhead Assembly Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom The printhead used in the printer...

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 1 757 inch apart Replace the FRUs in the following order 1 Developer drive assembly 2 Main drive gearbox assembly 5 Lines spaced 47 19 mm 1 858 inch apart Replace the FRUs in the following order 1 To...

Page 121: ...RUs 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 assembly 12 Lines spaced 99 49 mm 3 917 inch apart Replace the redrive assembly 13 Lines spaced 114 79 mm 4 519 inch apart Replace the alignment assembly FRU Action ...

Page 122: ...nters 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 the transfer arm assembly right side bearing for any signs of contamination pitting or a loose cable to the bearing If any problems are found replace the defective part Check the transfer roll shaft...

Page 123: ...ine 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 voltage remains at 0 V dc check the continuity of the front harness cable J10 2 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct ...

Page 124: ...is 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 one side of the page check the charge roll counterbalance spring on that side You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your...

Page 125: ...nuity 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 Turn the printer off and check the resistance between J10 7 and printer ground The resistance measures approximately 0 ohms If incorrect make sure the engine board is mounted correctly and securely g...

Page 126: ...heck 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 arm assembly bearing for any signs of wear or contamination Also check to ensure the transfer cable is firmly attached to the bearing If incorrect replace the right side transfer arm assembly Check th...

Page 127: ...ut 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 Repair as necessary 2 Transfer Roll Transfer Plate Assembly Check the transfer roll for any signs of toner buildup or loose toner around the area of the transfer plate assembly Clean the area and run anot...

Page 128: ...etween 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 contacts in the upper front cover and the smart chip Also check for proper seating of the smart cartridge cable to the engine board FRU Action 1 Smart Contact Assembly Engine Board Check the voltage o...

Page 129: ...designed 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 provides failure information on the display for approximately three seconds If the test indicates a problem replace the controller board ...

Page 130: ...he 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 Toner Sensor The toner sensor cable is part of the front harness and part of connector J10 on the engine board Check the voltage at J10 11 It reads approximately 5 V dc If incorrect replace the engine b...

Page 131: ...cently 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 Assembly Check the transfer roll for any signs of toner buildup surface damage to the roll oil or other contaminants on the surface of the roll Replace the transfer roll as necessary 2 Left Transfer...

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 Error Code Check the voltage at J10 3 The voltage changes from 24 V dc with the printer idle to 0 V dc when the printer runs the print test If the voltage is incorrect check the continuity of line J10 ...

Page 133: ...ostic 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 the operator panel in the order shown Print Registration Print Tests Hardware Tests Duplex Tests If installed Input Tray Tests Output Bin Tests Base Sensor Test Printer Setup Error Log EP Factory Defau...

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 progress Quick Disk Test Test Passed message displays if the test passes and the power indicator turns on solid Quick Disk Test Test Failed message displays if the test failed and the power indicator turn...

Page 135: ...Test 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 test can be canceled anytime during the test by pressing Return Stop Once the test is complete the power indicator turns on solid and a message displays xxxx Bad Blocks yyyyyy Usable message display...

Page 136: ...tted 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 passes and the power indicator turns on solid Flash Test Test Failed message displays if the test fails and the power indicator turns on solid 2 Press Go or Return Stop to return to the Device Tests...

Page 137: ...e 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 buttons 3 Turn the printer on and release the buttons once Performing Self Test displays Once the printer is idle the emulation can be downloaded again 4 Program the download emulation into the code overl...

Page 138: ...to 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 between the placement of the first scan line on the front and back side of a duplexed sheet If adjustment is necessary the Top Margin Offset must be adjusted first The range of the adjustment is 25 to 25...

Page 139: ...sensors 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 switch is open OP Open displays Duplex input sensor Duplex exit sensor Press Return Stop to exit the test ...

Page 140: ...o 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 hex Ignore bytes EE and FF If the test fails remove the drive belt from the duplex D C motor and run the motor test again For the duplex D C motor to pass the test the following results must display A...

Page 141: ...ar 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 2 To run the Duplex Feed 2 Test Select Duplex Feed 2 from the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 2 Feeding message displays while the paper is feeding...

