Lexmark 522n - C Color Laser Printer Service Manual
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Lexmark 522n - C Color Laser Printer Service Manual

Lexmark 522n - C Color Laser Printer Service Manual

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Lexmark™ T52x
4520-xxx
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 522n - C Color Laser Printer

  • Page 1 Lexmark™ T52x 4520-xxx • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 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 trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    4520-xxx Contents Notices and Safety Information ..... . . ix Laser Notices........ix Safety Information .
  • Page 4 4520-xxx Transfer Roll Service Check ..... 2-103 Diagnostic Aids ........3-1 Diagnostic Mode .
  • Page 5 4520-xxx Fuser Operation........3-27 Paper Feed Jams ....... . . 3-28 Repair Information .
  • Page 6 4520-xxx Operator Panel Assembly Removal....4-47 Operator Panel Cable/Cover Switch Removal..4-48 Optional 250/500 Paper Tray Assembly Removal..4-49 Paper Alignment Assembly Removal .
  • Page 7 4520-xxx Assembly 9: Main Drive ......7-20 Assembly 10: Developer Drive ..... 7-22 Assembly 11: Hot Roll Fuser .
  • Page 8 4520-xxx viii Service Manual...

  • Page 9: Notices And Safety Information

    4520-xxx Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown: Laser Advisory Label Notices and Safety Information...
  • Page 10 4520-xxx Class 1 Laser Statement Label Service Manual...

  • Page 11: Laser Notice

    4520-xxx Laser Notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825.
  • Page 12 4520-xxx Avis relatif à l’utilisation de laser Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825 relatives aux produits laser de Classe I.
  • Page 13 4520-xxx Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825 para productos láser de Clase I (1).
  • Page 14 4520-xxx Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt.
  • Page 15 4520-xxx Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 16 4520-xxx Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
  • Page 17 4520-xxx Japanese Laser Notice Chinese Laser Notice xvii Notices and Safety Information...

  • Page 18: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 19 Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. • Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à...
  • Page 20 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
  • Page 21 Este produto foi concebido, testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.

  • Page 22: Ozone Information

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

  • Page 23: Preface

    4520-xxx Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as special tools and test equipment are listed in this chapter. •...
  • Page 24 4520-xxx xxiv Service Manual...

  • Page 25: General Information

    The Lexmark T laser printers are letter quality page 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...

  • Page 26: Options

    4520-xxx Options The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country. Memory options of 4MB, 8MB, 16MB, 32MB, 64MB and 128MB SDRAM Flash memory options of 2MB, 4MB, 8MB and 16MB Integrated network options Token-Ring Ethernet...

  • Page 27: Maintenance Approach

    4520-xxx Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure.

  • Page 28: Acronyms

    4520-xxx Acronyms Customer Setup DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable, Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode LVPS Low Voltage Power Supply...

  • Page 29: Diagnostic Information

    4520-xxx 2. Diagnostic Information Start CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.

  • Page 30: Service Error Codes

    Error Code Action 900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash Indicates that the flash which the engine board code is programmed into is bad. Replace the engine board.
  • Page 31 4520-xxx Error Code Action 914 DC Pick Check the integrated paper tray (tray 1) for correct paper Motor: No loading. Reload the paper and POR the printer. If the encoder feedback error continues, go to the “Input Tray(s) Service Check” on page 2-62.
  • Page 32 4520-xxx Error Code Action 931-935 These errors represent a problem with the printhead. Go Printhead Error to the “Printhead Service Check” on page 2-87. 932 - Printhead: Lost Hsync 933 - Mirror Motor Locks/Lost Hsync 934 - Mirror Motor Lost Lock 935 - Mirror Motor unable to reach operating speed.
  • Page 33 4520-xxx Error Code Action 940 Service LV The low voltage power supply zero crossover test failed. Power Supply • Check the LVPS for correct installation. Ensure that the connector on the LVPS assembly is firmly seated with the connector on the interconnect card connector. This error may also be caused by a noisy AC input power source.
  • Page 34 4520-xxx Error Code Action 956 Configuration Indicates a problem with the Configuration ID. This error occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer. Setting the configuration ID correctly should fix this error.
  • Page 35 4520-xxx Error Code Action 980 <device> The engine is experiencing unreliable communications Comm to the specified device. 981 <device> The engine protocol violation detected by the specified device. 982 <device> Communications error detected by the specified device. Comm 983 <device> Invalid command received by the specified device.
  • Page 36 4520-xxx Sub Error Codes for 9XX and 2XX Error Codes The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit. When a 9XX or 2XX error displays, press and hold Return and press Select to enter for sub error codes.
  • Page 37 4520-xxx Base Printer Sub Error Codes Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem.
  • Page 38 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 84 xx 02 x1 This error is the most common type of paper jam. Possible causes are (x1=media size): *Multi sheet feeding. *A tray size sensing problem. *The media feeding from the paper source is slipping or media is slipping in input to the printer.
  • Page 39 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 84 xx 0f x1 The option Tray pass thru sensor was never deactivated. x2 x3 (x-1=media size) (x-2=media source) (x-3=media source where paper jam was detected) *Check the pass thru sensor and flag for correct operation.
  • Page 40 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 84 xx 1A There is media over the Tray 4 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.
  • Page 41 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 84 xx 20 x1 The imaged page is not the expected page. (x1=Media Size, x2=Media Source) Check the pass thru sensor to make sure it is operating properly.
  • Page 42 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 89 00 01 The exit sensor in the fuser is activated by a piece of media indicating there is a piece of media in the machine during POST.
  • Page 43 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 89 xx 0D The fuser exit sensor bounced. Check the exit sensor for correct operation. Check the fuser DC cable to J14 on the system board.
  • Page 44 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value. 8E x1 0B The DC auto compensator failed or stalled when trying to feed a sheet of media. 8E xx 11 It took too long for the DC auto compensator motor to come up to speed.
  • Page 45 4520-xxx Base Printer (Fuser) Sub Error Codes The following Sub Error Codes could be a help in diagnosing Fuser Assembly failures: First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value 920 Service - Fuser Error (Under temperature while printing) EN 08 xx yy xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach.
  • Page 46 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value EN 42 xx yy xx=Actual Fuser Temperature -- 1 yy=The temperature that the fuser wants to reach. EN z1 z2 -- - zz=00 The fuser temperature did not change enough from the fuser lamp temperature at turn on.
  • Page 47 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value 925 Service - Fuser Error (Wrong Fuser Lamp Installed) Note: The Sub Error Codes below are only for an incorrect lamp being installed. EN 07 xx yy This error code is generated anytime an incorrect lamp is zz 1 detected.
  • Page 48 4520-xxx First 6 Bytes Sub Error Code Explanation Data - Note: xx can be any value 84 xx 1D x1 The envelope feeder pass thru sensor activated but never deactivated. (x1=Media Size)(x2=Media Source) This error can be caused by an envelope over the pass thru sensor.
  • Page 49 4520-xxx Duplex Unit Sub Error Codes Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the duplex unit and is the only byte contained in the following table. Status Explanation Byte 4 No duplex error.

  • Page 50: User Status Messages

    4520-xxx User Status Messages User Status Message Status Action Ready The printer is ready to Press Menu to take receive and process the printer out of data. Ready and enter all the Menus except the TESTS MENU (Busy state). Ready/Hex The printer is ready and Press Menu to take HEX Trace is active,...
  • Page 51 4520-xxx User Status Message Status Action Printing Menu Settings The printer is processing Press Stop to take the or printing a list of printer out of Ready. current settings menus The Not Ready because Print Menu message is displayed. Settings is selected from No more data is the menu.
  • Page 52 4520-xxx User Status Message Status Action Restoring Factory The printer is restoring No button actions are Defaults factory defaults. possible while this message is displayed. Performing Self Tests The printer is running No button actions are the normal series of possible while this start-up tests after it is message is displayed.

  • Page 53: User Error Messages

    4520-xxx User Status Message Status Action Programming Disk The disk is being No button actions are (Do Not Power Off) programmed, which possible while this means fonts or macros message is displayed. are being written to disk. Note: If information is written to flash memory and to disk at the same time, the...
  • Page 54 4520-xxx User Error Message Explanation 230 Paper Jam The paper is most likely jammed in the Duplex Check Duplex Unit. Remove the duplex front cover to access the jam area. If the paper is jammed in the rear of the duplex, then replace the duplex front cover and open the duplex rear door.
  • Page 55 4520-xxx User Error Message Explanation 32 Unsupported Print Error 32 is displayed when the top cover is closed Cartridge and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval.
  • Page 56 4520-xxx User Error Message Explanation 52 Flash Full This message is displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. 53 Unformatted Flash This message is displayed when the printer detects an unformatted flash at power on.
  • Page 57 4520-xxx User Error Message Explanation 62 Disk Full This error code is displayed when there is not enough free space on the disk to hold the resources that have been requested to be written to the disk. This message displays for both resource and PostScript Disk operators when the disk is full.
  • Page 58 4520-xxx User Line 2 Messages If none of the conditions exist that are listed in the following table, line 2 is blank. If any of the messages in the table are displayed the following actions can be taken: Press Menu to take the printer offline and access the Ready Menu group.
  • Page 59 4520-xxx User Message Explanation Tray X Empty If any of the input trays are empty, then “Tray X Empty” displays where X designates which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are prioritized in this order: Tray 5, Tray 4,...Tray 1.
  • Page 60 4520-xxx User Line 2 Link Messages If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. Link messages are listed in the following table. User Message Explanation Parallel Standard Parallel Port, if available.
  • Page 61 4520-xxx Check Device Connection Messages The messages in the following table display when the printer looses communications with one of the following devices. User Status Message Explanation Check Env Feeder Check Envelope Feeder Connection. Connection Check Tray X Check Tray X (X=1,2,3,4 or 5). Connection Check Duplex Check Duplex Unit Connection.
  • Page 62 4520-xxx User Status Message Explanation Turn Printer OFF to Enable This message displays when a printer option, Option Input Tray, or Envelope Feeder, has been attached while the printer is powered on. To use the option, the printer must first be powered off and back on again.

