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Lexmark - Beck PC

1. 7 34 Service Manual 4520 xxx ae Units Description 15 1 99A0263 6 Parts Packet Screw INA Cover Mounting 2 99A2084 1 Engine Board Shield Assembly 3 99A2049 1 Shield Inner Assembly 2 Slot 210 220 3 99A2156 1 Shield Inner Assembly 1 Slot 001 002 4 99A2094 1 Shield Outer 2 Slot 210 220 4 99A2095 1 Shield Outer 1 Slot 001 002 5 99A0263 4 Parts Packet Screw Outer Shield Mounting 5 99A0263 6 Parts Packet Screw Outer Shield Mounting 6 99A0408 1 Cover INA Flat Blank NS 99A1611 1 Shield Ethernet Blank NS 99 0227 1 Clip Two Finger NS 99 0347 1 Clip Six Finger EMC Parts Catalog 7 35 4520 xxx Assembly 16 Electronics Ill 7 36 Service Manual 4520 xxx Units Description 16 1 99A0803 1 Fan Main 2 99A2030 1 Gearbox w Motor 3 56P1139 1 Board Input Tray ITC 4 99A2053 1 Cable Auto Connect Bottom 5 99A2046 1 Interconnect Board Assembly 6 99A2052 1 Cable Integrated Tray 7 99A2054 1 Cable Main Drive Motor 8 99A2042 1 Engine Board Assembly 9 56P1049 1 Sensor Standard Bin Level Parts Catalog 7 37 4520 xxx Assembly 17 Electronics IV 12 7 38 Service Manual 4520 xxx race Units Description 17 1 99A2014 1 Operator Panel Assembly 110 V 1 99A2015 1 Operator Panel Assembly 220 V 2 99A2060 1 Switch Cover Open w Operator Panel Cab
2. 917 Transfer Roll Indicates a problem in the transfer roll area Go to the Transfer Roll Service Check on page 2 103 920 Fuser Error 921 Fuser Error Indicates that the fuser is below temperature when printing Go to the Fuser Service Check on page 2 56 Indicates that the fuser is below standby temperature when the printer is idle Go to the Fuser Service Check on page 2 56 922 Fuser Error Fuser failed to reach standby temperature Go to the Fuser Service Check on page 2 56 923 Fuser Error Fuser is too hot during printing or when printer is idle Go to the Fuser Service Check on page 2 56 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit Go to the Fuser Service Check on page 2 56 925 Fuser Error Wrong fuser lamp installed Check the fuser lamp for the correct type of lamp that should be installed If the correct fuser lamp is installed and the 925 error remains the fuser may have reached standby temperature too quickly Check the following The correct hot roll has been installed The line voltage is not exceeding the maximum rating for the printer 929 Toner Sensor The toner sensor is not operating properly the developer drive assembly is not operating properly or the print cartridge is defective Go to the Toner Sensor Service Check on page 2 102 930 Printhead Error The wrong pri
3. Lexmark T52x 4520 xxx Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 4520 xxx Edition July 2002 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark and Lexmark
4. Optional 250 500 Paper Tray Assembly Removal Paper Alignment Assembly Removal Paper Deflectors Paper Input Sensor Paper Size Sensing Board Removal PICK Roll Removal auda ER Printhead Removal 122522222 dane man Redrive Assembly Smart Contact Assembly Removal Toner Sensor Transfer Roll Assembly Removal Upper Paper Deflector Assembly Removal Upper Front Cover Hinge Assembly Removal Upper Front Cover Interlock Switch Assembly Removal Connector Low Voltage Power High Voltage Power Engine Board 952 0465 ot amber nape a Bebe qe dedos Engine BOAO tidy dob Supe ap opas Ca dra mare Controller Board Non Controller Board Network each padre Rech band wees Interconnect Board Envelope Feeder Duplex Unit o a ss dra dpa Preventive Safety Inspection
5. If incorrect replace the engine board If correct replace the printhead assembly 2 Error Code 934 These error codes indicate a Mirror Motor Lost Lock problem with the mirror motor circuit Error Code 935 in the printhead assembly or the Mirror Motor unable to mirror motor cable to the engine reach operating speed board cable or engine board assembly Check the continuity of the mirror motor cable connected to J3 on the engine board If incorrect replace the cable The voltage at J3 7 measures approximately 24 V dc If incorrect replace the engine board If correct replace the FRUs in the following order 1 Printhead assembly 2 Engine board Diagnostic Information 2 87 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 Replace the charge roll if it is damaged or contaminated Replace the transfer roll if it is damaged or contaminated Make sure the fuser assembly is installed correctly Verify proper paper type texture and weight settings for the media being used Test the printer using plain paper 20 Ib Select the following menu settings as indicated Be sure and note the original settings so you can return the printer to the original customer printer setup Print Resolut
6. J8 Printhead HYSNC 5 V dc HsynclD Hsyncin AJOJN Ground 410 Cartridge Sensor Input Sensor HVPS AT Servo HVPS Servo OutT HVPS TXENABLE HVPS Transfer HVPS 24 V dc HVPS Charge HVPS Ground HVPS Developer HVPS oO 4 oOo a AJ 5 Ground In Sens E In Sns In Sens 5 V dc C Sens A CTSENSE C Sens A Ground C Sens Connector Locations 5 5 4520 xxx Connector Pin No Signal J11 Operator Panel J12 Transport Motor FPIRQ Ground 2 5 I2CDATA ON OFF Ground 45 V dc MTR1 Dir MTR4 MTR3 Oo ol SIb 24 V RET E 24 V RET 24 V dc J14 Autoconnect Options RXDIN Ground TxBR Ground 5 6 Service Manual 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 NI oO ol AJ Paper Low 5 V 416 Fuser Narmedia Thermgnd Therm Ground Thumpdrv 5 V dc Thumpret CO rn OO 8 Exit Sensor R J17 MPT Pick 1 MPT Pick
7. Print quality Skew Print quality Banding Go to the Paper Feed Service Check on page 2 84 Go to the Print Quality Banding on page 2 96 Print quality Random marks Go to the Print Quality Random Marks on page 2 91 Print quality Toner on backside of printed page Go to the Print Quality Toner on backside of printed page on page 2 99 Print quality Vertical black bands on edge of copy Go to the Print Quality Black bands on outer edges of the page on page 2 96 Unable to clear a 32 Unsupported Print Cartridge User Error Message Go to the Smart Contact Assembly Service Check on page 2 100 Symptom Table High Capacity Feeder 2000 Sheet Symptom the high capacity feeder installed Paper feed problem with the high capacity feeder Action The printer does not recognize Go to the High Capacity Feeder Input Tray Service Check on page 2 66 Diagnostic Information 2 37 4520 xxx Symptom Table Paper Trays Symptom Action Paper feed problem with 250 Sheet Paper Tray 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 Go to the Input Tray s Service Check on page 2 62 Symptom Table Duplex Unit Symptom Action Paper feed problem with
8. Lubrication Specifications sess rssi ades de dy Scheduled Maintenance Parts Catalog How to Use This Parts Catalog iss oos Assembly 12 sex decas ane Assembly 2 niece EHE pear Assembly 3 Assembly 4 Paper Feed Autocompensator Assembly 5 Paper Feed Multipurpose Unit Assembly 6 Paper Feed Alignment Assembly 7 Paper Feed Assembly 8 Integrated Paper Tray 500 Sheet vi Service Manual 4520 xxx Assembly 9 Main 7 20 Assembly 10 Developer 7 22 Assembly 11 Hot Roll 7 24 12 Tanla ua 7 26 Assembly 13 Charging 7 28 Assembly 14 Electronics 1 2 2 2 7 30 Assembly 15 Electronics Il 7 34 Assembly 16 Electronics 111 7528 Assembly 17 Electronics 7 38 Assembly 18 Electr nics V Laien NR 4 4 40408443 7 40 Assembly 19 Electronics 7 42 Assembly 20 250 Sheet 7 44 Assembly 21 Integrated Paper Tray 250 Sheet 7 48 Assembly 22 500 Sheet 7 50 Assembly
9. Solenoid Mounting 1 Board Cover Mounting 1 Fuser Cover Assembly 4 Hanger 7 5 99A1520 1 Gear Upper Redrive 6 99A2035 1 Housing Detack Assembly 7 99A2036 1 Hot Roll 8 99A2038 1 Backup Roll 9 99A2067 1 Envelop Conditioner Solenoid Assembly 10 99A1649 2 Screw Fuser Mounting 11 99A0267 2 Parts Packet Retainer Backup Roll Bellcrank 12 99A1651 1 Sensor Narrow Media 13 99A1551 1 Sensor Exit 14 99A0897 2 Spring Redrive Idler 15 99 0167 4 Roller Redrive Idler 16 99A2050 1 Lamp 115V 630W CC Gold 16 99A2051 1 Lamp 220V 630W CC Silver NS 99 1658 1 Cover Fuser Wiper Cavity NS 99 2037 2 Grip Ring NS 99 0148 1 Gear Idler Parts Catalog 7 25 4520 xxx Assembly 12 Transfer F ia Gi 7 26 Service Manual 4520 xxx ae ee Units Description 12 1 99A1015 1 Transfer Roll Assembly 2 99A0349 1 Arm Transfer Roll Assembly Right 3 99A0184 1 Spring Transfer Roll Right 4 99A0185 1 Shaft Transfer Pivot 5 99A0181 1 Spring Transfer Roll Left 6 99A1578 1 Arm Transfer Roll Left 6 99A0267 1 Parts Packet Retainer Pivot Shaft Parts Catalog 7 27 4520 xxx Assembly 13 Charging 7 28 Service Manual 4520 xxx an GE Units Description 13 1 99A0512 1 Link Assembly Charge Left Kit 2 99A0513 1 Link Assembly Charge Right Kit 3 99A1017 1 Roll Assembly Charge 4 99A1555 1 Bushing Charge Roll NS 99 0263 1 Parts Packet Screw Charge
10. The messages in the following table can occur in two ways The specified device could have been removed from the printer for instance to clear a paper jam Otherwise the device can still be attached to the printer but is experiencing a communications problem not fully connected or having a hardware failure If the device is temporarily removed or not connected properly then reattach it When the option is recognized the printer automatically clears the error and continues If the option is experiencing a hardware problem turn the printer off and back on If the error occurs again turn the printer off remove the option and call for service Diagnostic Information 2 33 4520 xxx User Status Message Explanation Turn Printer OFF to Enable Option This message displays when a printer 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 Data loss results if print jobs are active when the printer is power cycled If a print job is active then remove the option and finish the job The printer automatically clears the message once the option is removed Once the job is complete turn off the printer and attach the option again Insert Duplex Front Cover This message displays when the duplex front access cover is not installed Close Duplex Rear Door This message displays when the duplex rea
11. ppnad och sp rrar r urkopplade Str len r farlig Usynlig laserstr ling deksel apres og sikkernedl s brytes Unng eksponering for str len ide af funktion Undg undszettelse tor str ling recte Eviteu exposar vos hi HERRE STERN 29 Lann ERTZERA YFL ERT Sd CIENUCCIESU EO at Al iro SOA 85210512 24015 5 Gg SHA E Notices and Safety Information ix 4520 xxx Class 1 Laser Statement Label Service Manual CLASS 1 LASER PRODUCT LASER KLASSE 1 LOUKAN 1 LASERLAITE APPAREIL A LASER DE CLASSE 1 IEC 60825 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 1 laser products and elsewhere is certified as a Class laser product conforming 10 the requirements of IEC 60825 Class laser products are not considered to be hazardous The printer contains internally a Class 10 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r La