Page 142: ...s 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 three screens as only four entries display at a time 2 To move to the next screen press Menu to move forward or backward 3 Press Return Stop to exit the Error Log Clearing the Error Log To clear the...

Page 143: ...To 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 Button Test from the Diagnostic menu With no buttons pressed several OP Open appear on the display 2 Press each button one at a time and a CL Closed displays in place of an OP The proper operation of...

Page 144: ...Stop 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 of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count is reached the test is stopped ...

Page 145: ...power 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 the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the menu The power indicator blinks indicating the test is in...

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 the Pass Count increases by 1 however if the test fails a message displays for approximately three seconds and the Fail Count increases by 1 Once the maximum count is reached the test stops The power...

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 sensors are working correctly To run the Input Tray Sensor Test 1 Select the Sensor Test from the Input Tray Test menu Input Tray Empty OP Pass OP message displays EM Input Tray Empty Sensor LO Input Tray ...

Page 148: ...isplay 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 sensors located inside the printer are working correctly The following sensors can be checked Toner Optical Sensor Input Sensor Output Sensor Fuser Exit Narrow Media Sensor Front Door Sensor Upper Front ...

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 to save the value 5 To exit the Registration menu press Return To verify the margin values are correct you must print the Quick Test Page from the registration screen Press Go to print the test page ...

Page 150: ...cating 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 digit until you set the page count You can skip any digit by pressing Select 4 Press Select to save the new page count in NVRAM 5 Press Return Stop to exit the Diagnostic menu Viewing the Permanent ...

Page 151: ...nance 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 Select resets the maintenance page counter to zero Reset Maintenance Count Saved displays momentarily When the reset operation is complete the menu returns to the Printer Setup Reset Maintenance Coun...

Page 152: ...The 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 indicating that it is the first digit to be changed 3 To change the value press either Menu until the value you want is reached Press Select to move to the next digit or press Select again to skip a digit...

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 before allowing pages to print by changing this setting from 0 to 5 The factory sets the warm up at 0 or no warm up time This time period lets the backup roll heat up and helps reduce curl in some en...

Page 154: ...op 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 duplex setting or the presence of a duplex unit If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the f...

Page 155: ...ine 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 off 2 Press and hold Select and Return 3 Turn on the printer 4 Release the buttons once Performing the Self Test displays 5 The printer performs its normal POR cycle then print one copy of the Print Qu...

Page 156: ...t 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 Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information A list of all the printer settings contained in the operator panel menus and th...

Page 157: ...r 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 significant contributors to double feeding paper The pick arm is counter balanced by an extension spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no mor...

Page 158: ...serial 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 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex unit through a ground spring attached to the frame and base of the printer The ground connection is aut...

Page 159: ...increases 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 and J16 3 THERM are connected to module U10 U10 monitors the change in thermistor resistance and sends a signal HEATON from J30 A25 through the interconnect board to CN3 9 on the LVPS to signal the tri...

Page 160: ...aper 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 sensor flag in time or not at all Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sensor This can be caused by the paper arriving at the sensor to...

Page 161: ...rpose 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 or has not reached the base machine input sensor Error Message 27x Paper Jam Check Bin x Paper is jammed in output bin Generally this message appears when the paper has not cleared the exit sensor i...

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

Page 163: ...ctricity 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 ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrica...

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 being careful to maintain the adjustment 4 Reassemble the duplex unit To do the duplex motor belt adjustment 1 Do the removal procedure Duplex Motor Removal on page 4 20 to access the motor mounting scr...

Page 165: ...as 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 improving media stacking in the output bin 1 Enter the Diagnostic Mode 2 Select Ep Setup from the Diagnostic Menu 3 Select Gap Adjust 4 The range of the GAP adjustment is 0 to 255 Adjust the gap setting ...

Page 166: ...elf 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 horizontal lines that can be used for skew adjustment page count setting printer serial number code levels and print registration settings 6 Check the Quick Test Page for any sign of skew by checking...

Page 167: ...Registration 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 alignment assembly to the left side frame 3 Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer It is not necessary to completely remove...

Page 168: ...e 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 the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want ...