  • Page 63: Power-On Self Test (Post)

    4520-xxx Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: 1. The LED comes on. 2. The operator panel displays one and a half row of pels, and then clears.

  • Page 64: Symptom Tables

    4520-xxx Symptom Tables Symptom Table - Base Printer Symptom Action Dead Machine Go to the “Dead Machine Service Check” on page 2-43. Operator Panel - One or more Go to the “Operator Panel Buttons buttons do not work. Service Check” on page 2-79.
  • Page 65 4520-xxx Symptom Action Print quality - Skew Go to the “Paper Feed Service Check” on page 2-84. Print quality - Banding Go to the “Print Quality - Banding” on page 2-96. Print quality - Random marks Go to the “Print Quality - Random Marks”...
  • Page 66 4520-xxx Symptom Table: Paper Trays Symptom Action Paper feed problem with 250 Go to the “Input Tray(s) Service Sheet Paper Tray. Check” on page 2-62. Paper feed problem with 500 Sheet Paper Tray. Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option.

  • Page 67: Service Checks

    4520-xxx Service Checks 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 Review the following information before performing any service checks. •...

  • Page 68: Charge Roll Service Check

    4520-xxx Charge Roll Service Check Service Tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 inch) apart or spots on the page can be caused by a damaged or contaminated charge roll. Service Tip: Check to make sure the right charge roll arm bushing is correctly installed and operates correctly.
  • Page 69 4520-xxx Action Right Side Charge Roll Link Check the right side charge roll link Right Charge Roll Bushing assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination.

  • Page 70: Cover Open Switch/Cable Service Check

    4520-xxx Cover Open Switch/Cable Service Check Action Toner Cartridge Check the toner cartridge to make sure it is correctly installed and that the right and left cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch...

  • Page 71: Dead Machine Service Check

    4520-xxx Dead Machine Service Check Note: If a high-capacity input tray is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, go to “High-Capacity Feeder Input Tray Service . If the base printer continues to not operate Check”...
  • Page 72 4520-xxx Action LVPS Fuse F1 - Continues Replace fuse F1 if necessary. Turn to blow after LVPS installed the LVPS on/off switch off and in the printer. connect the AC line cord and turn the LVPS on. CAUTION: Before checking fuse F1 turn the LVPS Off and disconnect the AC line cord.

  • Page 73: Duplex Unit Service Check

    4520-xxx Duplex Unit Service Check The printer does not recognize the Duplex Unit is attached. The printer does not recognize tray options below the duplex unit are installed. Action Fuse F1 on Duplex Unit If fuse F1 is blown, replace the fuse. System Board If fuse F1 continues to blow, check the stepper motor for a short...
  • Page 74 4520-xxx POST fails, 230 Paper Jam, Check Duplex message displays. Action Duplex D.C. Servo Drive Check the D.C. servo motor cables Motor for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is found, replace the FRUs in the following order: 1.
  • Page 75 4520-xxx 230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive. Action Duplex Stepper Motor Check the stepper motor cable for cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tray.

  • Page 76: Envelope Feeder Service Check

    4520-xxx Envelope Feeder Service Check Service Tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise verify the interconnect card is functioning properly.
  • Page 77 4520-xxx Action Autoconnect on the Check for any signs of damage to Envelope Feeder. the connector or contacts. If you find damage, replace 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...
  • Page 78 4520-xxx Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete. Action Pass thru Sensor Check for any debris, pieces of envelope and so on over the pass thru sensor. Check for correct installation of the pass thru sensor flag.
  • Page 79 4520-xxx Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display "Load Envelopes" after envelopes are placed in the hopper. Service Tip: The kick rolls rotate during the attempted feed cycles. Action Envelope Out Hopper Check the envelope out sensor flag...
  • Page 80 4520-xxx 990 Service Error, envelopes fail to feed from the hopper. Action D.C. Feed Motor Assembly Check the motor and motor cable for any signs of loose wires or poor connections. Check to make sure the motor cable is connected to the envelope system board.
  • Page 81 4520-xxx 260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls are rotating. Check the deflector gap adjustment before continuing this service check. Action Deflector Gap Adjustment Check the deflector gap adjustment. The adjustment may be too narrow. Weight Assembly Check the weight assembly to make sure it moves up and down freely...
  • Page 82 4520-xxx 260 Paper Jam displays, envelope stops in feeder paper path. Action Kick Rolls/Feed Rolls/Drive Check all the rolls for any signs of oil, Rolls grease or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder.
  • Page 83 4520-xxx Main Fan Service Check Check the cable connections at J1 on the engine board and at the main fan assembly. The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode. Action Main Fan Manually spin the fan and check that...

  • Page 84: Fuser Service Check

    4520-xxx Fuser Service Check Cold Fuser Service Check Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error indicates the wrong fuser lamp is installed.
  • Page 85 4520-xxx Action Fuser Lamp Remove the controller board. Run the Diagnostic Print Test and Fuser Top Cover Assembly observe the lamp through the left side frame. If the lamp does not come on, do the following: • Remove the redrive assembly. •...
  • Page 86 4520-xxx Hot Fuser Service Check Error Code 923: Indicates the fuser is too hot during printing or when the printer is idle. Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit. Note: Check the fuser sub error codes to help diagnose between a 923 and 924 error.
  • Page 87 4520-xxx Action Engine Board Perform the print test with the RIP controller board removed. Check the voltage on J16-3 on the engine board. The voltage should measure approximately 1.6 V dc as the thermistor goes from cold to hot. If incorrect, replace the engine board.

  • Page 88: Fuser Solenoid Service Check

    4520-xxx Fuser Solenoid Service Check Service Tip: Try changing the envelope enhance level setting. A different setting may correct the problem. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3 Action Fuser Envelope Conditioner The operation of the fuser solenoid...

  • Page 89: Input Sensor Service Check

    4520-xxx Input Sensor Service Check Service Tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor. Service Tip: Run a Diagnostic Print Test in the continuous mode with the controller board removed.

  • Page 90: Input Tray(S) Service Check

    4520-xxx Input Tray(s) Service Check 250-Sheet and 500-Sheet Trays Service Tip: Try all the other input paper sources to make sure they are properly feeding paper. For 990 Error Code- Service Tray X, X= displays the number of the tray that has a problem or needs service. Action Tray X Option System Check the autoconect cables and...
  • Page 91 4520-xxx 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (The printer displays the value of X for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1) Action Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating...
  • Page 92 4520-xxx Tray X Low message displays when Tray X is full or has adequate paper in the tray. Action Paper Low Sensor Run the Tray X Sensor Test and Assembly check the sensor for proper Paper Low Sensor Flag operation. If incorrect, check the Tray X Option System following: Board...
  • Page 93 4520-xxx Printer does not recognize Tray X is installed. Action Autoconect Cables Check the autoconnect from the Tray X System Board printer or option above tray x. Check for signs of cuts, pinched wiring or damage to the contacts in the connector.

  • Page 94: High-Capacity Feeder Input Tray Service Check

    4520-xxx High-Capacity Feeder Input Tray Service Check Note: Voltage measurements in the high capacity feeder input tray service checks must be made with the high-capacity feeder attached to the base printer to obtain accurate results. Service Tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.
  • Page 95 4520-xxx The base printer does not recognize that the high-capacity input tray is installed. Action High-Capacity Feeder Check the high capacity feeder input Autoconnect Mechanical tray to make sure it is mounted Check correctly and is not pushed down into the frame assembly or damaged.
  • Page 96 4520-xxx Action High Capacity Feeder Check the voltage on J8-1 (green). Option Control Board The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized.
  • Page 97 4520-xxx 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (X=The printer displays the value of X for the paper tray where the error occurs. Example: 242 is a Paper Jam Tray 2) Action Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating...
  • Page 98 4520-xxx Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray. Action Paper Low Switch Run the sensor diagnostics for tray X Paper Low Switch Cable (X=the number that represents the High Capacity Feeder Input high capacity input tray).
  • Page 99 4520-xxx The elevator tray fails to stop at the correct position and continues to drive into the bottom frame. Action Lower Limit Switch Check continuity of the lower limit Lower Limit Switch Cable switch. If incorrect, replace the switch. If correct, check the switch cable.
  • Page 100 4520-xxx Paper from the high capacity feeder input tray does not reach the pass thru sensor. Service Tip: Be sure the paper in tray is within specifications. Action Autocompensator Check the autocompensator pick Assembly arm rollers for sign of glazing, toner or other buildup.
  • Page 101 4520-xxx The elevator moves in one direction only. Action Check the voltages at J1 on the high DC Drive Motor Assembly High capacity system board. The voltages Capacity Feeder measure as follows: System Board Static (Motor Not Running) J1-1 (Brown): approximately 0 V dc J1-2 (yellow): approximately 0 V dc Motor Running Forward J1-1 (Brown): Approximately 0 V dc...
  • Page 102 4520-xxx Paper size switch not selecting paper size that is selected. Action Paper Size Switch Check for continuity between the High Capacity Feeder common pin (J5-1) and the pin of the Option Control Board paper size selected. J5-1 (Black): Common Lead J5-2 (Blue) B5 J5-3 (Green) Executive J5-4 (Yellow) A4...
  • Page 103 4520-xxx Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch. Action High-Capacity Feeder Check the voltage on the board at Option Control Board J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at J4 and check the voltage again.
  • Page 104 4520-xxx Excessive Noise or Vibration Action DC Motor Assembly Check to make sure all the motor plate mounting screws are tight. Idler Pulley Check to make sure the idler pulley DC Motor Assembly is not binding on the pulley shaft. Check the pulley for any signs of wear.