12. Do the removal procedure Duplex Motor Removal on page 4 20 to access the motor mounting screws but do not remove the motor Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm 5 mm motor belt deflection Tighten both mounting screws being careful to maintain the adjustment 4 Reassemble the duplex unit 4 2 Service Manual 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 The solenoid air gap for all models is 3 5 mm Gap Adjustment The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the printer This adjustment does not reduce the printer overall performance such as pages per minute but can help in reducing the amount of curl of some printed medias thus improving media stacking in the output bin 1 Enter the Diagnostic Mode 2 Select Ep Setup from the Diagnostic Menu 3 Select Gap Adjust 4 The range of the GAP adjustment is 0 to 255 Adjust the gap setting by using the Menu lt gt button to select the value If GAP 0 displays it indicates a factory setting to minimum gap Select a value and run several copies of the media that displays a curl p
13. Press Menu to take the printer out of Ready and enter all the Menus except the TESTS MENU Busy state Ready Hex The printer is ready and HEX Trace is active which is known as HEX Trace Ready Press Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Select for the values Press Menu until Reset Printer is on the second line of the display Press Select to Reset the printer Busy The printer is busy receiving or processing data or printing data Note The printer indicator light blinks while the printer is processing data Press Stop to take the printer out of Busy The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the printer paper path Press Go to return to Ready Flushing Buffer The printer is flushing corrupted print data and the current print job is being discarded No button actions are possible while this message is displayed 2 22 Service Manual 4520 xxx User Status Message Status Action Printing Menu Settings The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the printer paper path Press Go to return to
14. ad utpat 3 18 Setting the Page 3 18 Viewing the Permanent Page Count 3 18 Maintenance Page Count 3 19 Setting Configuration 3 20 Restore EP Factory amp 3 21 Pill EE e PEE 3 22 Print Quality Test Pages E EE AER 3 23 Print Test with RIP Controller Board Removed 3 24 Printing Menu Settings 3 24 Autocompensator 3 25 Autoconnect System Paper Tray Options Envelope Feeder 3 26 iv Service Manual 4520 xxx S e EE EE 3 27 Paper Food Jatfid ceosuat4us dieat Qe d qe pde qd ea e 3 28 Repair Information 4 1 Handling ESD Sensitive 4 1 Adjustment 4 2 Duplex Motor Drive 83044 4 2 Fuser Solenoid Adjustment 4 3 Adjustment iua ARTE SE 4 3 Printhead Assembly 4 4 Paper Alignment Assembly Adjustment 4 5 Screw Identification 4 7 Removal Procedures br eR her RR S 4 12 Covers Removals lees 4 12 Center Pan Assembly 4 16 Controller Board Removal 4 17 Developer Drive Assembl
15. 1 8 Service Manual 99A1929 99A1930 99A1952 99A1967 99A2010 99A2011 99A2014 99A2015 99A2016 99A2017 99A2018 99A2019 99A2020 99A2021 99A2022 99A2024 99A2025 99A2026 99A2027 99A2029 99A2030 99A2033 99A2035 99A2036 99A2037 99A2038 99A2039 99A2042 99A2043 99A2044 99A2045 99A2046 99A2049 99A2050 99A2051 99A2052 99A2053 99A2054 99A2055 99A2056 99A2059 99A2060 99A2061 99A2062 99A2063 99A2065 99A2066 7 53 27 10 7 47 7 51 7 45 7 51 7 69 7 3 7 3 7 3 7 39 7 3 7 39 7 4 rs 4 5 7 5 79 1 5 K 2 5 7 9 7 41 7 43 7213 4 17 7 21 7 37 7 41 7 43 1 28 4 29 1 28 25 7 41 7 37 7 39 7 41 7 43 7 31 7 31 7 33 7 39 7 33 7 37 7 41 7 43 7 35 7 26 7 28 7 37 7 27 7 37 7 39 7 41 7 43 7 39 7 3 7 39 7 41 7 43 7 41 7 43 7 5 2 3 1 15 4520 xxx 99A2067 7 25 7 41 7 43 99A2070 7 11 99A2071 7 13 7 39 99A2075 7 3 99A2076 7 5 99A2077 7 5 99A2078 7 7 99A2079 7 11 99A2080 7 21 99A2081 7 23 99A2082 7 31 99A2083 7 31 99A2084 7 35 99A2087 7 3 99A2090 7 31 99A2091 7 31 99A2092 7 13 99A2093 7 19 99A2094 7 35 99A2095 7 35 99A2150 7 3 99A2151 7 17 99A2152 7 33 99A2156 7 35 99A2157 7 11 7 39 99A2160 7 49 99A2200 7 33 7 76 99A2409 7 75 99A2422 7 25 99A2423 7 25 99A2438 7 39 99A2486 7 33 7 76 99A2487 7 33 7 76 99A2488 7 76 99A2489 7 76 99A2528 7 33 Index 1 9 4520 xxx l 10 Service Manual
16. 8 EE 3 1 Diagnostic MOdG iss ena eme E REES as 3 1 sd ad dd Does S d aua Ded 1d 3 2 Quick DISK ossa Eu Erde Gr Rena he sach hd ana 3 2 Disk TOSUCIgal 3 3 Piast 6S 23 end 3 4 Disabling Download Emulations 3 5 Dupek EE 3 6 Duplex QUIK 3 6 Duplex Sensor TeSE 2 suck ANER 3 7 Duplex Motor Test sedi sed dorso pd Rep prd 3 8 Duplex DEET Duplex Feed 2 8 is ao Ru pde EE 3 9 EHO OD uos ie 3 10 Viewing Error WEE 3 10 Cleaning the Error Log ENEE 3 10 Hardware Tests trEsdu 3 obo EO 6 4 3 11 3 11 3 11 SDRAM Memory Test 3 12 Memory ES 3 13 Parallel Wap 3 13 Serial Wrap meragui bey 3 13 Input ite TOSS seh d dE tee A 3 15 Input Tray Feed 4 804 sees reisais raa 3 15 Input Tray Sensor ee SEN mr ma 3 15 Output Bin Test Standard 3 16 Base Sensor Test Losses csset erus EENS 3 16 ae EE EE ER 3 17 2
17. 99A1699 1 Guard Pass Thru Sensor NS 99A0413 6 Screw Top Motor Board NS 99A0484 1 Belt Gear Drive NS 99A0491 1 Bracket Stack Limiter NS 99A0400 1 Spring Restraint Roll Shaft NS 99A0489 1 Spring Latch Return NS 99A0487 1 Flag Envelope Out Sensor Parts Catalog 7 61 4520 xxx Assembly 25 High Capacity Feeder 7 62 Service Manual 4520 xxx ae es Units Description 25 1 99A0660 1 Frame Printer Support Frame 2 2 99A0675 3 Parts Packet Screw Printer Support 2 Frame Mounting 3 99A0698 2 Clamp Feed Frame 4 99A0675 4 Parts Packet Screw Feed Frame Clamp 5 99A0691 2 Bearing Nyliner Leadscrew Top 6 99A0656 1 Cover Side 7 99A0681 3 Strip Wear 8 9941818 1 Strip Wear Dimple 9 99A1809 1 Deflector Assembly Front 10 99A0675 3 Parts Packet Screw Deflector Mt 8 18 x 7 8 inch 11 99A1829 1 Label Tray Option Number 12 99A0662 2 Transfer Lead Screw Assembly 13 99A0716 1 Bearing Leadscrew Bottom 14 99A0676 4 Parts Packet Nut 6 32 Hinge Mounting 15 99A0677 4 Parts Packet Washer Hinge Mounting Flat 16 99A0677 4 Parts Packet Washer Hinge Mounting Star 17 99A0657 2 Hinge Door 18 99A0655 1 Door Assembly Front 19 99A0658 2 Magnet Door 20 99A0650 1 Frame Assembly 21 99A0661 1 Tray Assembly Elevator 22 99A1806 1 Card Assembly 2000 Option Control 23 99A0677 4 Parts Packet Washer Card Asm Mounting 24 99A0675 4 Parts Packet Scr
18. 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 No customer adjustments are necessary therefore no special trays are needed for card stock or labels The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm This movement produces a downward force at the pick rolls The friction between the pick roll and the paper produces a frictional locking condition If the paper is physically held and not allowed to feed then the motor stalls Slippage between the roll and the paper is theoretically impossible When the motor is energized the pick rolls are driven down into the stack increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam Once this critical threshold is achieved the normal force remains at a level just high enough to reliably feed the paper Rather than having a fixed spring force for feeding all weights of paper like the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness High normal force is one of the most significant contributors to double feeding paper The pick arm is counter balanced by an extension
19. on page 2 94 4 HVPS 917 Error Code Check the voltage at J10 3 The voltage changes from 24 V with the printer idle to 0 V dc when the printer runs the print test If the voltage is incorrect check the continuity of line J10 3 in the front cable harness to the HVPS If there is no continuity replace the cable harness If there is continuity replace the HVPS If the problem continues replace the engine board 2 104 Service Manual 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 Turn the printer off 2 Press and hold the Go and Return buttons 3 4 Release the buttons when Performing Self Test displays on Turn the printer on the operator panel The tests display on the operator panel in the order shown Print Registration Print Tests Hardware Tests Duplex Tests If installed Input Tray Tests Output Bin Tests Base Sensor Test Printer Setup Error Log EP Factory Defaults Exiting the Diagnostics Mode Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode Diagnostic Aids 3 1 4520 xxx Device Tests Quick Disk Test This test performs a non destru
20. 1 2 or 3 975 Unrecognizable Network Card x Replace Network Card x 976 Unrecoverable software error in Network Card x 977 Controller software detects that a Network Card is installed in slot x but cannot establish communications with it 978 Bad checksum while programming Network Card x Replace Network Card x 979 Flash parts failed while programming Network Card x If the printer is a network model replace the controller board 980 lt device gt Comm 981 lt device gt The engine is experiencing unreliable communications to the specified device The engine protocol violation detected by the specified device 982 Comm Communications error detected by the specified device 983 lt device gt Invalid command received by the specified device 984 lt device gt Invalid command parameter received by the specified device Note Service Errors 980 thru 984 lt device gt can be one of the following engine board duplex tray x 1 2 3 4 or 5 envelope feeder or output bin 990 lt device gt Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Note lt device gt can be one of the following duplex tray 1 2 3 4 or 5 envelope feeder or output bin 991 lt device gt Card The specified device has detected an equipment check in its system card Note l
21. 2 24 V dc J18A Auto Compensator 1 24 V dc 2 AUTOCOMP J18B Auto Compensator 1 Ground 2 ENCODER 3 5 Vdc Connector Locations 5 7 4520 xxx Connector Pin No Signal J19 MPT Paper Out 1 MPFSENSE 2 Ground 3 MPFLED J22 Smart Contact 1 Scart 5 V 2 Ground 3 Ground 5 8 Service Manual 4520 xxx Engine Board c 6 7188 00000000000 c J8 96 II O 916 1 od Connector Locations 5 9 4520 xxx Controller Board Non Network 5 10 Service Manual 4520 xxx Controller Board Network 6 10049 99 750 Connector Locations 5 11 4520 xxx Fuser Board Connector Pin No S