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 charge roll mounting 1 main drive gearbox mounting 3 EP module to left and right side frame attach 9 developer drive assembly mounting 2 stacker duct to frame mounting 2 cartridge hold down assembly mo...

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 3 right side frame to center pan attach 2 deflector mounting 2 M3x5 mm Taptite INA cover 2 screws per cover attach 6 Reference Number Screw Type Location Purpose Qty ...

Page 171: ...ground 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 center pan front attach 1 cable clip main drive gearbox BTM mounting 2 fuser screw mounting 7 M3x8 mm Taptite LVPS mounting 2 auto compensator hanger bracket mounting 1 Reference Number Screw Type Loca...

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 mounting 2 cable clip mounting 2 outer shield mounting 6 INA cover mounting 4 Reference Number Screw Type Location Purpose Qty ...

Page 173: ...e 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 Plastite Thread Forming with washer printhead to EP frame mounting 3 Reference Number Screw Type Location Purpose Qty ...

Page 174: ...nter 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 avoid pinching wires obstructing the paper path or restricting mechanical movement Covers Removals Left Door Removal 1 Open the upper and bottom front covers 2 Press the two left door latch buttons A an...

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: ...ont 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 the upper and lower latch and spring to prevent them from falling into the printer ...

Page 178: ...3 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 remove the cover Center Pan Assembly Removal 1 Remove the left and right side frames 2 Remove the pan assembly ...

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 the serial port mounting screws if present 6 Remove the controller board ...

Page 180: ...emoval 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 the main drive assembly when reinstalling the assembly ...

Page 181: ...y 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 cover assembly latches from the bottom of the duplex assembly 5 Remove the duplex front cover assembly Duplex Front Cover Door Removal 1 Remove the duplex front cover assembly 2 Holding the front of the ...

Page 182: ...bly 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 assembly and the frame assembly from the duplex unit 8 Remove the two duplex motor mounting screws and remove the motor Note Pay attention to cable routing to avoid pinching or cutting wires during reass...

Page 183: ...movals 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 the ground screw B 6 Remove the inner EMC shield ...

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: ...ngine 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 replaced the Configuration ID must be reset in NVRAM on the new engine board Go to Setting Configuration ID on page 3 20 ...

Page 186: ...moval 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 and remove the fan from the left side frame ...

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 lower deflector assembly 5 Remove the paper alignment assembly 6 Remove the left side frame mounting screws A ...

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: ...sator 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 remove the right side frame 7 Remove the smart cartridge contact assembly mounting screw C CAUTION Be sure the fuser assembly has cooled before working on any of the fuser FRUs ...

Page 190: ...er 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 engine board 6 Remove the fuser ...

Page 191: ...nformation 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 assembly ...

Page 192: ...he 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 fuser lamp contact to the fuser cover on each end of the cover 6 Detent the latch C and remove the cover 7 Detent the latch C and remove the cover ...

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 deflector 2 Remove the fuser transfer roll 3 Remove the inner paper deflector 4 Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting 5 Rem...

Page 195: ...e 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 Perform the Fuser Solenoid Adjustment on page 4 3 whenever you replace the fuser solenoid ...

Page 196: ...sure 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 from the fuser board 3 Noting the location of the sensor flag depress the two lower sensor mounting pins and remove the sensor assembly 4 Align the sensor flag with the flag opening in the lower exi...

Page 197: ...amp 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 install the correct lamp Fuser Lower Exit Guide Assembly Removal 1 Remove the fuser assembly 2 Remove the fuser cover assembly 3 Remove the fuser detack housing assembly 4 Disconnect the sensors from the ...

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 the HVPS The cable and connector can be easily damaged 6 Remove the HVPS mounting screw B 7 Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS ...

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 against the right side frame from the autocompensator pivot shaft 8 Disconnect the compensator sensor cable C from the assembly 9 Remove the compensator assembly mounting screw D 10 Remove the integrat...

Page 200: ...Pick 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 Unsnap the pick roll assembly D from its mounting and remove ...

Page 201: ...move 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 Place the printer on its back and remove the mounting screws A 6 Remove the interconnect board assembly ...

Page 202: ...ervice 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 printer ...