  • Page 105: Main Drive Service Check

    4520-xxx Main Drive Service Check Service Tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board. Service Tip: If there are equally spaced horizontal lines across the page, go to “Print Quality - Evenly spaced horizontal lines or marks.” on page 2-92 Warning: Whenever the gearbox assembly is removed from the machine it must be handled very carefully.
  • Page 106 4520-xxx Action Motor does not turn, no Check the voltages at J12 on the gear error code 936 or User engine board. message 201 Paper Jam displays. Pin number and voltage: J12-11 = +24 V dc J12-8 = +5 V dc (static) 0 V dc (when main drive motor running) J12-7= + 5 V dc (static) 0 V dc (when main drive motor running)

  • Page 107: Operator Panel Service Check

    4520-xxx Operator Panel Service Check Operator Panel Buttons Service Check Note: Before continuing with this service check do the “Button Test” in the diagnostic aids chapter. on page 3-11 Action Operator Panel Assembly If any button fails the Button Test, replace the operator panel assembly.
  • Page 108 4520-xxx Action Operator Panel Cable Check for proper installation of the cable at the engine board (J11) and at the operator panel. Check the continuity of the operator panel cable. If incorrect, replace the cable. Operator Panel Display Check the voltage at J11-2 on the blank, 5 beeps, LED Off engine board.

  • Page 109: Options Service Check

    Hard Disk Option Service Tip: The Lexmark T printers support one hard disk option. Check to make sure only one hard disk option is installed. Check to make sure the fixed disk and the fixed disk board are correctly installed.
  • Page 110 4520-xxx Note: The Quick Disk Test is a non-destructive test and indicates Pass or Fail. If the test fails, replace the hard disk. If a problem still exists, replace the hard disk board. is used to help restore the disk if the “Disk Test/Clean”...

  • Page 111: Output Bin Sensor Standard Tray Service Check

    4520-xxx Output Bin Sensor Standard Tray Service Check Service Tip: If the output bin standard tray fills up and the bin full sensor fails to post the message "Remove Paper Standard Bin," enter the Diagnostic Mode, select Output Bin Tests, select Sensor Tests and select Standard Bin.

  • Page 112: Paper Feed Service Check

    4520-xxx Paper Feed Service Check If you have a 936 Transport Motor Error go to the “Main Drive Service Check” on page 2-77 Action Alignment Assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight.
  • Page 113 4520-xxx Paper feed failures occur only near the top of the stack of paper. The most common cause of this problem is paper curl. Remove the paper from tray x and check for the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it may be necessary to reduce the stack height.

  • Page 114: Parallel Port Service Check

    4520-xxx Multipurpose Tray Paper fails to feed from the multipurpose tray. The pick roll should make one complete revolution and stop with the flat side down. If the pick roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of the pick roll or slick spots.

  • Page 115: Printhead Service Check

    4520-xxx Printhead Service Check The printhead assembly does not contain any service replaceable parts or components. If service error code 930 displays, the wrong printhead is installed in the printer. Note: A 201 paper jam may also indicate a failing printhead. The paper may have jammed prior to or at the input sensor.

  • Page 116: Print Quality Service Check

    4520-xxx Print Quality Service Check Service Tip: Before troubleshooting any print quality problems do the following: • Install another print cartridge if available before proceeding with the service checks. • Use Tray 1 to test for print quality of the base printer. •...
  • Page 117 4520-xxx Print Quality - All Black Page Service Tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
  • Page 118 4520-xxx Print Quality - Blank Page Action Print Cartridge Check the print cartridge for any signs of damage, especially the PC drum contact on the cartridge. High Voltage Contact Check the PC drum contact on the right side frame for damage, PC drum contact wear or contamination.
  • Page 119 4520-xxx Action 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 does not have a mechanical shutter as previous laser printers. The printer is interlocked through the front top cover interlock switch.
  • Page 120 4520-xxx Print Quality - Evenly spaced horizontal lines or marks. Action Lines spaced 3.19 mm This can be caused by the motor (.126 inch) apart pinion gear on the main drive motor. Replace the main drive motor. Lines spaced 22.32 mm This can be caused by a defective (.882 inch) apart gear in the main drive gearbox...
  • Page 121 4520-xxx Action Lines spaced 52.23 mm Replace the redrive assembly. (2.056 inch) apart Lines spaced 76.53 mm Replace the FRUs in the following (3.013 inch) apart order: 1. Alignment assembly 2. Main drive gearbox assembly Lines spaced 95.66 mm Replace the FRUs in the following (3.766 inch) apart order: 1.
  • Page 122 4520-xxx Print Quality - Background Service Tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background. Some problems occur with printers that run a large amount of graphics in a humid environment.
  • Page 123 4520-xxx Action Engine Board HVPS Check the following voltages at J10 Connector on the engine board. Measure the voltages from J10 to printer ground. Printer Idle J10-1 approximately 0 V dc J10-2 approximately 4 V dc J10-4 approximately 0 V dc Printer Printing J10-1 varies 0 V dc to +5 V dc J10-2 varies 0 V dc to +4 V dc...
  • Page 124 4520-xxx Print Quality - Banding Service Tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer, especially in the development and transfer process.
  • Page 125 4520-xxx Action HVPS Check the following voltages at J10-8 on the engine board: Printer Idle J10-8 measures 0 V dc Printer Printing Test Page J10-8 voltage changes from 0 V dc to +4 V dc If the voltage does not vary, check the continuity of line J10-8 in the front cable harness.
  • Page 126 4520-xxx Print Quality - Residual Image Service Tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade and other parts inside the print cartridge. Action Hot Roll Fuser Assembly Check the fuser assembly for signs of toner contamination.
  • Page 127 4520-xxx Print Quality - Toner on backside of printed page Service Tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper. Action Hot Roll Fuser Assembly Toner is being carried out on the backside of the media.

  • Page 128: Smart Contact Assembly Service Check

    Smart Contact Assembly Service Check Note: If you are unable to clear a “32-Unsupported Cartridge” User Error Message, be sure a Lexmark 4520 print cartridge is correctly installed in the printer. The cartridge is easily identified by the contact board on the right side rear of the cartridge. Install another print cartridge before attempting to troubleshoot the printer.

  • Page 129: Serial Port Service Check

    4520-xxx Serial Port Service Check Run the “Serial Wrap Test” on page 3-13 Note: The Serial Wrap Test is 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.

  • Page 130: Toner Sensor Service Check

    4520-xxx Toner Sensor Service Check Service Tip: Check the print darkness MENU setting before checking the toner sensor. This service check is intended to be used when a 929 Service Error displays. Action Developer Drive Assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code (Toner Sensor).

  • Page 131: Transfer Roll Service Check

    4520-xxx Transfer Roll Service Check Service Tip: The transfer roll is 51.02 mm (2.009 inch) circumference. Any print quality problems such as lines that are spaced 51.02 mm apart indicate you should check the transfer roll for damage, toner or foreign material buildup. Service Tip: The transfer roll assembly is part of the Maintenance Kit and is replaced when a '80 Scheduled Maintenance”...
  • Page 132 4520-xxx Action Right Transfer Arm Check the right transfer arm Assembly assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, check to make sure the arm is not broken and will lock into the EP frame correctly.

  • Page 133: Diagnostic Aids

    4520-xxx 3. Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostic Mode To enter the Diagnostic Mode: 1.

  • Page 134: Device Tests

    4520-xxx Device Tests Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block.

  • Page 135: Disk Test/Clean

    4520-xxx Disk Test/Clean Warning: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1 1/2 hours depending on the disk size. To run the Disk Test/Clean Test: 1.

  • Page 136: Flash Test

    4520-xxx Flash Test This test causes the file system to write and read data on the flash to test the flash. Warning: This test destroys all data on the flash because the flash is reformatted at the end of the test. To run the Flash Test: 1.

  • Page 137: Disabling Download Emulations

    4520-xxx Disabling Download Emulations Error Code 964: Download Emulation CRC Failure. Checksum failure detected in the emulation header or emulation file. Error Code 965: Download Emulation Outdated. Time stamps indicate the download emulation and RIP code are incompatible. To help resolve Download Emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations.

  • Page 138: Duplex Tests

    4520-xxx Duplex Tests Duplex Quick Test This test is used to verify that the Duplex Unit Top Margin is set correctly. This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the backside of the duplexed page.

  • Page 139: Duplex Sensor Test

    4520-xxx Duplex Sensor Test This test is used to determine whether or not the Duplex 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.

  • Page 140: Duplex Motor Test

    4520-xxx Duplex Motor Test This test lets you test the duplex unit paper feed drive system, and verify that the power and velocity values are acceptable. To run the Duplex Motor Test: 1. Select Motor Test from the Duplex Tests menu. The duplex motor test continues to run until the printer is powered off.

  • Page 141: Duplex Feed 1 Test

    4520-xxx Duplex Feed 1 Test This test feeds a blank sheet of paper to the duplex paper stop position 1. To run the Duplex Feed 1 Test: Select Duplex Feed 1 from the Duplex Test menu. • The power indicator blinks while the paper is feeding. •...

  • Page 142: Error Log

    4520-xxx Error Log Viewing the Error Log The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred).