22. 80 Scheduled Maintenance message displays Ask the customer if they have replaced the transfer roll recently CAUTION Make sure the printer is powered off before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer FRU Action Transfer Roll Assembly Check the transfer roll for any signs of toner buildup surface damage to the roll oil or other contaminants on the surface of the roll Replace the transfer roll as necessary Left Transfer Arm Assembly Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position If the arm is not locked down check to ensure the arm is not broken and will lock into the EP frame correctly Check the left transfer arm assembly spring for proper operation Diagnostic Information 2 103 4520 xxx FRU Action 3 Right Transfer Arm Assembly Check the right transfer arm 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 Check the right transfer arm assembly spring for proper operation For any background problems check to ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact correct go to Print Quality Background
23. 9941633 9941634 9941636 9941638 9941643 9941644 99 1645 99 1646 9941647 99 1649 99 1651 99 1654 99 1658 99 1664 99 1665 99 1666 99 1667 99 1668 99 1669 9941672 99 1673 9941674 99 1675 99 1676 9941677 99 1679 99 1680 99 1682 99 1683 99 1684 99 1685 99 1686 99 1691 99 1692 99 1693 99 1694 99 1695 99 1696 99 1697 99 1698 99 1699 99 1700 9941702 9941704 99 1705 7 5 7 11 7 78 2 99 751 7 45 7 5 PAL 7 53 7 73 7 15 7 17 17 85 7 05 7 41 7 43 4 77 T29 7 53 7 53 1 45 7 01 7 97 EE 7 71 7 53 7 55 7 97 7 59 7 55 7 55 7 55 1 59 7 55 7 59 7 55 7 55 7 77 SSC Kee 2 47 7 59 1 59 7 55 7 61 7 59 7 61 7 61 7 61 7 61 7 61 7 53 7 73 1 78 7194510 Index 1 7 4520 xxx 99A1706 7 73 99A1707 7 75 99A1750 7 53 99A1752 7 76 99A1753 7 76 99A1754 7 76 99A1755 7 76 99A1756 7 76 99A1757 7 76 99A1758 7 76 99A1759 7 76 99A1773 7 76 99A1774 7 76 99A1793 7 67 99A1794 7 67 99A1795 7 67 99A1796 7 67 99A1797 7 67 99A1798 7 67 99A1799 7 67 99A1800 7 67 99A1801 7 67 99A1802 7 67 99A1803 7 67 99A1804 7 67 99A1805 7 67 99A1806 7 63 99A1807 7 65 99A1808 7 65 99A1809 7 63 99A1812 7 19 7 49 7 71 99A1818 7 63 99A1819 7 73 7 75 99A1820 7 73 7 75 99A1829 7 47 7 51 7 63 99A1830 7 77 99A1850 7 5 99A1852 7 79 99A1853 7 79 99A1857 7 17 99A1889 7 77 99A1890 7 77 99A1894 7 49 99A1895 7 19 99A1896 7 7 99A1927 7 11 99A1928 7 47
24. Alignment assembly 2 Main drive gearbox assembly 11 Lines spaced 95 66 mm 3 766 inch apart Replace the FRUs in the following order 1 Toner cartridge 2 Main drive gearbox assembly 12 Lines spaced 99 49 mm 8 917 inch apart Replace the redrive assembly 13 Lines spaced 114 79 mm 4 519 inch apart Replace the alignment assembly Diagnostic Information 2 93 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 The customer may try to improve the print quality by increasing the transfer setting Check the charge roll to make sure it is not at the end of life FRU 1 Printhead Action The printhead on the Lexmark T printers cannot be cleaned Try another printhead if all other attempts fail to correct a background problem 2 Transfer Roll Assembly Check the high voltage contact from the HVPS to the transfer roll Check the transfer arm assembly right side bearing for any signs of contamination pitting or a loose cable to the bearing If any problems are found replace the defective part Check the transfer roll shaft for any signs of contamination wear or pitting on the ends
25. Lexmark T520 4520 001 Non network Lexmark T520n 4520 002 Network General Information 1 1 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 Tri Port Adapter IR Adapter IPDS Card Assembly PRESCRIBE Card Assembly Image QuickCard Assembly Bar code Card Assembly Parallel Interface Card SES for SCS USB Parallel Port Marknet Print Servers 250 500 sheet paper trays of A5 letter and legal size 250 Sheet UAT Universally Adjustable Tray 400 Sheet UAT Universally Adjustable Tray 2000 Sheet High Capacity Feeder Envelope Feeder Duplex Unit 250 Sheet For T520 amp T520n Duplex Unit 500 Sheet For T522 amp T522n Hard Disk 5 0 amp GB Forms Hard Disk 5 0 amp GB or Larger Vertical Kiosk Presenter Horizontal Kiosk Presenter 1 2 Service Manual 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 After you complete the repair perform tests as needed to verify
26. 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 220 V 630 W Maintenance Kit 99A2421 After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message See Maintenance Page Count on page 3 19 6 2 Service Manual 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 NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Parts Catalog 7 1 4520 xxx Assembly 1 Covers 7 2 Service Manual 4520 xxx 12 OE Units Description 1 1 99A2074 1 Cover Assembly Redrive Cap 2 99A1508 1 Cover Fuser Wick Assembly 3 99A1506 1 Cover Asm Laser Assembly 4 99A2087 1 Smart Contact Assembly 5 99A2075 1 Cover Right Side 6 99A2011 1 Hinge Upper Front Cover 7 99A2010 1 Kit Upper Front Cover with Labels 210
27. been disabled This possible while this occurs when Menu is message is displayed pressed while the printer is Ready and Menu Lockout is active The printer display shows this message for one second and then returns to the Ready message Activating Menu The printer is reset to No button actions are Changes activate a printer setting possible while this changed in the menus message is displayed User Error Messages User Error Message Explanation 200 Paper Jam Paper is jammed at the printer Input Sensor Remove Cartridge Open the printer upper front door and remove the print cartridge to access the paper jam area 201 Paper Jam Paper is jammed between the printer input and Remove Cartridge exit sensors Open the printer upper front door and remove the print cartridge to access the jam area 202 Paper Jam Paper is jammed at the printer exit sensor Open Open Rear Door the printer rear door to access the jam area Diagnostic Information 2 25 4520 xxx User Error Message Explanation 230 Paper Jam Check Duplex 24X Paper Jam Check Tray X 250 Paper Jam Check MP Feeder The paper is most likely jammed in the 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 If the paper is not jammed in the duplex unit then it may be jammed in the rear of t
28. 11 99A1601 1 Latch Back Restraint Parts Catalog 7 49 4520 xxx Assembly 22 500 Sheet Tray 7 50 Service Manual 4520 xxx an SEH Units Description 22 1 99 0350 1 Sensor Paper Low 2 99A0263 3 Parts Packet Screw Auto Comp Mounting 3 99A0405 1 Pick Arm Assembly 4 99A0070 2 Pick Roll Assembly 5 99A1636 1 Base 500 Tray 6 99A0058 4 Pad Base 500 7 99A0419 1 Spring Tray Bias 8 99A0026 1 Tray Bias Arm Assembly 9 99A0288 1 Sensor Option Pass Thru 10 99A0895 1 Restraint Side 500 Sheet Tray 11 99A0292 4 Wear Strips 12 99A1829 1 Label Tray Option Number 13 99A1583 1 Plate 500 Tray Wear 14 99A0126 4 Finger Autosize 15 99A0124 1 Plate Snap In 16 99A1952 1 Label Paper Size 17 99A1582 1 Slider Autosize 500 18 99A0120 2 Restraint Pad 19 99A1576 1 Tray Assembly 500 Sheet 20 99A1537 1 Knob Paper Size 21 99A1602 1 Restraint Back 500 Sheet Tray 22 99A1601 1 Latch Back Restraint 23 99A1666 1 Label Options 24 99A1967 1 Board Tray 25 99A0447 1 Shaft 500 Drive Parts Catalog 7 51 4520 xxx Assembly 22 500 Sheet Tray continued 7 52 Service Manual 4520 xxx Asm Part Index Number 22 26 99A0282 27 99A1750 28 99A0276 29 99A0263 30 99A0450 31 99A0451 32 99A0438 33 99A0275 34 99A0263 35 99A0267 36 99A0280 37 99A0446 38 99A0274 39 99A0063 40 99A0286 41 99 1664 42 99 0273 43 99 0279 44 99 0281 45 99 1702 46 99 1645 NS 99A0452 NS 99A1665 NS 99
29. 23 Duplex Unit 7 b4 Assembly 24 Envelope Feeder 7 60 Assembly 25 High Capacity Feeder 7 62 Assembly 26 Kiosk Vertical Paper Adapter 7 72 Assembly 27 Kiosk Horizontal Paper Adapter 7 74 Assembly 28 OPONE Lus axe ce adu iced 7 76 Assembly 29 Miscellaneous 7 78 1 Contents vii 4520 xxx viii Service Manual 4520 xxx Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label Invisible laser radiation when open and interlock defeated Avoid exposure to beam Radiation laser invisible si le gepost est ouvert et non bloque Eviter l exposition au rayon Unsichtbare laserstrablung wann drucker offen und sperre gel st Nicht dem strahi aussetzen Onziohtbare lasersiraling wanneer open en niet vergrendeld Vermijd blootstelling aan straal Radiazioni laser Invisibili se I dispositivo aperto e non bloccato Evitare l aposizione diretta Radiaci n l ser invisible si la puerta est abierta y al dispositivo no esta bloqueado Evite exponerse a la radiaci n Radia o laser irvisivel quando a tampa aberta Evite exposi o aos raios Avattaessa ja suojalukitus ohitottaessa olet atiina n kym t m ile lasers reilylle Ala katso s teeseen laserstr ining nar denna del
30. 3 Finger Autosize 8 99A0124 1 Plate Snap in 9 99A1582 1 Slider Autosize 500 10 99A0120 2 Pad Restraint 11 99A2093 1 Restraint Back Parts Catalog 7 19 4520 xxx Assembly 9 Main Drive 7 20 Service Manual 4520 xxx 15 Units Description 9 1 99A2030 1 Gearbox w Motor 2 99A0134 1 Shaft Power Takeoff 250 2 99A1569 1 Shaft Power Takeoff 500 3 99A0275 1 Spring Power Takeoff Shaft 4 99A2080 1 Gear Bevel with Grease Packet NS 99 0263 4 Parts Packet Screw Gearbox Mounting NS 99 0263 3 Parts Packet Screw Motor Mounting NS 99A0260 2 Clip Cable Parts Catalog 7 21 4520 xxx Assembly 10 Developer Drive 7 22 Service Manual 4520 xxx Asm Part index Idee Units Description 10 1 99A1544 1 Developer Drive Assembly 2 99A2081 1 Parts Packet Developer Drive Shaft Coupler Gear 55 3 99A0263 3 Parts Packet Screw Developer Drive Ground Parts Catalog 7 23 4520 xxx Assembly 11 Hot Roll Fuser 7 24 Service Manual 4520 xxx Part index Number Units Description 11 1 99A2423 1 Fuser Assembly w 115V 630W Lamp 1 99A2422 1 Fuser Assembly w 220V 630W Lamp 2 99A0725 1 Wiper Assembly Wet 3 56P0150 1 Kit Fuser Cover Assembly with Thermistor Thermal Fuse and L amp R Fuser Lamp Contact Assemblies W Fuser Cover Control Card 4 99A0263 4 Parts Packet Screws Contact Assembly 4