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: ...from 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 the main drive assembly 9 Disconnect the cable from the main drive motor 10 Remove the main drive assembly Note Be sure the main drive assembly gear shaft aligns with the hub on the left side frame wh...

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: ...mbly 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 tray from the two mounting posts Warning Be careful not to break the hinges ...

Page 208: ...Manual 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 deflector assembly ...

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 the operator panel ...

Page 210: ...e 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 bracket assembly 5 Route the cables and toroid through the rectangular window in the cover hinge pivot arm 6 Snap the operator panel into the upper front cover 7 Be sure the toroid is on the opposite e...

Page 211: ...sembly 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 1 Remove the paper tray frame assembly 2 Disconnect all cables from the paper tray board 3 Remove the three paper tray board mounting screws and remove the board Note Reinstall with the paper out se...

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 the paper alignment assembly mounting screws A ...

Page 213: ...ocate 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 4 5 when you reinstall the assembly ...

Page 214: ...ssembly 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 multipurpose tray and remove the tray from the two mounting posts 2 Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right 3 Remove the uppe...

Page 215: ...se 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 screws A 3 Remove the paper size sensing board Pick Roll Removal 1 Remove the upper paper deflector 2 Release the pick roll retaining tab and slide the pick roll off the shaft ...

Page 216: ...y 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 you remove or replace the printhead assembly or loosen the mounting screws ...

Page 217: ...20 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 remove the redrive assembly ...

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 Disconnect the smart contact assembly cable C from the engine board ...

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: ...left 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 mounting posts 2 Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right 3 Remove the upper deflector assembly ...

Page 221: ...n 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 assembly to a position that lets you lift the left pivot arm from the mounting bracket C 7 Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left to clear the r...

Page 222: ...sembly 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 switch assembly cable and disconnect the cable on the engine board ...

Page 223: ...ions 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 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc ...

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

Page 225: ...onnector 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 OUT ...

Page 226: ...an 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 Printhead 1 Ground 2 Video 3 Ground 4 5 Phead 5 LPOW 6 Ground 7 LADJ 8 LFB 9 LENA ...

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 9 Ground In Sens 10 In Sns In Sens 11 5 V dc C Sens 12 CTSENSE C Sens 13 Ground C Sens Connector Pin No Signal ...

Page 228: ...r 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 3 TxBR 4 Ground Connector Pin No Signal ...

Page 229: ...SIZE1 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 Auto Compensator J18B Auto Compensator 1 24 V dc 2 AUTOCOMP 1 Ground 2 ENCODER 3 5 V dc Connector Pin No Signal ...

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: ...o 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 ThumpA J5 Narrow Media Sensor 1 5 V dc 2 Nar Media 3 Ground ...

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

Page 236: ...c 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 2 Ground J6 Engine Board 1 N A J7 Controller Board 1 N A J11 INA 1 1 N A J12 INA 2 1 N A ...

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

Page 238: ...r 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 Motor Phase A 3 Motor Phase B 4 Motor Phase A ...

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 Sensor 2 Input 3 Ground J6 Rear Cover Open Switch 1 Top Cover Open 2 Ground J7 Jam Removal Tray Open Switch 1 Front Drawer Open 2 Ground J8 Paper Exit Sensor 1 5 V dc Sensor 2 Exit 3 Ground ...

Page 241: ...oconnect 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 Ground 5 PrtRxD Connector Pin No Signal ...

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

Page 243: ...ltered 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 exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause prem...

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 Maintenance Kit 99A2420 220 V 630 W Maintenance Kit 99A2421 After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message See Maintenance Page Count on page ...

Page 245: ...majority 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 description NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration ...

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

Page 247: ...ank 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 Switch Cover Open w Operator Panel Cable Assembly 14 99A1509 1 Cover Left Door 001 002 1 slot 14 99A1510 1 Cover Left Door 210 220 2 slot 15 99A1587 1 Support Paper NS 99A0577 1 Cable Tie NS 99A1594 1 Re...

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

Page 249: ...y 14 99A2022 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 Charge Roll 1 Block Contact Mounting 4 Screw Contact Mounting 5 18 99A0466 1 Sensor Toner Cartridge Level 19 99A0039 2 Roller Developer Support 20 99A0026 1 Tray Bias Arm Assembly 21 99A2024 1 P...