  • Page 143: Hardware Tests

    4520-xxx Hardware Tests Select the following Hardware Tests from this menu: • LCD Test • Button Test • DRAM Memory Test • ROM Memory Test • Parallel Wrap (if available) • Serial Wrap (if available) • Serial 1 Wrap (if available) •...

  • Page 144: Sdram Memory Test

    4520-xxx SDRAM Memory Test The purpose of this test is to check the validity of SDRAM, both standard and optional. The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly. To run the SDRAM Memory Test: 1.

  • Page 145: Rom Memory Test

    4520-xxx ROM Memory Test The ROM Memory Test is used to check the validity of the controller board code and fonts. To run the ROM Memory Test: 1. Select ROM Memory Test from the menu. P and F represent the same numbers for DRAM.
  • Page 146 4520-xxx To run the Serial Wrap Test: 1. Disconnect the serial interface cable and install the wrap plug. 2. Select the appropriate Serial Wrap Test from the menu: Serial Wrap, Serial 1 Wrap, Serial 2 Wrap or Serial 3 Wrap. P and F represent the same numbers for DRAM.

  • Page 147: Input Tray Tests

    4520-xxx Input Tray Tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder.

  • Page 148: Output Bin Test - Standard Bin

    4520-xxx Output Bin Test - Standard Bin This test is used to verify if the standard bin sensor is working correctly. To run the Standard Bin Sensor Test: 1. Select Output Bin Tests from the Diagnostic menu. 2. Select Output Bin Tests - Sensor Tests. 3.

  • Page 149: Print Registration

    4520-xxx Print Registration The print registration range is: Bottom Margin: -20 to +20 Each increment causes approximately .55 mm shift in the bottom margin. Top Margin: -25 to +25 Left Margin: -25 to +25 Right Margin: -10 to +10 To set Print Registration: 1.

  • Page 150: Printer Setup

    4520-xxx Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer NVRAM Memory where the page count is stored. To set the Page Count: 1.

  • Page 151: Maintenance Page Count

    4520-xxx Maintenance Page Count This counter is reset by the servicer after a “80 Scheduled Maintenance” message displays (300K copies) and a maintenance kit is installed. To view the Maintenance Page Count: 1. Select Maintenance Count Value from the Diagnostic menu. 2.

  • Page 152: Setting Configuration Id

    4520-xxx Setting Configuration ID The configuration ID is used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The Configuration ID is originally set at the factory when the printer is manufactured, however it requires resetting whenever you replace the engine board and can be set on the operator panel.

  • Page 153: Restore Ep Factory Defaults

    4520-xxx Restore EP Factory Defaults To restore each of the printer settings contained in the EP Setup menu to their factory default value select Restore from the menu. To exit the menu without restoring the settings to the factory default values, select Do Not Restore.

  • Page 154: Print Tests

    4520-xxx Print Tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. Each of the installed options is listed in the following order in the menu: Tray 1 Tray 2 (if installed) Tray 3 (if installed)

  • Page 155: Print Quality Test Pages

    4520-xxx Print Quality Test Pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality test consists of three pages. Page one contains a mixture of graphics and text.

  • Page 156: Print Test With Rip (Controller Board) Removed

    4520-xxx Print Test with RIP (Controller Board) Removed This service mode lets you test and service the printer without the controller board installed. You can verify that the motors, sensors, printhead and EP process are working correctly. You can also make meter measurements on the engine board connectors with the controller board removed.

  • Page 157: Autocompensator Operation

    4520-xxx Autocompensator Operation The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively.

  • Page 158: Autoconnect System, Paper Tray Options, Envelope Feeder

    4520-xxx Autoconnect System, Paper Tray Options, Envelope Feeder Electrical Autoconnect Cabling and Connectors The printer options make electrical connection automatically, requiring no external cables when the option is mechanically installed under the printer. Communication between the option and the base printer stops when you remove an option. The printer no longer recognizes the option and deletes associated messages.

  • Page 159: Fuser Operation

    This is a complete assembly and the parts cannot be individually replaced as in previous Lexmark laser printers. The thermal fuse (two fuses in series) protects the fuser assembly and surrounding parts from ignition in the event of a failure in the fuser control circuitry by opening the AC circuit to the lamp.

  • Page 160: Paper Feed Jams

    4520-xxx Paper Feed Jams Paper Jams - Base Printer Error Message 200 - Paper Jam - Remove Cartridge This message indicates that paper is jammed at the printer input sensor. This condition can be caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper over the sensor or paper arriving at the sensor too late.
  • Page 161 4520-xxx Error Message 24x (x=Tray 1 through 5) Paper Jam Check Tray x The paper has not cleared the pass thru sensor or reached the pass thru sensor of the option above tray x. Error Message 250 - Paper Jam - Check MP Feeder The paper is jammed in the multipurpose feeder and has not reached the base machine input sensor or has not reached the input sensor in time.
  • Page 162 4520-xxx 3-30 Service Manual...

  • Page 163: Repair Information

    4520-xxx 4. Repair Information Warning: Read the following before handling electronic parts. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: •...

  • Page 164: Adjustment Procedures

    4520-xxx Adjustment Procedures Duplex Motor Drive Belts Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor or loosen the motor or drive belt idler pulley. Service Tip: Excessive belt tension can result in stalling the duplex motor.

  • Page 165: Fuser Solenoid Adjustment

    4520-xxx Fuser Solenoid Adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature.

  • Page 166: Printhead Assembly Adjustment

    4520-xxx Printhead Assembly Adjustment Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws. Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly. Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots.

  • Page 167: Paper Alignment Assembly Adjustment

    4520-xxx Paper Alignment Assembly Adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one.
  • Page 168 4520-xxx B. Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in “Print Registration” on page 3-17. The reference screw can be adjusted without loosening the locknut.

  • Page 169: Screw Identification Table

    4520-xxx Screw Identification Table The following table contains screw types, locations, and quantities necessary to service the printer. Each screw callout in the removal procedure graphic displays the screw reference number listed in the table. Pay careful attention to each screw type location when doing removals.
  • Page 170 4520-xxx Reference Screw Type Location Purpose Number M3.5x8 mm spring mounting Thread Cutting controller board mounting (front) integrated tray ITC mounting board stacker support to right attach side frame M3.5x12 mm engine board shield to attach Thread Cutting left frame paper alignment mounting assembly...
  • Page 171 4520-xxx Reference Screw Type Location Purpose Number M3x6 mm outer shield mounting Taptite inner redrive deflector mounting interconnect board to mounting center pan engine board mounting controller board to attach interconnect board ground controller board to inner mounting shield controller board (back) mounting engine board to attach...
  • Page 172 4520-xxx Reference Screw Type Location Purpose Number M3x12 mm HVPS board mounting Taptite Panhead M3x28 mm developer drive ground attach Taptite (bottom hole) Panhead M3x6 mm stacker duct mounting Taptite controller to shield mounting Panhead controller board mounting in pan mounting shield ground attach...
  • Page 173 4520-xxx Reference Screw Type Location Purpose Number M3.5x8 mm autocompensator mounting Plastite Thread Forming M3.5x10 mm right side cover mounting Plastite Thread right side frame to pan attach Forming left side frame to pan attach M3x6 mm fuser board mounting SEMS Machine ground cable Screw with...

  • Page 174: Removal Procedures

    4520-xxx Removal Procedures CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the hand grips on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
  • Page 175 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). 4-13 Repair Information...
  • Page 176 4520-xxx 3. Remove the redrive assembly. 4. Remove the right side cover mounting screw (B). 5. Remove the right side cover. 4-14 Service Manual...
  • Page 177 4520-xxx Upper Front Cover Removal 1. Raise the upper front 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: Center Pan Assembly Removal

    4520-xxx Laser Assembly Cover Removal 1. Remove the left door. 2. Remove the right cover. 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.

  • Page 179: Controller Board Removal

    4520-xxx Controller Board Removal 1. Remove the 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.

  • Page 180: Developer Drive Assembly Removal

    4520-xxx Developer Drive Assembly Removal 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. 4-18 Service Manual...

  • Page 181: Duplex Board Removal

    4520-xxx Duplex Board Removal 1. Lift the base printer from the duplex assembly. 2. Remove the four duplex board cover mounting screws. 3. Gently disconnect the cables from the duplex board. Warning: To avoid damage to the cables and connectors. 4.

  • Page 182: Duplex Motor Removal

    4520-xxx Duplex Motor Removal 1. Remove the duplex front cover door. 2. Gently disconnect the cables from the duplex board. Warning: To avoid damage to the cables and connectors. 3. Remove the four mounting screws from the left and right return guides and remove the guides.

  • Page 183: Emc Shields Removals

    4520-xxx EMC Shields Removals 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.
  • Page 184 4520-xxx Outer EMC Shield Removal 1. Remove the left door. 2. Loosen the outer EMC shield mounting screws (A) and remove the shield. 4-22 Service Manual...

  • Page 185: Engine Board Removal

    4520-xxx Engine Board Removal 1. Remove the inner EMC shield. 2. Disconnect all cables from the engine 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.

  • Page 186: Main Fan Removal

    4520-xxx Main Fan Removal 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 Removals

    4520-xxx Frames Removals EP Frame Assembly Removal 1. Remove the left and right side 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.
  • Page 188 4520-xxx 7. Place the printer on its back and remove the left side frame mounting screws (A). 8. Remove the left side frame. 4-26 Service Manual...
  • Page 189 4520-xxx Right Side Frame Removal 1. Remove the right side cover. 2. Remove the LVPS. 3. Remove the multipurpose tray assembly. 4. Disconnect the autocompensator 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.

  • Page 190: Fuser Removal

    4520-xxx Fuser 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.