31. 6 3a 2 99A2091 1 Fuse for 220 V ac LVPS 3 15a 3 99A2043 1 LVPS 110 V ac 3 99A2044 1 LVPS 220 V ac Parts Catalog 7 31 4520 xxx Assembly 14 Electronics 1 continued 7 32 Service Manual 4520 xxx Part dE CN Units Description 14 4 99A0263 1 Parts Packet Screw s Controller Board 2 Controller Board Mtg Front 2 Controller Mtg Ground 1 Engine Board Mtg 6 Engine Board Mtg Top 2 e HVPS INA Cover 12 Interconnect Board 2 Interconnect Board Shield Ground 1 Interconnect Shield Mtg 5 Outer Shield 10 Parallel Connector Mtg 2 5 99A2045 1 Power Supply High Voltage 6 99A2046 1 Interconnect Board Assembly 2 slot 210 220 6 99A2152 1 Interconnect Board Assembly 1 slot 001 002 7 56P 1005 1 Engine Board Assembly 210 220 7 56P 1004 1 Engine Board Assembly 001 002 8 99A2486 1 Card Assembly Bar Code 8 99A2200 1 Card Assembly IPDS and SC5 TNE 8 99A2487 1 Card Assembly Prescribe 5 4 2 Flash 8 99A2528 1 Card Assembly Image Quick 9 99A0426 2 Screws Parallel Connector Mounting 10 56P0188 1 Controller Board Assembly Non Network 210 220 10 56P0189 1 Controller Board Assembly Network 210 220 10 56P0190 1 Controller Board Assembly Non Network 001 002 10 56P0191 1 Controller Board Assembly Network 001 002 Parts Catalog 7 33 4520 xxx Assembly 15 Electronics Il
32. 80 99A0276 81 99A0451 82 99A0267 83 99A0675 84 99A0277 85 99A0445 86 99A0280 87 99A0275 88 99A0272 89 99A0446 Gear Bevel Parts Packet Screw Frame Mounting Roll Assembly Drive 250 Option Roll Skew Backup Parts Packet Retainer Roller Parts Packet Screw Wear Plate Mounting Plate Wear Pass Thru Stud Assembly 250 Frame Bearing Drive Shaft Low Spring Power Takeoff Shaft 250 Drive Aligner Assembly Paper Sch s et ce eh Sak a ett ect Parts Catalog 7 67 4520 xxx Assembly 25 High Capacity Feeder continued D 7 68 Service Manual 4520 xxx Asm Part Index Number 25 90 99A0267 91 99A0274 92 99A0278 93 99A1967 94 99A0263 Units Description Parts Packet Retainer Aligner Assembly Gear Feed Roll Bellcrank Roller Release Card Assembly 2000 Tray Option Parts Packet Screw Tray Option Card Mtg E oa oa NS 99A0675 10 Parts Packet Screw Door to Door Frame Mounting NS 99A0676 6 Parts Packet Nut Support Frame 1Hex Support Frame 2 Hex NS 99 0677 6 Parts Packet Washer Support Frame 1 Star Support Frame 2 Star NS 99A0684 1 Cable HCIT 14Pin Flex NS 99A0286 1 Spring Backup Roller Parts Catalog 7 69 4520 xxx Assembly 25 High Capacity Feeder continued 7 70 Service Manual 4520 xxx Asm Part Index Number Units Description 25 95 99A0263 3 Parts
33. 81 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 The Disk Test Clean on page 3 3 is used to help restore the disk if the disk contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section Warning This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu operation This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network Card Option Note The network is installed on the controller board on network model printers Error Code 976 Network Card X X Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed in the socket on the interconnect board and is properly grounded If you find no problem contact your next level of support before replacing the network card Error Code 977 Network Card X A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communications with the network card 2 82 Service Manual 4520 xxx Output Bin Sensor Standard Tray Service Check Service Ti
34. Cut the cable tie from the fuser board cable bundle Disconnect the narrow media sensor from the fuser board The sensor can be removed without removing the lower exit guide assembly Noting the location of the sensor flag depress the two lower sensor mounting pins and remove the sensor assembly Align the sensor flag with the flag opening in the lower exit guide assembly and snap the sensor into place Be sure the sensor operates correctly Replace the cable tie on the cable bundle Fuser Exit Sensor Flag Assembly Removal 5 Cut the cable tie from the fuser board cable bundle Disconnect the exit sensor from the fuser board Noting the location of the sensor flag depress the two lower sensor mounting pins and remove the sensor assembly Align the sensor flag with the flag opening in the lower exit guide assembly and snap the sensor into place Be sure the sensor operates correctly Replace the cable tie on the cable bundle Note The exit sensor assembly can be removed without removing the lower exit guide assembly Make sure the narrow media sensor flag is correctly positioned before snapping the sensor in place 4 34 Service Manual 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 agains
35. Empty Sensor LO Input Tray Paper Low Sensor e Input Tray Pass Thru Sensor 2 Once this message displays the servicer can manually actuate each sensor The tray empty sensor can be actuated by hand however a sheet of paper can be used to cover the pass thru sensor When the sensor is closed CL displays when the sensor is open OP displays 3 Press Return Stop to exit the test The multipurpose tray and the envelope feeder do not have a paper low sensor The multipurpose tray does not have a pass thru sensor Diagnostic Aids 3 15 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 Select Sensor Tests Standard Bin Standard Bin Full CL message displays Manually actuate the bin sensor by moving the flag in and out of the sensor The display indicates OP open when the flag is out of the sensor and CL closed when the flag is in the sensor 4 Press Return Stop to exit the test Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly The following sensors can be checked Toner Optical Sensor Input Sensor Output Sensor Fuser Exit Narrow Media Sensor Front Door Sensor Upper Front Cover To run the Base Sensor Test 1 Select the Ba
36. Flag Assembly 4 34 Fuser Transfer Plate 4 32 High Voltage Power Supply 4 36 Integrated Tray Compensator Assembly 4 37 Integrated Tray Compensator Pick Roll Assembly 4 38 Interconnect Board Assembly 4 39 Left Door 4 12 Low Voltage Power Supply 4 40 Main Drive Assembly 4 43 Main Drive Motor 4 44 Main Fan 4 24 Multipurpose Tray Lower Deflector Assembly 4 45 Operator Panel Assembly 4 47 Operator Panel Cable Cover Open Switch Assembly 4 48 Optional Paper Tray Assembly 4 49 Paper Alignment Assembly 4 50 Paper Deflectors 4 52 Inner Paper Deflector Assembly 4 52 Upper Paper Deflector Assembly 4 52 Paper Input Sensor 4 53 Paper Size Sensing Board 4 53 Pick Roll 4 53 Printhead 4 54 Redrive Assembly 4 55 Smart Contact Assembly 4 56 Toner Sensor 4 57 Transfer Roll Assembly 4 58 Upper Front Cover Hinge Assembly 4 59 Upper Front Cover Interlock Switch Assembly 4 60 Upper Paper Deflector Assembly 4 58 Restore EP Factory Defaults 3 21 ROM Memory Test 3 13 5 Safety Information xviii Safety Inspection Guide 6 1 Scheduled Maintenance 6 2 Screw Identification Table 4 7 SDRAM Memory Test 3 12 Serial Wrap Test 3 13 Service Checks Charge Roll 2 40 Cover Open Switch Cable 2 42 Dead Machine 2 43 Duplex Unit 2 45 Envelope Feeder 2 48 Fuser 2 56 Fuser Solenoid 2 60 High Capacity Feeder Input Tray 2 66 Input Sensor 2 61 Input Tray s Option 2 62 Main Drive 2 77 Operator Panel 2 79 Options 2 81 Output Bin Sensor 2 83 Pap
37. If this does not fix the problem replace the system board 956 Processor Failure 957 ASIC Failure 959 SRAM Failure Memory Error 958 NAND Before proceeding when a 958 NAND failure is Failure displayed perform a power on reset POR to see if the ECC error correction code can reflash NAND If this does fix the problem replace the system board 960 RAM Indicates a DRAM Memory Error on the controller board Replace the controller board 961 RAM in Slot 1 is Bad Replace the card in Slot 1 If this does not fix the problem replace the controller board 962 RAM in Slot 2 is Bad 963 RAM in slot 3 is Bad Replace the card in Slot 2 If this does not fix the problem replace the controller board Replace the card in slot 3 If this does not fix the problem replace the controller board 964 Emulation Error 965 Emulation Error Indicates a failure within the Download Emulation which 15 programmed into the code overlay card The specific error is as follows 964 Download Emulation CRC Failure Checksum Failure 965 Download Emulation Outdated The Download Emulation and the controller code are incompatible Go to the Disabling Download Emulations on page 3 5 2 6 Service Manual 4520 xxx Error Code Action 975 979 Network Card X The following errors indicate a failure with the network card in the specified slot X any card installed in slots
38. J voor andere landen in IEC 60825 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse IIIb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn 20 ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder belgeleengdeomradet 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser XiV Service Manual 4520 xxx Huomautus laserlaitteesta kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia kayttajalle Kirjoittimessa on sis inen luokan 1116 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoaluee
39. Pick Roll Shaft Parts Catalog 7 13 4520 xxx Assembly 6 Paper Feed Alignment 7 14 Service Manual 4520 xxx aa Units Description 6 1 99A0089 1 Alignment Assembly Paper Feed 2 99A0263 3 Parts Packet Screw Paper Feed 3 99A2066 1 Clip Reference Ground 4 99A0492 1 Screw Paper Reference Adjustment 5 99A0565 1 Washer Reference Adjustment 6 99A0566 1 Nut Paper Reference Adjustment NS 99 0263 2 Alignment Asm Mounting Parts Catalog 7 15 4520 xxx Assembly 7 Paper Feed Output 2 i mE H 22 e NN SC ZS 7 16 Service Manual 4520 xxx Part os index Nubes Units Description 7 1 99A2029 1 Redrive Assembly 500 Input 250 Output 210 220 1 99A2151 1 Redrive Assembly 250 Input 250 Output 001 002 2 99A1644 1 Door Assembly Redrive 250 NS 99A0104 1 Spring Upper Diverter NS 99A1857 1 Deflector Upper Redrive NS 99A0263 2 Parts Packet Screw Duplex Path Parts Catalog 7 17 4520 xxx Assembly 8 Integrated Paper Tray 500 Sheet 7 18 Service Manual 4520 xxx a ERES Units Description 8 1 99A1601 1 Latch Back Restraint 2 99A1576 1 Tray Assembly 500 Sheet 3 99A1895 1 Restraint Side 4 99A0292 4 Strip Wear 5 9941812 1 Label Tray Option Number 6 99A1583 1 Plate 500 Tray Wear 7 99A0126
40. Ready after the page prints Press Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Select for the values Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Printing Directory List A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the paper path Press Go to return to Ready after the page prints Press Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Select for the values Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Diagnostic Information 2 23 4520 xxx User Status Message Status Action Restoring Factory Defaults The printer is restoring factory defaults No button actions are possible while this message is displayed Performing Self Tests The printer is running the normal series of start up tests after it is powered on When the tests are complete the printer returns to Ready No button actions are possible while this message is displayed Not Ready Press Go The printer is in the Not Ready state which means it is not ready to receive or proce