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

Page 251: ...1896 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 Gear NS 99A1596 1 Contact LSF Ground NS 99A1538 1 Contact RSF Ground NS 99A1540 4 Nut Plate Frame 210 220 NS 99A1541 1 Spring Duplex Ground ...

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 Includes All Cables NS 99A0263 3 Parts Packet Screw Printhead Mounting ...

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

Page 255: ...ay 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 Spring Bellcrank Internal 250 5 99A1930 1 Spring Bellcrank Internal 500 NS 99A0263 1 Parts Packet Screw Hanger ...

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

Page 257: ...Deflector 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 Out 10 99A0082 1 Plate Assembly MPT 11 99A2071 1 Sensor MPT Paper Out 12 99A0073 2 Screw Damper 13 99A0263 1 Parts Packet Screw Frame Mounting 14 99A2027 1 Solenoid Assembly MPT 15 99A0074 2 Bushing ...

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

Page 259: ...ignment 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 Nut Paper Reference Adjustment NS 99A0263 2 Parts Packet Screw Alignment Asm Mounting ...

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

Page 261: ... 1 99A2029 1 Redrive Assembly 500 Input 250 Output 210 220 1 99A2151 1 Redrive Assembly 250 Input 250 Output 001 002 2 99A1644 1 Door Assembly Redrive 250 NS 99A0104 1 Spring Upper Diverter NS 99A1857 1 Deflector Upper Redrive NS 99A0263 2 Parts Packet Screw Duplex Path ...

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

Page 263: ...aint 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 Plate Snap in 9 99A1582 1 Slider Autosize 500 10 99A0120 2 Pad Restraint 11 99A2093 1 Restraint Back ...

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

Page 265: ...arbox 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 Gearbox Mounting NS 99A0263 3 Parts Packet Screw Motor Mounting NS 99A0260 2 Clip Cable ...

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

Page 267: ...og 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 Drive Ground ...

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

Page 269: ... Board Cover Mounting 1 Fuser Cover 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 99A1649 2 Screw Fuser Mounting 11 99A0267 2 Parts Packet Retainer Backup Roll Bellcrank 12 99A1651 1 Sensor Narrow Media 13 99A1551 1 Sensor Exit 14 99A0897 2 Spring Redrive Idler...

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 1 Arm Transfer Roll Left NS 99A0267 1 Parts Packet Retainer Pivot Shaft ...

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 1 Parts Packet Screw Charge Roll ...

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 1342534 1 Power Cord Set 8 ft Chile HV 1 1339543 1 Power Cord Set 8 ft Denmark 1 1339542 1 Power Cord Set 6 ft Italy 1 1374067 1 Power Cord Set 8 ft Peru HV 1 1339544 1 Power Cord Set 8 ft Straight ...

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

Page 277: ...46 1 Interconnect Board Assembly 2 slot 210 220 6 99A2152 1 Interconnect Board Assembly 1 slot 001 002 7 56P1005 1 Engine Board Assembly 210 220 7 56P1004 1 Engine Board Assembly 001 002 8 99A2486 1 Card Assembly Bar Code 8 99A2200 1 Card Assembly IPDS and SC5 TNE 8 99A2487 1 Card Assembly Prescribe 5 4 2 Flash 8 99A2528 1 Card Assembly Image Quick 9 99A0426 2 Screws Parallel Connector Mounting 10...

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

Page 279: ...sembly 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 Mounting 5 99A0263 6 Parts Packet Screw Outer Shield Mounting 6 99A0408 1 Cover INA Flat Blank NS 99A1611 1 Shield Ethernet Blank NS 99A0227 1 Clip Two Finger EMC NS 99A0347 1 Clip Six Finger EMC ...

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

Page 281: ...n Main 2 99A2030 1 Gearbox w Motor 3 56P1139 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 Main Drive Motor 8 99A2042 1 Engine Board Assembly 9 56P1049 1 Sensor Standard Bin Level ...