  • Page 191: Fuser Board Removal

    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. 4-29 Repair Information...

  • Page 192: Fuser Cover Removal

    4520-xxx Fuser Cover Removal 1. Remove the fuser assembly. 2. Note the thermistor cable routing and disconnect the cable from the 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.
  • Page 193 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. 4-31 Repair Information...

  • Page 194: Fuser Detack Housing Assembly Removal

    4520-xxx Fuser Detack Housing Assembly Removal 1. Remove the fuser assembly. 2. Remove the fuser cover assembly. 3. Remove the fuser lamp. Use care when handling the lamp. 4. Disengage the hot roll bearing clips to free the fuser frame walls.

  • Page 195: Fuser Envelope Conditioner Solenoid Removal

    4520-xxx Fuser Envelope Conditioner Solenoid Removal 1. Remove 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”...

  • Page 196: Fuser Narrow Media Sensor/Flag Assembly Removal

    4520-xxx Fuser Narrow Media Sensor/Flag Assembly Removal 1. Remove the fuser assembly. 2. Cut the cable tie from the fuser board cable bundle. 3. Disconnect the narrow media sensor from the fuser board. The sensor can be removed without removing the lower exit guide assembly.

  • Page 197: Fuser Lamp Removal

    4520-xxx Fuser Lamp Removal 1. Remove the fuser assembly. 2. Disconnect the fuser lamp AC cable from the top cover assembly. 3. Remove the fuser lamp. Warning: Hold the left lamp bracket and carefully remove the two mounting screws. There is pressure against the other end of the lamp therefore care must be used when removing the lamp from the fuser.

  • Page 198: High Voltage Power Supply Removal

    4520-xxx High Voltage Power Supply Removal 1. Remove the inner paper deflector. 2. Remove the toner sensor cable from the retainer (A) on the front of the HVPS. 3. Remove the right side cover. 4. Disconnect the HVPS cable from the HVPS at connector (C). 5.

  • Page 199: Integrated Tray Compensator Assembly Removal

    4520-xxx Integrated Tray Compensator Assembly Removal 1. Remove the paper tray. 2. Remove the left door. 3. Remove the inner EMC shield. 4. Disconnect the compensator motor cable (A) from the engine board. 5. Place the printer on its side. 6.
  • Page 200 4520-xxx Integrated Tray Compensator 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.

  • Page 201: Interconnect Board Assembly Removal

    4520-xxx Interconnect Board Assembly Removal 1. Remove the inner EMC shield. 2. Remove 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.

  • Page 202: Low Voltage Power Supply Removal

    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. 4-40 Service Manual...
  • Page 203 4520-xxx 4. Press the release latch on the fuser lamp cable connector (B) and disconnect from the LVPS. 5. Remove the fuser assembly. 4-41 Repair Information...
  • Page 204 4520-xxx 6. Disconnect the interconnect card cable from the LVPS (C). 7. Remove the LVPS. 4-42 Service Manual...

  • Page 205: Main Drive Assembly Removal

    4520-xxx Main Drive Assembly Removal 1. Remove the inner EMC shield. 2. Remove the gear guard. 3. Remove the developer drive assembly. 4. Remove the transfer shaft (A) through the bottom of the printer. 5. Remove all cables from the cable clamps (B) on the main drive assembly.

  • Page 206: Main Drive Motor Removal

    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. 4-44 Service Manual...

  • Page 207: Multipurpose Tray/Lower Deflector Assembly Removal

    4520-xxx Multipurpose Tray/Lower Deflector Assembly 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.
  • Page 208 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. 4-46 Service Manual...

  • Page 209: Operator Panel Assembly Removal

    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. 4-47 Repair Information...

  • Page 210: Operator Panel Cable/Cover Switch Removal

    4520-xxx Operator Panel Cable/Cover Switch Removal Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable/cover open switch assembly. 1. Remove the left door, left cover, upper front cover, outer EMC shield and inner EMC shield. 2.

  • Page 211: Optional 250/500 Paper Tray Assembly Removal

    4520-xxx Optional 250/500 Paper Tray Assembly Removal Note: Remove the printer and other paper feed options to access the failing optional paper tray assembly. Paper Tray Compensator Assembly Removal 1. Remove the printer and other paper feed options. 2. Disconnect the compensator assembly bias spring from the tray frame.

  • Page 212: Paper Alignment Assembly Removal

    4520-xxx Paper Alignment 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). 4-50 Service Manual...
  • Page 213 4520-xxx 6. Locate 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. 4-51 Repair Information...

  • Page 214: Paper Deflectors Removals

    4520-xxx Paper Deflectors Removals Inner Paper Deflector Assembly Removal 1. Remove the paper tray. 2. Remove the upper deflector assembly. 3. Place the printer on its side. 4. Remove the lower deflector assembly. 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.

  • Page 215: Paper Input Sensor Removal

    4520-xxx Paper Input Sensor Removal 1. Remove the inner paper deflector assembly. 2. Disconnect the paper input sensor cable from the input sensor. 3. Release 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.

  • Page 216: Printhead Removal

    4520-xxx Printhead Removal 1. Remove the laser assembly 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: Redrive Assembly Removal

    4520-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. 4-55 Repair Information...

  • Page 218: Smart Contact Assembly Removal

    4520-xxx Smart Contact Assembly Removal 1. 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: Toner Sensor Removal

    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. 4-57 Repair Information...

  • Page 220: Transfer Roll Assembly Removal

    4520-xxx Transfer Roll Assembly Removal 1. Open the upper front cover and remove the print cartridge. 2. Unsnap the transfer roll assembly from the left pivot arm. 3. Lift the transfer roll assembly toward the left and remove it from the printer.

  • Page 221: Upper Front Cover Hinge Assembly Removal

    4520-xxx Upper Front Cover Hinge Assembly Removal 1. Remove the upper front cover. 2. Remove the laser assembly cover. 3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge.

  • Page 222: Upper Front Cover Interlock Switch Assembly Removal

    4520-xxx Upper Front Cover Interlock Switch Assembly 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: Connector Locations

    4520-xxx 5. Connector Locations Low Voltage Power Supply Connector Pin No. Signal CN3 Interconnect Board +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc Ground Ground Ground Ground...
  • Page 224 4520-xxx Service Manual...

  • Page 225: High Voltage Power Supply

    4520-xxx High Voltage Power Supply Connector Pin No. Signal CN1 Engine Board Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT Connector Locations...

  • Page 226: Engine Board

    4520-xxx Engine Board Connector Pin No. Signal J1 Main Fan Fan Stall Ground Main Fan J3 Printhead (Mirror Motor) +24 V dc Return +24 V dc Return ReFREQ LOCKn Start* +24 V dc Return +24 V dc J4 Cover Closed Switch Cover Closed Ground +5 V dc...
  • Page 227 4520-xxx Connector Pin No. Signal J6 Output Level Sensor HOPFULL* Ground Opt2 Ground J8 Printhead HYSNC +5 V dc HsyncID Hsyncin Ground J10 Cartridge/Sensor/Input AT Servo (HVPS) Sensor/HVPS Servo OutT (HVPS) TXENABLE (HVPS) Transfer (HVPS) +24 V dc (HVPS) Charge (HVPS) Ground (HVPS) Developer (HVPS) Ground (In Sens)
  • Page 228 4520-xxx Connector Pin No. Signal J11 Operator Panel FPIRQ Ground I2CCLK +5 V dc I2CDATA J12 Transport Motor ON/OFF Ground +5 V dc MTR1 MTR4 MTR3 +24 V RET +24 V RET +24 V dc J14 Autoconnect (Options) RXDIN Ground TxBR Ground Service Manual...
  • Page 229 4520-xxx Connector Pin No. Signal J15 Integrated Paper Tray - Paper +5 V dc Size Sensor PSIZE2 Ground PSIZE1 +24 V dc Ground POUT +5 V dc Paper Low +5 V dc J16 Fuser Narmedia* Thermgnd Therm Ground Thumpdrv +5 V dc Thumpret Exit Sensor*R J17 MPT Pick...
  • Page 230 4520-xxx Connector Pin No. Signal J19 MPT Paper Out MPFSENSE Ground MPFLED J22 Smart Contact Scart 5 V Ground Ground Service Manual...

  • Page 231: Engine Board

    4520-xxx Engine Board Connector Locations...

  • Page 232: Controller Board - Non Network

    4520-xxx Controller Board - Non Network 5-10 Service Manual...

  • Page 233: Controller Board - Network

    4520-xxx Controller Board - Network 5-11 Connector Locations...

  • Page 234: Fuser Board

    4520-xxx Fuser Board Connector Pin No. Signal J1 Engine Board NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* J2 Thermistor ThermGnd HRTherm J3 Thumper Ground +42 V dc J4 Thumper Solenoid ThumpB ThumpA J5 Narrow Media Sensor +5 V dc Nar Media Ground 5-12...
  • Page 235 4520-xxx 5-13 Connector Locations...

  • Page 236: Interconnect Board

    4520-xxx Interconnect Board Connector Pin No. Signal J2 LVPS +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground J3 LVPS Ground Ground Ground Ground +5 V dc +5 V dc +5 V dc +5 V dc J5 Autoconnect +24 V dc...
  • Page 237 4520-xxx 210/220 001/002 5-15 Connector Locations...

  • Page 238: Envelope Feeder Board

    4520-xxx Envelope Feeder Board Connector Pin No. Signal Ground Tx (EOC) Ground Rx (EOC) +24 V dc Return +24 V dc Ground Paper Present +5 V dc Ground Paper Present +5 V dc Motor - Phase B- Motor - Phase A- Motor - Phase B+ Motor - Phase A+ 5-16...
  • Page 239 4520-xxx 5-17 Connector Locations...