41. be caused by the paper exiting the input sensor too late or jamming in the fuser assembly prior to activating the exit sensor flag in time or not at all Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sensor This can be caused by the paper arriving at the sensor too late the paper is jammed in the fuser assembly or is jammed exiting the fuser assembly in the redrive assembly or the exit sensor flag is not operating correctly Paper Jams Options Error Message 230 Paper Jam Check Duplex Unit The paper is most likely jammed in the duplex unit however the paper can also be jammed in the redrive at the input to the duplex unit The redrive assembly may not be correctly installed or locked in position or the duplex link is bent and not aligned properly to allow paper to feed correctly into the duplex unit 3 28 Service Manual 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 Error Message 260 Paper Jam Check Envelope Feeder An envelope is jammed in the envelope feeder or has not reached the base machine input sensor Error Message 27x Paper Jam C
42. because this board contains the printer NVRAM Memory where the page count is stored To set the Page Count 1 Select Page Count from the Diagnostic menu The current page count displays The leftmost digit blinks indicating it is the first digit to be changed 2 Press either Menu until the value you want displays 3 Press Select to move to the next digit press Menu until the value you want displays Continue with each digit until you set the page count You can skip any digit by pressing Select 4 Press Select to save the new page count in NVRAM 5 Press Return Stop to exit the Diagnostic menu Viewing the Permanent Page Count The Permanent Page Count can only be viewed and cannot be changed To view the Permanent Page Count 1 Select Permanent Page Count from the menu 2 Press Return Stop to exit the Diagnostic menu 3 18 Service Manual 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 Press Return to go to the previous menu To reset the Maintenance Page Count to zero Select Reset Maintenance Count Pressing Select resets the maintenance page counter to zero Reset Maintenance Count Saved displays momentarily When the reset operation is complete the menu returns to the Print
43. 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 Use the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer Service error codes are indicated by a three digit error code If a service error code is displayed go to the Service Error Codes on page 2 2 User status messages provide the user with information on the current status of the printer Ready is displayed on the first line of the display unless Power Saver is invoked and then Power Saver is displayed If a user status message is displayed go to the User Status Messages on page 2 22 User error messages are indicated by a two or three digit error code that provides the user with information that explains a problem with a print cartridge paper jam option port and so on If a user error message is displayed go to the User Error Messages on page 2 25 If your machine completes the Power On Self Test POST on page 2 35 without an error and you have a symptom go to the Symptom Tables on page 2 36 Locate your symptom and take the appropriate action If a service error code appears while you are working on the machine go to the Ser
44. does not correct the problem replace the HVPS Diagnostic Information 2 95 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 Inspect the alignment assembly main drive assembly and all other paper feed components for signs of wear dirt binds or damage especially the drive gears Banding appears as light or dark horizontal lines on a uniformly gray page Banding can also be caused by a defective charge roll brush contact or HVPS Check the charge roll contact for any signs of damage and for proper connection to the HVPS and print cartridge Print Quality Black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide narrow light or dark FRU Action Charge Roll Counterbalance Springs If the problem is just on one side of the page check the charge roll counterbalance spring on that side You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample See if the problem changes or
45. finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the test fails a message displays for approximately three seconds and the Fail Count increases by 1 Once the maximum count is reached the test stops The power indicator goes on solid and the final results display 4 Press Return Stop to exit the test 3 14 Service Manual 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 The paper is placed in the output bin To run the Input Tray Feed Test 1 Select Input Tray Feed Test from the menu 2 Select the input source from the sources displayed on the Feed Test menu All installed sources are listed 3 Select either Single feeds one sheet of media from the selected source or Continuous continues feeding media from the selected source until Return Stop is pressed 4 Press Return Stop to exit test Input Tray Sensor Test This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Select the Sensor Test from the Input Tray Test menu Input Tray Empty OP Pass OP message displays EM Input Tray
46. full 63 Unformatted Disk This error code displays when the printer detects an unformatted disk at power on Press Go to clear the message The disk is marked as bad and normal operation continues Disk operations are not allowed until the disk is formatted 80 Scheduled The operator panel displays this message at each Maintenance 250K page count interval It is necessary to replace the fuser assembly transfer roller and charge roll at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit For more information go to Scheduled Maintenance on page 6 2 81 Engine Code CRC This error displays when the microcode to be Failure programmed in the engine flash code module has failed a CRC check Press Go to clear the message The microcode data is discarded and must be re transmitted from the host computer 88 Toner Low This message displays when toner low occurs and the toner low alarm is activated Press Go to clear this message Diagnostic Information 2 29 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 The Menu buttons are not active if Menu Lockout is turned on Press Stop to take the printer offline The No
47. fuser temperature and varies from approximately 2 0 V dc cold to 2 3 V warm during idle to approximately 2 7 during continuous printing These voltages are assuming the fuser temperature is set to normal The HEATON signal from CN3 9 varies from 0 V de lamp on to 5 V lamp off and is connected to the cathode of an Opto triac to control the fuser lamp The second part of the assembly is the fuser frame which contains the hot roll backup roll and associated parts as well as the paper exit guide assembly narrow media sensor fuser control board and the envelope conditioner solenoid Diagnostic Aids 3 27 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 Note A defective engine board or printhead can also cause a 200 Paper Jam message to occur prior to the paper reaching the input sensor flag This error can display due to a problem with the HSYSC signal to or in the printhead Use the sub error code table to assist in isolating a 200 paper jam message Error Message 201 Paper Jam Remove Cartridge This message indicates the paper is jammed between the printer input and exit sensors This condition can
48. goes away H this fixes or changes the problem then check the springs and charge roll link arm assemblies for binds or defective parts Replace as necessary Charge Roll Assembly Charge Roll Link Arm Check the charge roll for any signs of toner buildup or other contamination on the outer edges that correspond to the bands on the page Check the charge links and arms for proper operation binds or incorrectly mounted counterbalance springs Repair or replace as necessary 2 96 Service Manual 4520 xxx FRU Action 3 HVPS Check the following voltages at J10 8 on the engine board Printer Idle J10 8 measures 0 V Printer Printing Test Page J10 8 voltage changes from 0 V de to 4 V If the voltage does not vary check the continuity of line J10 8 in the front cable harness If there is no continuity replace the cable harness If there is continuity replace the HVPS If this does not correct the problem replace the engine board Turn the printer off and check the resistance between J10 7 and printer ground The resistance measures approximately 0 ohms If incorrect make sure the engine board is mounted correctly and securely grounded If correct replace the engine board Diagnostic Information 2 97 4520 xxx Print Quality Residual Image Service Tip Install a new print cartridge if available before doing this service check Residual image can be caus
49. guides and remove the guides 4 Remove the four mounting screws on the right side of the duplex frame assembly 5 Position the duplex assembly on its side 6 Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly 7 Remove the center drive deflector assembly and the frame assembly from the duplex unit 8 Remove the two duplex motor mounting screws and remove the motor Note Pay attention to cable routing to avoid pinching or cutting wires during reassembly Ensure cables are securely placed into the cable retaining tabs Adjust the Duplex Motor Drive Belts on page 4 2 whenever you remove or replace the duplex motor 4 20 Service Manual 4520 xxx EMC Shields Removals Inner EMC Shield Removal Remove the left door Remove the outer EMC shield Remove all option boards from the connector board slots Remove the inner EMC shield mounting screws A Remove the ground screw B Remove the inner EMC shield 102 102 Repair Information 4 21 4520 xxx Outer EMC Shield Removal 1 Remove the left door 2 Loosen the outer EMC shield mounting screws A and remove the shield A 202 A 202 4 22 Service Manual 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 A 202 B 104 4 Remove the engi