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

Page 283: ...ut 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 250 001 002 7 99A2438 1 MPT Solenoid 8 99A2042 1 Engine Board Assembly 9 99A2055 1 Cable Front Harness 10 99A2045 1 Power Supply High Voltage 11 99A2087 1 Smart Contact Assembly 12 99A0466 1 Sensor Toner Cart...

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

Page 285: ...99A2042 1 Engine Board Assembly 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 99A2062 1 Cable Engine Board to Fuser Board 10 99A1651 1 Sensor Narrow Media 11 99A2061 1 Cable Fuser AC Fuser to LVPS ...

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

Page 287: ...99A2042 1 Engine Board Assembly 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 99A2062 1 Cable Engine Board to Fuser Board 10 99A1651 1 Sensor Narrow Media 11 99A2061 1 Cable Fuser AC Fuser to LVPS ...

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

Page 289: ...ssembly 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 99A0677 4 Parts Packet Washer 19 99A0263 4 Parts Packet Screw 20 99A0070 2 Roll Assembly Pick 21 99A1638 1 Base 250 Option 22 99A0026 1 Tray Bias Arm Assembly 23 99A0419 1 Spring Tray Bias 24 99A0058 4 Pad...

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

Page 291: ...119 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 Size 45 99A0893 1 Restraint Back 250 Sheet Tray 46 99A0127 1 Slider Autosize 250 NS 99A0286 1 Spring Backup Roller NS 99A1928 1 Spring Bellcrank 250 Tray Option NS 99A0438 2 Bushing Drive Roll NS 99A027...

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

Page 293: ...160 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 99A0124 1 Plate Snap In 9 99A0127 1 Slider Autosize 250 10 99A0120 2 Restraint Pad 11 99A1601 1 Latch Back Restraint ...

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

Page 295: ...8 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 99A0124 1 Plate Snap In 16 99A1952 1 Label Paper Size 17 99A1582 1 Slider Autosize 500 18 99A0120 2 Restraint Pad 19 99A1576 1 Tray Assembly 500 Sheet 20 99A1537 1 Knob Paper Size 21 99A1602 1 Restrain...

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

Page 297: ...ew 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 Activate 40 99A0286 1 Spring Backup Roller 41 99A1664 1 Bellcrank Roller Release 42 99A0273 1 Gear Bevel 43 99A0279 1 Bearing Drive Shaft 44 99A0281 1 Cable 500 Auto Connect Top 45 99A1702 1 Stud Assemb...

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

Page 299: ...sembly 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 18 99A1680 1 Guide Return RH Lower 500 Duplex 19 99A1579 1 Guide Upper 500 Duplex 20 99A1133 1 Tray Assembly Jam Removal 250 Duplex 20 99A1134 1 Tray Assembly Jam Removal 500 Duplex 21 99A0342 1 Guid...

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

Page 301: ...4 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 40 99A0413 2 Parts Packet Screw 41 99A0413 4 Parts Packet Screw NS 99A1129 1 Roller Duplex Pass Thru NS 99A0627 1 Jumper Engine Board 250 Duplex NS 99A0404 2 Parts Packet Retainer 6 mm Backup Roll N...

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 Main Drive 56 99A0337 1 Main Drive Assembly 57 99A0319 1 Sensor Input Optical 250 Duplex 57 99A1676 1 Sensor Input Optical 500 Duplex 58 99A0404 4 Parts Packet Retainer 6 mm Drive Roll 59 99A0336 1 Shaf...

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

Page 305: ...arts 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 Parts Packet Retainer 7 mm Shaft NS 99A0384 1 Shaft Drive Pressure Roller NS 99A0385 1 Cable Auto Connect Front NS 99A0494 1 Spring Cam Clutch NS 99A0427 1 Label Envelope Orientation Icon NS 99A0469 1 De...

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 Washer Hinge Mounting Star 17 99A0657 2 Hinge Door 18 99A0655 1 Door Assembly Front 19 99A0658 2 Magnet Door 20 99A0650 1 Frame Assembly 21 99A0661 1 Tray Assembly Elevator 22 99A1806 1 Card Assembly 2...