  • Page 240: Duplex Unit Board

    4520-xxx Duplex Unit Board Note: Duplex connectors J10 and J11 are interchangeable. No problem results if the connectors are switched. Connector Pin No. Signal J1 Motor Motor - Motor + J2 DC Motor +5 V dc Sensor Sensor/Encoder Board Tach + Ground J3 Stepper Motor STPMOTA -...
  • Page 241 4520-xxx Connector Pin No. Signal J9 Autoconnect, Option Below Ground PrtxDout Ground PrtRxd J10 Autoconnect, Option Below +24 V dc Ground J11 Printer Autoconnect +24 V dc Ground J12 Printer Autoconnect Ground PrtxDin Ground PrtRxD 5-19 Connector Locations...
  • Page 242 4520-xxx 5-20 Service Manual...

  • Page 243: Preventive Maintenance

    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.

  • Page 244: Scheduled Maintenance

    4520-xxx Scheduled Maintenance The operator panel displays the message “80 Scheduled Maintenance” 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 with the following part numbers: 115 V 630 W Maintenance Kit 99A2420...

  • Page 245: Parts Catalog

    4520-xxx 7. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a 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.

  • Page 246: Assembly 1: Covers

    4520-xxx Assembly 1: Covers Service Manual...
  • Page 247 4520-xxx Asm- Part Units Description Index Number 1 - 1 99A2074 Cover Assembly, Redrive Cap 99A1508 Cover, Fuser Wick Assembly 99A1506 Cover Asm, Laser Assembly 99A2087 Smart Contact Assembly 99A2075 Cover, Right Side 99A2011 Hinge, Upper Front Cover 99A2010 Kit, Upper Front Cover with Labels 210/220 99A2150 Kit, Upper Front Cover with Labels 001/002 99A0007...

  • Page 248: Assembly 2: Frame

    4520-xxx Assembly 2: Frame Service Manual...
  • Page 249 4520-xxx Asm- Part Units Description Index Number 2 - 1 99A1643 Shroud, Fan 99A2063 Fan, Main 99A0138 Sensor, Standard Bin Level 99A1613 Flag, Output Paper Level 99A0062 Bracket, Level Sensor 99A2016 Duct, Left Stacker 99A0867 Duct, Main Body 99A2017 Guide, Redrive Exit 99A2018 Support, Left Lower Stacker 99A2076...
  • Page 250 4520-xxx Assembly 2: Frame (continued) Service Manual...
  • Page 251 4520-xxx Asm- Part Units Description Index Number 2 - 30 99A2025 Left Side Frame 99A0128 Board, Input Tray (ITC) 99A1896 Guard, Gear 99A2078 Pan, Motor Drip 99A0567 Link, Gear Release 99A0556 Spring, Counterbalance 99A0263 Parts Packet, Screw 99A1524 Spring, Cartridge Load 99A1546 Shield, Gear 99A1596...

  • Page 252: Assembly 3: Printhead

    4520-xxx Assembly 3: Printhead Service Manual...
  • Page 253 4520-xxx Asm- Part Units Description Index Number 3 - 1 99A2026 Printhead Assembly 99A0263 Parts Packet, Screw (Printhead Mounting) Parts Catalog...

  • Page 254: Assembly 4: Paper Feed (Autocompensator)

    4520-xxx Assembly 4: Paper Feed (Autocompensator) 7-10 Service Manual...
  • Page 255 4520-xxx Asm- Part Units Description Index Number 4 - 1 99A2070 Sensor, Paper Out Internal Tray 99A2079 Pick Arm Assembly (500) 210/220 99A2157 Pick Arm Assembly (250) 001/002 99A0070 Pick Rolls 99A1616 Flag, Paper Out 500 Tray 99A1609 Flag, Paper Out 250 Tray 001/002 99A1927 Spring, Bellcrank Internal 250 99A1930...

  • Page 256: Assembly 5: Paper Feed - Multipurpose Unit

    4520-xxx Assembly 5: Paper Feed - Multipurpose Unit 7-12 Service Manual...
  • Page 257 4520-xxx Asm- Part Units Description Index Number 5 - 1 99A0075 Screw, Socket Set M4X5 mm 99A0071 Arm Assembly, MPT 99A0076 Pick Roll Assembly 99A0081 Spring Assembly, Separator 99A0083 MPT Pad/Separator Arm Assembly 99A2092 Deflector Assembly, MPT 99A1531 Deflector, Lower 99A0263 Parts Packet, Screw (Lower Deflector Mounting 8 mm)

  • Page 258: Assembly 6: Paper Feed - Alignment

    4520-xxx Assembly 6: Paper Feed - Alignment 7-14 Service Manual...
  • Page 259 4520-xxx Asm- Part Units Description Index Number 6 - 1 99A0089 Alignment Assembly Paper Feed 99A0263 Parts Packet, Screw (Paper Feed) 99A2066 Clip, Reference Ground 99A0492 Screw, Paper Reference Adjustment 99A0565 Washer, Reference Adjustment 99A0566 Nut, Paper Reference Adjustment 99A0263 Parts Packet, Screw (Alignment Asm Mounting) 7-15...

  • Page 260: Assembly 7: Paper Feed - Output

    4520-xxx Assembly 7: Paper Feed - Output 7-16 Service Manual...
  • Page 261 4520-xxx Asm- Part Units Description Index Number 7 - 1 99A2029 Redrive Assembly, Inner 250 210/220 99A2151 Redrive Assembly, Inner 250 001/002 99A1644 Door Assembly, Redrive 250 99A0104 Spring, Upper Diverter 99A1857 Deflector, Upper Redrive 99A0263 Parts Packet, Screw (Duplex Path) 7-17 Parts Catalog...

  • Page 262: Assembly 8: Integrated Paper Tray - 500 Sheet

    4520-xxx Assembly 8: Integrated Paper Tray - 500 Sheet 7-18 Service Manual...
  • Page 263 4520-xxx Asm- Part Units Description Index Number 8 - 1 99A1601 Latch, Back Restraint 99A1576 Tray Assembly 500 Sheet 99A1895 Restraint, Side 99A0292 Strip, Wear 99A1812 Label, Tray Option Number 99A1583 Plate, 500 Tray Wear 99A0126 Finger, Autosize 99A0124 Plate, Snap-in 99A1582 Slider, Autosize 500 99A0120...

  • Page 264: Assembly 9: Main Drive

    4520-xxx Assembly 9: Main Drive 7-20 Service Manual...
  • Page 265 4520-xxx Asm- Part Units Description Index Number 9 - 1 99A2030 Gearbox, w/Motor 99A0134 Shaft, Power Takeoff 250 99A1569 Shaft, Power Takeoff 500 99A0275 Spring, Power Takeoff Shaft 99A2080 Gear, Bevel with Grease Packet 99A0263 Parts Packet, Screw (Gearbox Mounting) 99A0263 Parts Packet, Screw (Motor Mounting) 99A0260...

  • Page 266: Assembly 10: Developer Drive

    4520-xxx Assembly 10: Developer Drive 7-22 Service Manual...
  • Page 267 4520-xxx Asm- Part Units Description Index Number 10 - 1 99A1544 Developer Drive Assembly 99A2081 Parts Packet, Developer Drive Shaft, Coupler Gear #55 99A0263 Parts Packet, Screw (Developer Drive Ground) 7-23 Parts Catalog...

  • Page 268: Assembly 11: Hot Roll Fuser

    4520-xxx Assembly 11: Hot Roll Fuser 7-24 Service Manual...
  • Page 269 4520-xxx Asm- Part Units Description Index Number 11 - 1 99A2423 Fuser Assembly w/115V 630W Lamp 99A2422 Fuser Assembly w/220V 630W Lamp 99A0725 Wiper Assembly, Wet 99A2033 Cover, Fuser Assembly with Thermistor, Thermal Fuse, and L & R Fuser Lamp Contact Assemblies 99A0263 Parts Packet, Screws:...

  • Page 270: Assembly 12: Transfer

    4520-xxx Assembly 12: Transfer 7-26 Service Manual...
  • Page 271 4520-xxx Asm- Part Units Description Index Number 12 - 1 99A1015 Transfer Roll Assembly 99A0349 Arm, Transfer Roll Assembly Right 99A0184 Spring, Transfer Roll Right 99A0185 Shaft, Transfer Pivot 99A0181 Spring, Transfer Roll Left 99A1578 Arm, Transfer Roll Left 99A0267 Parts Packet, Retainer (Pivot Shaft) 7-27 Parts Catalog...

  • Page 272: Assembly 13: Charging

    4520-xxx Assembly 13: Charging 7-28 Service Manual...
  • Page 273 4520-xxx Asm- Part Units Description Index Number 13 - 1 99A0512 Link Assembly, Charge Left Kit 99A0513 Link Assembly, Charge Right Kit 99A1017 Roll Assembly, Charge 99A1555 Bushing, Charge Roll 99A0263 Parts Packet, Screw (Charge Roll) 7-29 Parts Catalog...

  • Page 274: Assembly 14: Electronics 1

    4520-xxx Assembly 14: Electronics 1 7-30 Service Manual...
  • Page 275 4520-xxx Asm- Part Units Description Index Number 14 - 1 1342514 Power Cord Set, 8 ft. U.S., Canada (LV), Nicaragua, Venezuela, Peru (LV), Bolivia (HV), Colombia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Panama 1339535 Power Cord Set, 8 ft. U.S., Canada (LV), Nicaragua, Venezuela, Peru (LV), Bolivia, Colombia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras,...