50. not work Go to the Operator Panel Buttons Service Check on page 2 79 Operator Panel Display is blank Printer sounds 5 beeps Go to the Operator Panel Service Check on page 2 79 Operator Panel Display is blank Printer does not sound 5 beeps Replace the operator panel assembly Operator Panel continuously displays all diamonds sounds 5 beeps and does not complete POST Go to the Operator Panel Service Check on page 2 79 Paper feed problems Base printer or Integrated 500 Paper Tray Go to the Paper Feed Service Check on page 2 84 Paper jams at exit of Redrive Assembly No Duplex Unit installed Go to the Paper Feed Service Check on page 2 84 Paper jams at exit of Redrive Assembly Duplex Unit installed Go to the Duplex Unit Service Check on page 2 45 Fuser Solenoid fails to operate Print quality Black page Go to the Fuser Solenoid Service Check on page 2 60 Go to the Print Quality All Black Page on page 2 89 Print quality Blank page Go to the Print Quality Blank Page on page 2 90 Print quality Light print Go to the Print Quality Light Print on page 2 98 Print quality Background Go to the Print Quality Background on page 2 94 Print quality Residual image Go to the Print Quality Residual Image on page 2 98 2 36 Service Manual 4520 xxx Symptom Action
51. of the shaft that go into the bearings If a problem is found clean the ends of the shaft or replace the transfer roll assembly 3 High Voltage Contacts Check the high voltage contacts on the right side frame to ensure they are clean and not bent deformed or pitted If incorrect replace the contact 2 94 Service Manual 4520 xxx FRU Action 4 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 J10 2 varies 0 V dc to 4 V dc J10 4 varies 0 V dc to 1 9 V de If J10 1 voltage is incorrect check the continuity of the front harness cable J10 1 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 2 voltage is incorrect or if the voltage remains at 0 V dc check the continuity of the front harness cable J10 2 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 4 voltage is incorrect check the front harness cable J10 3 line If there is not continuity replace the harness cable If correct replace the engine board if this
52. piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio Lainformaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias XX Service Manual 4520 xxx Informa es de Seguran a e Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substitui o As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Informaci de Seguretat e Aquest producte est dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot s
53. print cartridge twice The last good print cartridge ID is stored in NVRAM 2 26 Service Manual 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 If pages are allowed to print then they are not reprinted once a good print cartridge is inserted If this does not fix the problem go to the Smart Contact Assembly Service Check on page 2 100 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being used 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error This message can only occur if the Resolution Reduction setting is turned on Note 1200 dpi pages are not resolution reduced If a 1200 dpi job runs out of memory a Memory Full error is displayed 37 Insufficient Collation This message is displayed when the prin
54. procedure may take two or three attempts before you get satisfactory results When you have the correct adjustment gently tighten the printhead mounting screws being careful not to move the printhead assembly 4 4 Service Manual 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 If you are replacing the alignment assembly go to step A If you are only adjusting the reference adjustment screw go to step B A 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 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the alignment assembly to the left side frame 3 Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer It is not necessary to completely remove the screw 4 Install the new alignment assembly Turn the reference screw clockwise with a 7 mm nut d
55. setting is correct for the size paper in the tray 84 xx 1 There is media over the Tray 6 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 6 and see if Tray 6 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 1D The envelope feeder pass thru sensor never deactivated The display of this code indicates that an envelope never crossed over the sensor flag and passed beyond the sensor or the flag and sensor are not operating properly Go to the Envelope Feeder Service Check on page 2 48 84 xx 1E x1 x2 The envelope feeder pass thru sensor was never activated x1 Media Size x2 Media Source Ensure that envelopes are feeding over the sensor If an envelope feeds over the sensor but the sensor does not activate check the sensor and flag for correct operation If the sensor and flag are operating correctly go to the Envelope Feeder Service Check on page 2 48 2 12 Service Manual 4520 xxx First 6 Bytes Sub Error Code Data Note Explanation xx can be any value 84 xx 20 x1 The imaged page is not the expected page x2 x1 Media Size x2 Media Source Check the pass thru sensor to make sure it is operating properly If no pr
56. side frame to attach 1 Thread Cutting center pan 6 toner level sensor mounting 1 102 d charge roll mounting 1 i 27 main drive gearbox mounting 3 EP module to left and attach 9 right side frame developer drive mounting 2 assembly stacker duct to frame mounting 2 cartridge hold down mounting 2 assembly MPT deflector mounting 2 interconnect board attach 2 shield ground engine board shield to attach 1 frame laser cover mounting 4 deflector mounting 2 Repair Information 4 7 4520 xxx Reference 201 Wu Number Screw Type Location Purpose Qty M3 5x8 mm spring mounting 1 Thread Cutting G controller board mounting 2 front 102 ii integrated tray ITC mounting 2 stacker support to right attach 2 side frame M3 5x12 mm engine board shield to attach 1 Thread Cutting left frame 9 paper alignment mounting 2 104 E assembly ya i i toner cartridge guide mounting 2 track left side frame to center attach 3 pan right side frame to attach 2 center pan deflector mounting 2 M3x5 mm INA cover attach 6 Taptite 2 screws per cover 4 8 Service Manual 4520 xxx 203 1 11111111 hanger bracket Reference N mber Screw Type Location Purpose Qty M3x6 mm outer shield
57. the input sensor 02 The duplex unit engine board never received media notification from the printer 03 The trailing edge of the sheet of paper never cleared the input sensor 04 The leading edge of the sheet of paper never arrived at the exit sensor Note This error is the most common due to the long length of the paper path between the input sensor and the exit sensor 05 The duplex logic thinks a sheet of paper is feeding to the duplex unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the duplex unit 06 The exit sensor detected a sheet of paper too early 07 The sheet of paper trailing edge did not clear the exit sensor in the desired length of time 08 The feed motor experienced a complete motor stall The D C motor is under speed The motor never reached the correct operating speed 13 There is paper left in the duplex unit Paper was sensed during the homing operation during POST 15 There is paper left in the duplex unit Paper was sensed during the D C motor diagnostic test during POST 18 The D C motor experienced an acceleration error 3D There is paper left in the duplex unit Paper was sensed during IR clear during POST Diagnostic Information 2 21 4520 xxx User Status Messages User Status Message Status Action Ready The printer is ready to receive and process data
58. the main drive motor A 212 A 212 4 44 Service Manual 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 Warning Be careful not to break the hinges Repair Information 4 45 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 A 102 A 104 4 46 Service Manual 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 Repair Information 4 47 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 2 Remove the left door left cover upper front cover outer EMC shield and inner EMC shield Disconnect the operator panel cover open switch cable from the engine board Remove the operator panel Pull the cables through the rectangular hole in the hinge pivot arm Plug the new operato
59. 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 323 Repair Information 4 15 4520 xxx Laser Assembly Cover Removal Remove the left door Remove the right cover Remove the rear paper deflector Press the fuser wiper cover latch and remove the cover Remove the paper full sensor flag assembly from the mounting bracket 6 Remove the mounting screws A and remove the cover A 102 amp 102 102 Center Pan Assembly Removal 1 Remove the left and right side frames 2 Remove the pan assembly 4 16 Service Manual 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 Remove the controller board 002 A 102 A 102 Repair Information 4 17 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
60. with diamond design and MarkNet are trademarks of Lexmark International Inc registered in the United States and or other countries ImageQuick and Optra Forms are trademarks of Lexmark International Inc Other trademarks are the property of their respective owners Copyright Lexmark International Inc 2001 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 P N 12G3967 4520 xxx Contents Notices and Safety Information ix Leer pect Sues We qus BOS ix Safety lege xviii BEE e xxiii General Information 1 1 EE EE E E ed ee adl 1 2 Maintenance 1 3 Tools Required for Service 1 3 AGIONYING doe x ra aeons 1 4 Diagnostic 2 1 EE 2 1 Sevice Error Codes aa da ces RR ei LEES E 2 2 User Status Messages 2 22 User Error 2 25 P
61. 2 3 4 Remove the paper tray Remove the left door Remove the inner EMC shield Disconnect the compensator motor cable A from the engine board Place the printer on its side Locate the integrated tray compensator assembly B on the bottom of the printer and disconnect the compensator arm bias spring from the frame Remove the C clip that rests against the right side frame from the autocompensator pivot shaft Disconnect the compensator sensor cable C from the assembly Remove the compensator assembly mounting screw D Remove the integrated tray compensator assembly D 203 Repair Information 4 37 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 Unsnap the pick roll assembly D from its mounting and remove 4 38 Service Manual 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 5 Place the printer on its back and remove the mounting screws A E E E Ai A 202 6 Remove the interconnect board asse