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

Page 309: ...A0653 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 Nut Power Supply Cover 46 99A0714 1 Cover Power Supply 47 99A0675 2 Parts Packet Screw Power Supply Bd Mtg 48 99A0677 2 Parts Packet Washer Power Supply Board 49 99A0667 1 Power Supply Board 50 99A07...

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

Page 311: ...eptacle 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 1 Cable 250 Auto Connect 77 99A0279 1 Bearing Drive Shaft 78 99A0273 1 Gear Bevel 79 99A0263 2 Parts Packet Screw Frame Mounting 80 99A0276 1 Roll Assembly Drive 250 Option 81 99A0451 1 Roll Skew Ba...

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

Page 313: ...r 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 Support Frame 1Hex Support Frame 2 Hex NS 99A0677 6 Parts Packet Washer Support Frame 1 Star Support Frame 2 Star NS 99A0684 1 Cable HCIT 14Pin Flex NS 99A0286 1 Spring Backup Roller ...

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 Packet Washer Bracket 250 Frame Retention Mounting 105 99A0263 4 Parts Packet Screw Bracket 250 Frame Retention Mounting 106 99A0679 2 Bracket 250 Frame Retention NS 99A0717 1 Cable Paper Low Switch NS 99...

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

Page 317: ...r 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 Drive Roller 14 99A0125 1 Frame Assembly Right Side 15 99A0232 1 Cover Right 16 99A1820 2 Belt 185G 17 99A0226 1 Guide Paper Exit 18 99A0122 2 Shaft Assembly Drive Roller 19 99A0137 1 Frame Assembly Lef...

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

Page 319: ...7 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 Tray Assembly Drive Roller 14 99A0907 1 Frame Assembly Right Side 15 99A0232 1 Cover Right 16 99A1820 2 Belt 185G 17 99A0122 2 Shaft Assembly Drive Roller 18 99A0906 1 Frame Assembly Left Side 19 99A00...

Page 320: ...28 99A1759 1 8MB Flash 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 Disk with Control Board 5 0GB 28 99A0629 1 Adapter Card SES for SCS 28 13A0296 1 Cable Twinax 28 13A0297 1 Cable Coax 28 99A0545 1 Adapter Serial 28 13A0298 1 Cable Serial 28 99A0923...

Page 321: ...0 Ethernet 28 12G1696 1 MarkNet N2002e 10Base2 10Baset 28 12G1697 1 MarkNet N2000t 4 16 28 99A0560 1 Adapter Omnibus INA Card 28 99A1889 1 Paper Presentator Front 28 56P0161 1 INA Serial Parallel C 28 56P0162 1 Adapter Parallel 1284 C B 28 90A2485 1 Tray Assembly UAT 400 Sheet 28 99A1683 1 Card Assembly FORMS Flash DIMM 2mb 28 99A1684 1 Card Assembly FORMS Flash DIMM 4mb 28 99A1685 1 Card Assembly...

Page 322: ...arings 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 Capacity Feeder 29 99A0083 1 Parts Kit Multipurpose Tray 29 99A0512 1 Parts Kit Charge Roll Link Asm Left Side 29 99A0513 1 Parts Kit Charge Roll Link Asm Right Side 29 99A0702 2 Printer Stand Caster Non ...

Page 323: ...ndex Part Number Units Description 29 99A0208 1 Parts 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 4069 500 250 printer ...

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

Page 325: ...ex 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 ...

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 7 60 Frame 7 4 High Capacity Feeder 7 62 Hot Roll Fuser 7 24 Integrated Paper Tray 250 Sheet 7 48 Integrated Paper Tray 500 Sheet 7 18 Kiosk Horizontal Paper Adapter 7 74 Kiosk Vertical Paper Adapter...

Page 327: ...embly 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 53 Printhead 4 54 Redrive Assembly 4 55 Smart Contact Assembly 4 56 Toner Sensor 4 57 Transfer Roll Assembly 4 58 Upper Front Cover Hinge Assembly 4 59 Upper Front Cover Interlock Switch Assembly 4 6...