  • Page 276: Assembly 15: Electronics Ii

    4520-xxx Assembly 14: Electronics I (continued) 7-32 Service Manual...
  • Page 277 4520-xxx Asm- Part Units Description Index Number 14 - 4 99A0263 Parts Packet, Screw(s): • Controller Board Mtg (2) • Controller Board Mtg Front (2) • Controller Mtg Ground (1) • Engine Board Mtg (6) • Engine Board Mtg Top (2) •...

  • Page 278: Assembly 16: Electronics Iii

    4520-xxx Assembly 15: Electronics II 7-34 Service Manual...
  • Page 279 4520-xxx Asm- Part Units Description Index Number 15 - 1 99A0263 Parts Packet, Screw (INA Cover Mounting) 99A2084 Engine Board Shield Assembly 99A2049 Shield, Inner Assembly, 2 Slot 210/220 99A2156 Shield, Inner Assembly, 1 Slot 001/002 99A2094 Shield, Outer 2 Slot 210/220 99A2095 Shield, Outer 1 Slot 001/002 99A0263...

  • Page 280: Assembly 17: Electronics Iv

    4520-xxx Assembly 16: Electronics III 7-36 Service Manual...
  • Page 281 4520-xxx Asm- Part Units Description Index Number 16 - 1 99A0803 Fan, Main 99A2030 Gearbox, w/Motor 99A0128 Board, Input Tray (ITC) 99A2053 Cable, Auto Connect Bottom 99A2046 Interconnect Board Assembly 99A2052 Cable, Integrated Tray 99A2054 Cable, Main Drive Motor 99A2042 Engine Board Assembly 99A0138 Sensor, Standard Bin Level...

  • Page 282: Assembly 18: Electronics V

    4520-xxx Assembly 17: Electronics IV 7-38 Service Manual...
  • Page 283 4520-xxx Asm- Part Units Description Index Number 17 - 1 99A2014 Operator Panel Assembly 110 V 99A2015 Operator Panel Assembly 220 V 99A2060 Switch, Cover Open w/Operator Panel Cable Assembly 99A0053 Sensor, Input 99A2079 Pick Arm Assembly (500) 210/220 99A2157 Pick Arm Assembly (250) 001/002 99A2071 Sensor, MPT Paper Out...

  • Page 284: Assembly 19: Electronics Vi

    4520-xxx Assembly 18: Electronics V 7-40 Service Manual...
  • Page 285 4520-xxx Asm- Part Units Description Index Number 18 - 1 99A2026 Printhead Assembly 99A2056 Cable, Laser 99A2042 Engine Board Assembly 99A2046 Interconnect Board Assembly 99A2067 Solenoid Assembly, Envelope Conditioner 99A2039 Fuser Board Assembly 99A1551 Sensor, Exit 99A2033 Cover, Fuser Assembly with Thermistor 99A2062 Cable, Engine Board to Fuser Board 99A1651...

  • Page 286: Assembly 19: Electronics Vi

    4520-xxx Assembly 19: Electronics VI 7-42 Service Manual...
  • Page 287 4520-xxx Asm- Part Units Description Index Number 19 - 1 99A2026 Printhead Assembly 99A2056 Cable, Laser 99A2042 Engine Board Assembly 99A2046 Interconnect Board Assembly 99A2067 Solenoid Assembly, Envelope Conditioner 99A2039 Fuser Board Assembly 99A1551 Sensor, Exit 99A2033 Cover, Fuser Assembly with Thermistor 99A2062 Cable, Engine Board to Fuser Board 99A1651...

  • Page 288: Assembly 20: 250-Sheet Tray

    4520-xxx Assembly 20: 250-Sheet Tray 7-44 Service Manual...
  • Page 289 4520-xxx Asm- Part Units Description Index Number 20 - 1 99A0263 Parts Packet, Screw (Option Board) 99A1967 Board, Option Tray 99A0627 Jumper, pin 99A0263 Parts Packet, Screw (Switch Spring) 99A0063 Spring, Switch Activate 99A0445 Stud Assembly, 250 Frame 99A0448 Arm, Paper Out 250 99A0263 Parts Packet, Screw (Auto Comp Mounting) 99A1054...
  • Page 290 4520-xxx Assembly 20: 250-Sheet Tray (continued) 7-46 Service Manual...
  • Page 291 4520-xxx Asm- Part Units Description Index Number 20 - 34 99A1601 Latch, Back Restraint 99A0120 Restraint Pad 99A1536 Tray Assembly, 250-Sheet Option 99A0892 Restraint, Side 250-Sheet Tray 99A0119 Wear Strips 99A1829 Label, Tray Option Number 99A0121 Clip, 250 Tray Wear 99A0126 Finger, Autosize 99A0124...

  • Page 292: Assembly 21: Integrated Paper Tray - 250 Sheet

    4520-xxx Assembly 21: Integrated Paper Tray - 250 Sheet 7-48 Service Manual...
  • Page 293 4520-xxx Asm- Part Units Description Index Number 21 - 1 99A1536 Tray, Integrated 250 Sheet 99A2160 Restraint, Back 250 Sheet Tray 99A1894 Restraint, Side 250 Sheet Tray 99A0119 Wear Strips 99A1812 Label, Tray Option Number 99A0121 Clip, 250 Tray Wear 99A0126 Finger, Autosize 99A0124...

  • Page 294: Assembly 22: 500-Sheet Tray

    4520-xxx Assembly 22: 500-Sheet Tray 7-50 Service Manual...
  • Page 295 4520-xxx Asm- Part Units Description Index Number 22 - 1 99A0350 Sensor, Paper Low 99A0263 Parts Packet, Screw (Auto Comp Mounting) 99A0405 Pick Arm Assembly 99A0070 Pick Roll Assembly 99A1636 Base, 500 Tray 99A0058 Pad, Base 500 99A0419 Spring, Tray Bias 99A0026 Tray Bias Arm Assembly 99A0288...
  • Page 296 4520-xxx Assembly 22: 500-Sheet Tray (continued) 7-52 Service Manual...
  • Page 297 4520-xxx Asm- Part Units Description Index Number 22 - 26 99A0282 Cable, 500 Auto Connect Bottom 99A1750 Wear Plate, Pass Thru 99A0276 Roll Assembly, Drive 500 99A0263 Parts Packet, Screw (Wear Plate Mounting) 99A0450 Retainer, Roller 99A0451 Roller, Skewed Backup 99A0438 Bearing, Drive Roll 99A0275...

  • Page 298: Assembly 23: Duplex Unit

    4520-xxx Assembly 23: Duplex Unit 7-54 Service Manual...
  • Page 299 4520-xxx Asm- Part Units Description Index Number 23 - 1 99A1674 Cover, Engine Board 99A0322 Main Frame Assembly 250 Duplex 99A1693 Main Frame Assembly 500 Duplex 99A0324 Idler Assembly, Belt Tension 99A0326 Spring, Aligner 99A0323 Guide Assembly, Paper 99A1675 Guide Assembly, Paper 99A0314 Spring, Chassis Ground 99A0413...
  • Page 300 4520-xxx Assembly 23: Duplex Unit (continued) 7-56 Service Manual...
  • Page 301 4520-xxx Asm- Part Units Description Index Number 23 - 30 99A0311 Cable, Auto Connect Bottom 99A0274 Gear, Pass Thru Drive Roll 99A0310 Cable, Auto Connect Top 99A0413 Parts Packet, Screw (Main Frame Assembly Mounting) 99A0317 Gear, Duplex Bevel 99A0434 Pan, Engine Board Drip 99A0279 Bearing, Drive Shaft 99A0191...
  • Page 302 4520-xxx Assembly 23: Duplex Unit (continued) 7-58 Service Manual...
  • Page 303 4520-xxx Asm- Part Units Description Index Number 23 - 42 99A1290 Top Cover Assembly, Movable 250 Duplex 99A1280 Top Cover Assembly, Movable 500 Duplex 99A1634 Top Cover Assembly, Fixed 250 Duplex 99A1679 Top Cover Assembly, Fixed 500 Duplex 99A0435 Guide, Lower Entry 250 Duplex 99A1691 Guide, Lower Entry 500 Duplex 99A1672...

  • Page 304: Assembly 24: Envelope Feeder

    4520-xxx Assembly 24: Envelope Feeder 7-60 Service Manual...
  • Page 305 4520-xxx Asm- Part Units Description Index Number 24 - 1 99A0389 Paper Weight Assembly 99A1694 Guide, Edge 99A1696 Cover, Top 99A0485 Sensor, Envelope Pass Thru 99A0393 Clutch, Restraint/Gear 99A1697 Cover, Right Side 99A0390 Support, Slide Out 99A0488 Roller, Support 99A0382 Motor, Stepper D.C.