62. 2 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 19 There is media over the Tray 3 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 3 and see if Tray 3 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray Diagnostic Information 2 11 4520 xxx First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 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 Try running the Input Tray Tests for Tray 4 and see if Tray 4 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 1B There is media over the Tray 5 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 5 and see if Tray 5 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size
63. 220 7 99A2150 1 Kit Upper Front Cover with Labels 001 002 8 99A0007 1 Label TLI ID Serial No Blank 9 99A1502 1 Latch Upper Cover 10 99A0004 1 Spring Latch 11 99A1511 1 Cover Assembly Lower Front 12 99A2014 1 Operator Panel Assembly 110V 12 99A2015 1 Operator Panel Assembly 220V 13 99A2060 1 Switch Cover Open w Operator Panel Cable Assembly 14 99A1509 1 Cover Left Door 001 002 1 slot 14 99A1510 1 Cover Left Door 210 220 2 slot 15 99A1587 1 Support Paper NS 99 0577 1 Cable Tie NS 99A1594 1 Retainer Cable NS 9940263 5 Parts Packet Screw Left Side Cover Mounting NS 99 0263 3 Parts Packet Screw Right Side Cover Mounting NS 99 0263 6 Parts Packet Screw Laser Cover NS 99 0263 5 Parts Packet Screw Upper Front Cover Mounting Parts Catalog 7 3 4520 xxx Assembly 2 Frame 7 4 Service Manual 4520 xxx a ees Units Description 2 1 99A1643 1 Shroud Fan 2 99A2063 1 Fan Main 3 56P1049 1 Sensor Standard Bin Level with Cable 4 99A1613 1 Flag Output Paper Level 5 99A0062 1 Bracket Level Sensor 6 99A2016 1 Duct Left Stacker 7 99A0867 1 Duct Main Body 8 99A2017 1 Guide Redrive Exit 9 99A2018 1 Support Left Lower Stacker 10 99A2076 1 Pan Drip ITC 11 99A2077 4 Pad Machine Mounting 12 99A2021 1 Support Right Stacker Plate 13 99A2020 1 Transfer Plate Assembly 14 99A2022 1 Right Sideframe 15 99A1518 1 Frame Extension Right 210 220 16 99A0028 1 Spring Tray Bias 17 99A0585 1 Part
64. 6 inch apart This can be caused by the motor pinion gear on the main drive motor Replace the main drive motor 2 Lines spaced 22 32 mm 882 inch apart Lines spaced 28 7 mm 1 130 inch apart Lines spaced 47 83 mm 1 883 inch apart Lines spaced 63 77 mm 2 511 inch apart This can be caused by a defective gear in the main drive gearbox assembly Replace the main drive gearbox assembly 3 Lines spaced 38 26 mm 1 506 inch apart This can be caused by defective gear s in the main drive gearbox Replace the FRUs in the following order 1 Main drive gearbox 2 Reference edge 4 Lines spaced 44 64 mm 1 757 inch apart Replace the FRUs in the following order 1 Developer drive assembly 2 Main drive gearbox assembly 5 Lines spaced 47 19 mm 1 858 inch apart Replace the FRUs in the following order 1 Toner cartridge 2 Charge roll 3 Developer drive assembly 6 Lines spaced 49 16 mm 1 935 inch apart Replace the toner cartridge 7 Lines spaced 49 74 mm 1 958 inch apart Replace the FRUs in the following order 1 Redrive assembly 2 Fuser assembly 8 Lines spaced 51 02 mm 2 009 inch apart Replace the transfer roll 2 92 Service Manual 4520 xxx FRU Action 9 Lines spaced 52 23 mm 2 056 inch apart 10 Lines spaced 76 53 mm 3 013 inch apart Replace the redrive assembly Replace the FRUs in the following order 1
65. 677 2 ALOV V WMECHSSCEMMWANTIET 22X1I0v VY Wpiifsl amp tEdizvcxAxoncoxEv co 7Zyr sZ i72zHnb 3b OL P AARMELTOIEF CO 04 448971 7170 95 4 7 0 BH 58507 RORY Ik 5 LWATACTULS ii BORE 2 Odre H ARI FATOVANVELLOL ik Chinese Laser Notice OL ae A DHHS 21 CFR Subchapter I Xj 47 28 I 1 8 amp 26 A Fe m H Hb WOLZ 825 1 HE SE THI Bh 0 TR ROG EE TIED OLA 27 115 3b 9 Sms ebe gi EG HBR WE 770 795 nm Z BHI E RiR HABA Notices and Safety Information xvii 4520 xxx Korean Laser Notice 158 olx ASSO CHE DHHS 21 CFR Subchapter 32 PAS ges Ol SoA 22 2 eE 8 TAS 1E SORA 01558 158 AOA d se HNE zaage 5 PAVE WS lol alo HZA 770 795 Loje mhol Class Il 3b aous HOA 251 Veit S BA ZOLL su amp LE Weg MIA SERA 4219 Class 29 al o x SO Sog Aas MAO rio Safety Information e 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 obviou
66. 7 2 7 5 7 39 7 45 1 51 7 59 4 4 7 5 7 45 7 53 7 11 7 45 7 51 7 71 7 19 12 7 13 TAD 7413 I 1 75 7 13 7 13 7 13 7 78 7 13 7 73 7 15 7 73 7 75 7 73 1 45 7 73 7 15 2 15 SE 7 47 7 49 7 19 7 47 7549 7 51 7 47 7 49 J 13 1 25 7 19 7 47 7 49 7 51 7 73 7 19 7 47 7 49 7 51 7 47 7 49 4 21 4520 xxx 99A0137 99A0148 99A0167 99A0181 99A0184 99A0185 99A0188 99A0191 99A0197 99A0208 99 0219 99 0226 99 0227 99 0231 99 0232 99A0234 99A0240 99A0260 99A0263 PL 1 21 7 29 10 25 7 29 7 93 7 38 7 805 7 51 7 59 7 57 7 68 I 99A0267 7 73 7 25 7525 7527 7 27 7527 7 65 2 87 7573 7 16 1 19 7 18 7 65 7 73 7 35 7 78 7 75 7 73 7 15 7 73 7 15 7 19 7 73 7 21 7 3 7 9 d T 713 7 19 7515 7 28 EL 753 7 07 1 69 7 18 9940268 9940269 99 0271 99A0272 99A0273 99A0274 99A0275 99A0276 99A0277 99A0278 99A0279 99A0280 99A0281 99A0282 99A0286 99A0288 99A0292 99A0299 99A0307 99A0308 99A0310 99 0311 99 0312 7 18 4 98 y 6a 7 61 7 78 7 45 7 67 7 45 7 53 7 67 7 45 7 58 7 57 7 69 7 21 7 45 7 53 7 67 7 45 7 53 7 67 7 45 7 67 7 47 7 69 7 45 7 53 7 57 7 67 7545 7 53 1590 7 87 7 45 7 53 7 67 7 45 7 53 7 47 7 53 7 69 Z5 Ol 7 11 Z 19 1501 7 55 7 78 7599 7 59 7 57 7 57 255 99A0314 99A0315 99A0316 99A0317 99A0319 99A0321 99A0322 99A0323 99 0324 9
67. 7 7 7 99A0715 7 65 99A0572 7 78 99A0716 7 63 99A0577 7 3 7 78 99A0717 7 71 99A0585 7 78 99A0719 7 65 99A0627 7 45 7 57 99A0720 7 71 99A0629 7 76 99A0725 7 25 99A0650 7 63 99A0799 7 77 99A0651 7 65 99A0803 7 37 99A0653 7 65 99A0867 7 5 99A0654 7 65 99A0892 7 47 99A0655 7 63 99A0893 7 47 99A0656 7 63 99A0895 7 51 99A0657 7 63 99A0897 7 25 99A0658 7 63 99A0906 7 75 99A0659 7 65 99A0907 7 75 99A0660 7 63 99A0923 7 76 99A0661 7 63 99A0952 7 59 99A0662 7 63 99A1015 7 27 99A0663 7 65 99A1017 7 29 99A0664 7 65 99A1054 7 45 99A0667 7 65 99A1055 7 71 99A0672 7 67 99A1059 7 59 99A0675 7 63 7 65 7 67 7 69 7 78 99A1129 7 57 1 6 Service Manual 4520 xxx 99A1130 99A1131 99A1133 99A1134 99A1164 99A1182 99A1280 99A1290 99A1502 99A1506 99A1508 99A1509 99A1510 99A1511 99A1512 99A1517 99A1518 99A1520 99A1524 99A1525 99A1531 99A1536 99A1537 99A1538 99A1540 99A1541 99A1544 99A1546 99A1551 99A1553 99A1555 99A1569 99A1576 99A1578 99A1579 99A1582 99A1583 99A1587 99A1593 99 1594 99 1596 99 1601 99 1602 99 1605 99 1609 99 1611 99 1612 7 89 7 55 79 7 85 7 59 7 76 7 59 1559 7 3 7 3 7 3 73 7 3 Kee 7 3 4 9 759 7 25 4 7 7 5 7 13 7 47 7 49 7 47 7 51 7 7 7 23 7 7 7 25 7 41 7 43 7 43 7 29 7 81 7 19 7 51 7 27 7 55 7 19 7 51 7 18 6591 7 3 7529 752 7 19 7 47 7 49 7 51 7591 7 77 7511 7 35 7 39 99 1613 9941616
68. 7 99A0191 1 Fuse 8A SB 38 99A1669 1 Board System with Jumper 250 500 Duplex 39 99A1666 1 Label Options 40 99A0413 2 Parts Packet Screw 41 99A0413 4 Parts Packet Screw NS 99A1129 1 Roller Duplex Pass Thru NS 99A0627 1 Jumper Engine Board 250 Duplex NS 99A0404 2 Parts Packet Retainer 6 mm Backup Roll NS 99A0413 2 Parts Packet Screw M3x6L G Supradrive Parts Catalog 7 57 4520 xxx Assembly 23 Duplex Unit continued 7 58 Service Manual 4520 xxx Asm Part Index Number 23 42 99A1290 42 99A1280 43 99A1634 43 99A1679 44 99A0435 44 99A1691 45 99A1672 46 99A0332 47 99A0307 48 99A0335 49 99A0334 50 99A0952 51 99A0413 52 99A0330 53 99A0269 54 99A0308 55 99A0404 56 99A0337 57 99A0319 57 99A1676 58 99A0404 59 99A0336 59 99A1692 60 99A1059 NS 99A0413 NS 99A0404 NS 99A0058 NS 99A1695 NS 99A0404 NS 99A1164 Units Description Top Cover Assembly Movable 250 Duplex Top Cover Assembly Movable 500 Duplex Top Cover Assembly Fixed 250 Duplex Top Cover Assembly Fixed 500 Duplex Guide Lower Entry 250 Duplex Guide Lower Entry 500 Duplex Guide Assembly Paper Decurl Guide Center Drive Upper Air Plenum Spring Decurl Shaft Bushing Decurl Shaft Frame Assembly 250 Duplex Parts Packet Screw Outer Frame Guide Assembly Center Drive Parts Packet Fan Mounting Kit Fan Cooling Duplex Parts Packet Retainer 5 mm Main Drive Main Drive Assembly Sensor Input Optical 250 Duplex Se
69. 8 99A1680 19 99A1579 20 99A1133 20 99A1134 21 99A0342 21 99A1682 22 99A1131 23 99A0341 24 99A0413 25 99A1668 25 99A1677 26 99A0316 27 99A0315 28 99A0325 29 99A0280 Parts Packet Cam Follower Assembly Kit Actuator Assembly Deflector Parts Packet Screw Actuator Mtg Guide Return RH Upper 250 Duplex Parts Packet Screw Guide Mounting Guide Return RH Lower 250 Duplex Guide Return RH Lower 500 Duplex Guide Upper 500 Duplex Tray Assembly Jam Removal 250 Duplex Tray Assembly Jam Removal 500 Duplex Guide LH Lower Return 250 Duplex Guide LH Lower Return 500 Duplex Guide Return LH Upper 250 Duplex Sensor Exit Optical Parts Packet Screw Upper Guide Base Assembly w Tray Bias 250 Duplex Base Assembly w Tray Bias 500 Duplex Shaft Duplex Drive Spring Duplex Shaft Gear Pass Thru Idler zech ech eck cL et echt ech sl Ki ech RI ech ek obo x ek sech K Q9 ek wb echt c Bearing Drive Shaft Low Parts Catalog 7 55 4520 xxx Assembly 23 Duplex Unit continued 7 56 Service Manual 4520 xxx a eee Units Description 23 30 99A0311 1 Cable Auto Connect Bottom 31 99A0274 1 Gear Pass Thru Drive Roll 32 99A0310 1 Cable Auto Connect Top 33 99A0413 4 Parts Packet Screw Main Frame Assembly Mounting 34 99A0317 1 Gear Duplex Bevel 35 99A0434 1 Pan Engine Board Drip 36 99A0279 1 Bearing Drive Shaft 3
70. 9 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 To remove the charge roll 1 Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 2 Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing 3 Remove the charge roll from the left side charge roll bearing and remove the roll from the printer Leave the paper wrapped around the charge roll until it is reinstalled FRU Action Charge Roll Assembly Check the charge roll for correct installation toner buildup marks cuts or other signs of contamination or damage Replace as necessary Left Side Charge Roll Link Check the left side charge roll link assembly for correct assembly operation Check for damage to the arm or bearing assembly 2 40 Service Manual 4520 xxx FRU Action 3 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 correc