Page 328: ...1 1342534 7 31 1342536 7 31 1374067 7 31 43H5248 7 31 56P0150 7 25 56P0161 7 77 56P0162 7 77 56P0188 7 33 56P0189 7 33 56P0190 7 33 56P0191 7 33 56P1004 7 33 56P1005 7 33 56P1049 7 5 7 37 56P1100 7 77 56P1101 7 77 56P1139 7 7 7 37 90A2485 7 77 99A0004 7 3 99A0007 7 3 99A0026 7 5 7 45 7 51 99A0028 7 5 99A0039 7 5 99A0053 7 5 7 39 99A0058 7 45 7 51 7 59 99A0062 7 5 99A0063 7 5 7 45 7 53 99A0070 7 11...

Page 329: ... 7 53 7 55 7 67 99A0281 7 45 7 53 7 67 99A0282 7 45 7 53 99A0286 7 47 7 53 7 69 99A0288 7 45 7 51 7 71 99A0292 7 19 7 51 99A0299 7 55 7 78 99A0307 7 59 99A0308 7 59 99A0310 7 57 99A0311 7 57 99A0312 7 55 99A0314 7 55 99A0315 7 55 99A0316 7 55 99A0317 7 57 99A0319 7 59 99A0321 7 55 99A0322 7 55 99A0323 7 55 99A0324 7 55 99A0325 7 55 99A0326 7 55 99A0328 7 55 99A0329 7 55 99A0330 7 59 99A0332 7 59 9...

Page 330: ...65 99A0660 7 63 99A0661 7 63 99A0662 7 63 99A0663 7 65 99A0664 7 65 99A0667 7 65 99A0672 7 67 99A0675 7 63 7 65 7 67 7 69 7 78 99A0676 7 63 7 65 7 69 7 78 99A0677 7 45 7 63 7 65 7 69 7 71 7 78 99A0678 7 71 99A0679 7 45 7 71 99A0681 7 63 99A0684 7 69 99A0685 7 65 99A0687 7 67 99A0690 7 63 99A0691 7 63 99A0692 7 71 99A0695 7 65 99A0698 7 63 99A0702 7 78 99A0703 7 78 99A0704 7 78 99A0705 7 78 99A0706...

Page 331: ...99A1596 7 7 99A1601 7 19 7 47 7 49 7 51 99A1602 7 51 99A1605 7 77 99A1609 7 11 99A1611 7 35 99A1612 7 39 99A1613 7 5 99A1616 7 11 99A1633 7 78 99A1634 7 59 99A1636 7 51 99A1638 7 45 99A1643 7 5 99A1644 7 17 99A1645 7 53 99A1646 7 73 99A1647 7 75 7 77 99A1649 7 25 99A1651 7 25 7 41 7 43 99A1654 7 77 99A1658 7 25 99A1664 7 53 99A1665 7 53 99A1666 7 45 7 51 7 57 7 61 7 71 99A1667 7 53 99A1668 7 55 99...

Page 332: ...A1889 7 77 99A1890 7 77 99A1894 7 49 99A1895 7 19 99A1896 7 7 99A1927 7 11 99A1928 7 47 99A1929 7 53 99A1930 7 11 99A1952 7 47 7 51 99A1967 7 45 7 51 7 69 99A2010 7 3 99A2011 7 3 99A2014 7 3 7 39 99A2015 7 3 7 39 99A2016 7 5 99A2017 7 5 99A2018 7 5 99A2019 7 5 99A2020 7 5 99A2021 7 5 99A2022 7 5 99A2024 7 5 99A2025 7 7 99A2026 7 9 7 41 7 43 99A2027 7 13 99A2029 7 17 99A2030 7 21 7 37 99A2033 7 41 ...

Page 333: ...23 99A2082 7 31 99A2083 7 31 99A2084 7 35 99A2087 7 3 99A2090 7 31 99A2091 7 31 99A2092 7 13 99A2093 7 19 99A2094 7 35 99A2095 7 35 99A2150 7 3 99A2151 7 17 99A2152 7 33 99A2156 7 35 99A2157 7 11 7 39 99A2160 7 49 99A2200 7 33 7 76 99A2409 7 75 99A2422 7 25 99A2423 7 25 99A2438 7 39 99A2486 7 33 7 76 99A2487 7 33 7 76 99A2488 7 76 99A2489 7 76 99A2528 7 33 ...

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

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