  • Page 306: Assembly 25: High-Capacity Feeder

    4520-xxx Assembly 25: High-Capacity Feeder 7-62 Service Manual...
  • Page 307 4520-xxx Asm- Part Units Description Index Number 25 - 1 99A0660 Frame, Printer Support Frame 2 99A0675 Parts Packet, Screw (Printer Support 2 Frame Mounting) 99A0698 Clamp, Feed Frame 99A0675 Parts Packet, Screw (Feed Frame Clamp) 99A0691 Bearing, Nyliner Leadscrew Top 99A0656 Cover, Side 99A0681...
  • Page 308 4520-xxx Assembly 25: High Capacity Feeder (continued) 7-64 Service Manual...
  • Page 309 4520-xxx Asm- Part Units Description Index Number 25 - 28 99A0188 Guide, Rear Paper use with 99A0219 99A0675 Parts Packet, Screw (Top Frame Mounting) 99A0219 Frame Assembly, Top with labels 99A0675 Parts Packet, Screw 99A0677 Parts Packet, Washer (Top Frame Clamp) 99A0719 Clamp, Top Frame Mounting 99A0676...
  • Page 310 4520-xxx Assembly 25: High Capacity Feeder (continued) 7-66 Service Manual...
  • Page 311 4520-xxx Asm- Part Units Description Index Number 25 - 60 99A1793 Parts Packet, Screw w/washer (Motor Mt) 99A1794 Parts Packet, Nut & washer (Drive Pulley Plate) 99A1795 Motor Assembly, DC 99A0672 Parts Packet, Foot (Stabilizer) 99A0687 Parts Packet, Mounting Feet 99A1796 Belt, DC Motor Drive 99A1797...
  • Page 312 4520-xxx Assembly 25: High Capacity Feeder (continued) 7-68 Service Manual...
  • Page 313 4520-xxx Asm- Part Units Description Index Number 25 - 90 99A0267 Parts Packet, Retainer (Aligner Assembly) 99A0274 Gear, Feed Roll 99A0278 Bellcrank, Roller Release 99A1967 Card Assembly, 2000 Tray Option 99A0263 Parts Packet, Screw (Tray Option Card Mtg) 99A0675 Parts Packet, Screw (Door to Door Frame Mounting) 99A0676 Parts Packet, Nut Support Frame 1Hex,...
  • Page 314 4520-xxx Assembly 25: High Capacity Feeder (continued) 7-70 Service Manual...
  • Page 315 4520-xxx Asm- Part Units Description Index Number 25 - 95 99A0263 Parts Packet, Screw (Auto Comp Assembly Mounting) 99A1055 Arm Assembly, Pick 2000 99A0070 Roll Assembly, Pick 99A0692 Base, 2000 Option 99A0263 Parts Packet, Screw (Deflector Mounting) 99A0678 Deflector, Base 99A0288 Sensor, Pass Thru 99A1812...

  • Page 316: Assembly 26: Kiosk - Vertical Paper Adapter

    4520-xxx Assembly 26: Kiosk - Vertical Paper Adapter 7-72 Service Manual...
  • Page 317 4520-xxx Asm- Part Units Description Index Number 26 - 1 99A0231 Bail, Support 99A1646 Arm Assembly, Pivot 99A1819 Mounting, Frame Assembly 99A0240 Parts Packet, Retainer 99A0234 Parts Packet, Screw 99A1705 Gear, Idler 99A1704 Gear, Idler 99A0197 Shaft, Drive Rear 99A0079 Tray Assembly, Backup Roller 99A0208 Parts Packet, Pulley...

  • Page 318: Assembly 27: Kiosk - Horizontal Paper Adapter

    4520-xxx Assembly 27: Kiosk - Horizontal Paper Adapter 7-74 Service Manual...
  • Page 319 4520-xxx Asm- Part Units Description Index Number 27 - 1 99A0231 Bail, Support 99A1647 Arm Assembly, Pivot 99A1819 Mounting, Frame Assembly 99A2409 Parts Packet, Retainer 99A0234 Parts Packet, Screw 99A1705 Gear, Idler 99A1704 Gear, Idler 99A0197 Shaft, Drive Rear 99A0079 Tray Assembly, Backup Roller 99A0208 Parts Packet, Pulley...

  • Page 320: Assembly 28: Options

    4520-xxx Assembly 28: Options Asm- Part Units Description Index Number 99A1752 4MB SDRAM DIMM 99A1753 8MB SDRAM DIMM 99A1754 16MB SDRAM DIMM 99A1755 32MB SDRAM DIMM 99A1756 64MB SDRAM DIMM 99A1773 128MB SDRAM DIMM 99A1757 2MB Flash DIMM 99A1758 4MB Flash DIMM 99A1759 8MB Flash DIMM 99A1774...
  • Page 321 4520-xxx Assembly 28: Options (continued) Asm- Part Units Description Index Number 99A1890 Tray Assembly, 250 Special Media 99A1647 Rib Assembly, 250 Special Media Tray 99A1654 Tray, Universal Adjustable 250 Sheet 99A0910 Cartridge, Empty Shipping (2) 99A0909 Cartridge, Empty Shipping (1) 99A0799 Drive, Forms HD 2.1GB or larger 99A1605...

  • Page 322: Assembly 29: Miscellaneous

    4520-xxx Assembly 29: Miscellaneous Asm- Part Units Description Index Number 99A1633 Parts Packet, Screw 99A0585 Parts Packet, Contact Kit 99A0267 Parts Packet, Retainers 99A0268 Parts Packet, Springs Paper Feed 99A0269 Parts Packet, Duplex Option Fan Mounting 99A0299 Parts Packet, Duplex Option Cam Follower Assembly 99A0271 Parts Packet, Envelope Option Gears...
  • Page 323 4520-xxx Assembly 29:Miscellaneous (continued) Asm- Part Units Description Index Number 99A0208 Parts Packet, Pulley - Kiosk 99A0234 Parts Packet, Screw - Kiosk 99A0394 Grease Packet, Nyogel 744 99A0462 Grease Packet, IBM 23 99A1852 Packaging, 4069 250/250 printer 99A1853 Packaging, 4069 500/250 printer 99A1854 Packaging, 4069 500/500 printer 99A1855...
  • Page 324 4520-xxx 7-80 Service Manual...
  • Page 325 4520-xxx Index Hardware Tests 3-11 Button Test 3-11 Acronyms LCD Test 3-11 Adjustment Procedures Parallel Wrap Test 3-13 Duplex Motor Drive Belts ROM Memory Test 3-13 Fuser Solenoid SDRAM Memory Test 3-12 Gap Adjustment Serial Wrap Test 3-13 Paper Alignment Assembly Input Tray Tests 3-15 Printhead Assembly...
  • Page 326 4520-xxx Fuser Board 5-12 Developer Drive 7-22 Duplex Unit 7-54 Electronics I 7-30 Electronics II 7-34 Hardware Tests 3-11 Electronics III 7-36 HVPS Connectors Electronics IV 7-38 Electronics VI 7-42 Envelope Feeder 7-60 7-42 Frame Input Tray Feed Test 3-15 High-Capacity Feeder 7-62 Input Tray Sensor Test...
  • Page 327 4520-xxx Duplex Motor 4-20 Paper Size Sensing Board 4-53 EMC Shields 4-21 Pick Roll 4-53 Inner EMC Shield 4-21 Printhead 4-54 Outer EMC Shield 4-22 Redrive Assembly 4-55 Engine Board 4-23 Smart Contact Assembly 4-56 Frames 4-25 Toner Sensor 4-57 EP Frame Assembly 4-25 Transfer Roll Assembly...
  • Page 328 4520-xxx Part Numbers Transfer Roll 2-103 Setting Configuration ID 3-20 12G1696 7-77 Setting the Page Count 3-18 12G1697 7-77 Status Messages 2-22 13A0296 7-76 Symptom Tables 2-36 13A0297 7-76 Base Printer 2-36 13A0298 7-76 Duplex Unit 2-38 1339535 7-31 Envelope Feeder 2-38 1339537 7-31...

  • Page 329: Index

    4520-xxx 99A0084 7-13 99A0274 7-45 7-53 7-57 7-69 99A0085 7-73 7-75 99A0275 7-21 7-45 7-53 7-67 99A0086 7-73 7-75 99A0276 7-45 7-53 7-67 99A0087 7-73 7-75 99A0277 7-45 7-67 99A0088 7-73 7-75 99A0278 7-47 7-69 99A0089 7-15 99A0279 7-45 7-53 7-57 7-67 99A0104...
  • Page 330 4520-xxx 99A0389 7-61 99A0627 7-45 7-57 99A0390 7-61 99A0629 7-76 99A0392 7-63 99A0650 7-63 99A0393 7-61 99A0651 7-65 99A0394 7-79 99A0653 7-65 99A0400 7-61 99A0654 7-65 99A0404 7-57 7-59 7-61 7-78 99A0655 7-63 99A0405 7-51 99A0656 7-63 99A0408 7-35 99A0657 7-63 99A0413 7-55...
  • Page 331 4520-xxx 99A0720 7-71 99A1546 99A0725 7-25 99A1551 7-25 7-41 7-43 99A0799 7-77 99A1553 7-43 99A0803 7-37 99A1555 7-29 99A0867 99A1569 7-21 99A0892 7-47 99A1576 7-19 7-51 99A0893 7-47 99A1578 7-27 99A0895 7-51 99A1579 7-55 99A0897 7-25 99A1582 7-19 7-51 99A0906 7-75 99A1583 7-19...
  • Page 332 4520-xxx 99A1679 7-59 99A1807 7-65 99A1680 7-55 99A1808 7-65 99A1682 7-55 99A1809 7-63 99A1683 7-77 99A1812 7-19 7-49 7-71 99A1684 7-77 99A1818 7-63 99A1685 7-77 99A1819 7-73 7-75 99A1686 7-77 99A1820 7-73 7-75 99A1691 7-59 99A1829 7-47 7-51 7-63 99A1692 7-59 99A1830 7-77...
  • Page 333 4520-xxx 99A2038 7-25 99A2152 7-33 99A2039 7-25 7-41 99A2155 7-33 99A2042 7-33 7-37 7-39 7-41 7-43 99A2156 7-35 99A2043 7-31 99A2157 7-11 7-39 99A2044 7-31 99A2158 7-33 99A2045 7-33 7-39 99A2159 7-33 99A2046 7-33 7-37 7-41 7-43 99A2160 7-49 99A2049 7-35 99A2200 7-33...
  • Page 334 4520-xxx I-10 Service Manual...

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