71. 9 0325 99 0326 99 0328 99 0329 99 0330 99 0332 99 0334 99 0335 99 0336 99 0337 99 0340 99 0341 99 0342 99 0347 99 0349 99 0350 99 0382 99 0384 99 0385 99 0388 99 0389 99 0390 99 0392 99 0393 99 0394 99 0400 99 0404 99 0405 99 0408 99 0413 99 0419 99 0426 99A0427 99 0434 99 0435 99 0438 99 0445 99 0446 2 59 7 55 1 99 7 07 7 59 7 59 7 55 7 55 7 55 1 55 7 55 3 55 7 55 4 59 1 99 7 59 7 59 7 59 4 59 7 55 4553 7 55 7 35 7527 7 45 7 51 7 61 7 61 7 61 7 61 7 61 7 61 7 63 7 61 7 79 7 61 1 57 7 58 7 61 7 78 7 51 7 35 7 59 7 87 7 59 7 01 7 78 7 45 7 51 7 33 7 61 7 97 7 59 7 47 7 53 7 45 7 67 7 53 7 67 Index 5 4520 xxx 99A0447 7 51 99A0676 7 63 7 65 7 69 7 78 99A0448 7 45 99A0677 7 45 7 63 7 65 7 69 99A0450 7 45 7 53 7 71 7 78 99A0451 7 45 7 53 7 67 99A0678 7 71 99A0452 7 53 99A0679 7 45 7 71 99A0462 7 79 99A0681 7 63 99 0466 7 5 7 39 99A0684 7 69 99A0469 7 61 99A0685 7 65 99A0484 7 61 9940687 7 67 99A0485 7 61 99A0690 7 63 99A0487 7 61 99A0691 7 63 99A0488 7 61 99A0692 7 71 99A0489 7 61 99A0695 7 65 99A0491 7 61 99 0698 7 63 99A0492 7 15 99A0702 7 78 99A0494 7 61 99A0703 7 78 99A0512 7 29 7 78 99A0704 7 78 99A0513 7 29 7 78 99A0705 7 78 99A0545 7 76 99A0706 7 78 99A0549 7 5 99A0707 7 78 99A0556 7 7 99A0710 7 78 99A0560 7 77 99A0711 7 78 99A0565 7 15 99A0712 7 78 99A0566 7 15 99A0714 7 65 99A056
72. A1667 NS 99A1929 Units Description Cable 500 Auto Connect Bottom Wear Plate Pass Thru Roll Assembly Drive 500 Parts Packet Screw Wear Plate Mounting Retainer Roller Roller Skewed Backup Bearing Drive Roll Spring Power Takeoff Parts Packet Screw Board Mounting Parts Packet Retainer Aligner Assembly Bearing Drive Shaft Low Aligner Assembly Paper Gear Feed Roll Spring Switch Activate Spring Backup Roller Bellcrank Roller Release Gear Bevel Bearing Drive Shaft Cable 500 Auto Connect Top Stud Assembly 500 Frame Arm Paper Out 500 Washer Frame Mounting Deflector Base 500 Bracket 500 Tray Retention Spring Bellcrank 500 Option Tray a PY BR oa ow on on on 0 5 BA Mi h a a Parts Catalog 7 53 4520 xxx Assembly 23 Duplex Unit 7 54 Service Manual 4520 xxx am SEH Units Description 23 1 99A1674 Cover Engine Board 2 99A0322 Main Frame Assembly 250 Duplex 2 99A1693 Main Frame Assembly 500 Duplex 3 99A0324 Idler Assembly Belt Tension 4 99A0326 Spring Aligner 5 99A0323 Guide Assembly Paper 6 99A1675 Guide Assembly Paper 7 99A0314 Spring Chassis Ground 8 99A0413 Parts Packet Screw Motor Mount 3 mm 9 99A0328 Belt Motor 114 Gear 10 99A0329 Pulley Main Drive 96 54 Gear 11 99A0321 Motor Assembly DC Drive 12 99A1673 Cable D C Motor Tach 250 Duplex 13 99A0299 14 99A0312 15 99A0413 16 99A1130 17 99A0413 18 99A0340 1
73. Duplex Paper jams at Paper Removal Tray Paper fails to pass from lower option thru the Duplex Unit Paper skews in the Duplex Unit Go to the Duplex Unit Service Check on page 2 45 Symptom Table Envelope Feeder Symptom Action Envelopes do not feed from the envelope feeder Envelopes do not feed properly into base printer Go to the Envelope Feeder Service Check on page 2 48 2 38 Service Manual 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 Paper feed problems especially paper jams Go to Viewing the Error Log on page 3 10 and check the printer error log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option Paper feed problems with error message Use the Sub Error Codes for 9XX and 2XX Error Codes on page 2 8 to help diagnose the problem Print quality problems Go to Print Quality Test Pages on page 3 23 and print a test page to help diagnose problems before changing any settings or working on the printer Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options Diagnostic Information 2 3
74. Once the maximum pass count or fail count is reached the test stops with the power indicator on solid The results appear on the screen Parallel Wrap Test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the menu The power indicator blinks indicating the test is in progress The test runs continuously until canceled Each time the test finishes the screen updates If the test passes the Pass Count increases by 1 however if the test fails a message displays for approximately three seconds Once the maximum count is reached the test stops The power indicator goes on solid and the final results display 3 Press Return Stop to exit the test Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested Diagnostic Aids 3 13 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 The power indicator blinks indicating the test is running 3 This test runs continuously unless canceled by pressing Return Stop Each time the test
75. PPLY BOARD 4520 xxx High Voltage Power Supply Connector Pin No Signal CN1 Engine Board 1 Developer PWM 24 V dc Return Charge PWM 24 V IN TX PWM TX Enable TX CUR PWM 41 oi a AJ wy SVRO OUT 2 cs S 2 5 3 E E Sal n eum m p ar e CH oe l E CR 8 s sei d od HE tin dE am SE i Connector Locations 5 3 4520 xxx Engine Board Connector Pin No Signal J1 Main Fan Fan Stall Ground wo m Main Fan J3 Printhead Mirror Motor 24 V Return 24 V Return ReFREQ LOCKn Start 24 V dc Return NIOJ oO BR 24 V dc J4 Cover Closed Switch Cover Closed Ground m 45 V dc J5 Printhead Ground Video Ground 5 Phead LPOW Ground LADJ LFB NI 0 ay AJ LENA 5 4 Service Manual 4520 xxx Connector Pin No Signal J6 Output Level Sensor 1 HOPFULL Ground Opt2 AJOJN Ground
76. Packet Screw Auto Comp Assembly Mounting Arm Assembly Pick 2000 Roll Assembly Pick Base 2000 Option Parts Packet Screw Deflector Mounting Deflector Base 96 99A1055 97 99A0070 98 99A0692 99 99A0263 100 99A0678 101 99A0288 102 99A1812 103 99A1666 104 99A0677 Sensor Pass Thru Label Tray Option Number Label Options Parts Packet Washer Bracket 250 Frame Retention Mounting Ra ae oa on on an po a 105 99A0263 4 Parts Packet Screw Bracket 250 Frame Retention Mounting 106 99A0679 2 Bracket 250 Frame Retention NS 99A0717 1 Cable Paper Low Switch NS 99A0720 1 Cable Lower Limit Switch Parts Catalog 7 71 4520 xxx Assembly 26 Kiosk Vertical Paper Adapter 7 72 Service Manual 4520 xxx a Units Description 26 1 99A0231 1 Bail Support 2 99A1646 1 Arm Assembly Pivot 3 99A1819 1 Mounting Frame Assembly 4 99A0240 12 Parts Packet Retainer 5 99A0234 16 Parts Packet Screw 6 99A1705 1 Gear Idler 7 99A1704 2 Gear Idler 8 99A0197 1 Shaft Drive Rear 9 99A0079 1 Tray Assembly Backup Roller 10 99A0208 3 Parts Packet Pulley 11 99A0087 6 Spring Backup Roller 12 99A0086 6 Roller Backup 13 99A1706 1 Tray Assembly Drive Roller 14 99A0125 1 Frame Assembly Right Side 15 99A0232 1 Cover Right 16 99A1820 2 Belt 185G 17 99A0226 1 Guide Paper Exit 18 99A0122 2 Shaft Assembly Drive Roller 19 99A0137 1 Frame Assembly Left Side 20 99A0088 1 Cover B
77. Power Supply 51 99A0685 1 Bushing 52 99A0676 2 Parts Packet Nut 2 56 53 99A0654 1 Switch Paper Low 54 99A0651 1 Sensor Assembly Paper Out Upper Limit 55 99A0675 3 Parts Packet Screw Support 1 Frame 56 99 0659 1 Frame Printer Support 1 57 99A0695 1 Parts Kit Paper Size Switch Assembly 58 99A0677 2 Parts Packet Washer Sensor Bracket Mig 59 99A0675 2 Parts Packet Screw Sensor Bracket Mtg Parts Catalog 7 65 4520 xxx Assembly 25 High Capacity Feeder continued 7 66 Service Manual 4520 xxx Asm Part EH index Number Units Description 25 60 99A1793 3 Parts Packet Screw w washer Motor Mt 61 99A1794 3 Parts Packet Nut amp washer Drive Pulley Plate Motor Assembly DC Parts Packet Foot Stabilizer Parts Packet Mounting Feet Belt DC Motor Drive Idler Pulley Belt Tension 62 99A1795 63 99A0672 64 99A0687 65 99A1796 66 99A1797 67 99A1798 68 99A1799 69 99A1800 70 99A1801 71 99A1802 72 99A1803 73 99A1804 Plate Drive Pulley AC Receptacle Lower AC Pulley Drive Retainer C Clip AC Receptacle Upper AC Cover Top LVPS Nut w lock washer Top LVPS Cover Mounting 74 99A1804 1 Nut w lock washer Top LVPS Cover Mounting Grommet Top LVPS Cover Cable 250 Auto Connect Bearing Drive Shaft or a 2a oa on nin on P 75 99A1805 76 99A0281 77 99A0279 78 99A0273 79 99A0263
78. Roll Parts Catalog 7 29 4520 xxx Assembly 14 Electronics 1 7 30 Service Manual 4520 xxx Part index Number Units Description 14 1 1342514 1 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 1 1339535 1 Power Cord Set 8 ft U S Canada LV Nicaragua Venezuela Peru LV Bolivia Colombia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Panama Brazil LV AP English 1 1339538 1 Italy 6 ft Paraguay Uruguay Finland Norway Sweden 1 1342536 1 Power Cord Set 6 ft APG LV 1 1339537 1 Power Cord Set 8 ft U K Ireland 1 1339539 1 Power Cord Set 6 ft Israel Germany 1 1339540 1 Power Cord Set 6 ft Switzerland 1 1339541 1 Power Cord Set 6 ft South Africa 1 1339546 1 Power Cord Set 6 ft Two Prong Argentina HV 1 1342534 1 Power Cord Set 8 ft Chile HV 1 1339543 1 Power Cord Set 8 ft Denmark 1 1339542 1 Power Cord Set 6 ft Italy 1 1374067 1 Power Cord Set 8 ft Peru HV 1 1339544 1 Power Cord Set 8 ft Straight Argentina HV 1 1339545 1 Power Cord Set 8 ft Right Angle Argentina HV 1 1342530 1 Power Cord Set Brazil HV Paraguay HV Uruguay HV 2 99A2082 1 Fuse for 110 V ac LVPS 10a 2 99A2083 1 Fuse for 110 V ac LVPS 5a 2 99A2090 1 Fuse for 220 V ac LVPS
79. SDRAM DIMM 128MB SDRAM DIMM 2MB Flash DIMM 4MB Flash DIMM 8MB Flash DIMM Card Assembly 16MB Flash DIMM Card Assembly Bar Code Card Assembly Prescribe 5 4 2 Flash Card Assembly IPDS and SCS Tne Hard Disk with Control Board 5 0GB Adapter Card SES for SCS Cable Twinax Cable Coax Adapter Serial Cable Serial Board USB Parallel Port Card Assembly Image Quick Optra Forms Hard Disk with Control Board 4520 xxx Assembly 28 Options continued Asm Index 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 Part Number 99A1890 99A1647 99A1654 56P1100 99A0799 99A1605 99A1830 12G1696 12G1697 99A0560 99A1889 56P0161 56P0162 90A2485 99A1683 99A1684 99A1685 99A1686 56P1101 56P0161 56P0162 Units c c c cl cl c 0 4 c 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 o Description Tray Assembly 250 Special Media Rib Assembly 250 Special Media Tray Tray Universal Adjustable 250 Sheet Cartridge Empty Shipping T62X T52X Drive Forms HD 2 1GB or larger Kit Cap Stack Bails 500 Marke N2001e 10 100 Ethernet MarkNet N2002e 10Base2 10Baset MarkNet N2000t 4 16 Adapter Omnibus INA Card Paper Presentator Front INA Serial amp Parallel C Adapter Parallel 1284 C B Tray Assembly UAT 400 Sheet Card Assembly FORMS Flash DIMM 2mb Card Assembly FORMS Flash DIMM 4mb Card Assembly FORMS Flash DIMM 8mb Card Assembly FORMS Flash DIMM 16mb Cable Asse
80. Shaft Low Gear Feed Roll Gear Bevel Bearing Drive Shaft Cable 250 Auto Connect Option on Pa on 4 A A 0 5 Parts Catalog 7 45 4520 xxx Assembly 20 250 Sheet Tray continued 7 46 Service Manual 4520 xxx Asm Part Index Number 20 34 99A1601 35 99A0120 36 99A1536 37 99A0892 38 99A0119 39 99A1829 40 99A0121 41 99 0126 42 99A0124 43 99A1952 44 99A1537 45 99A0893 46 99A0127 NS 99A0286 NS 99A1928 NS 99A0438 NS 99A0278 Units Description Latch Back Restraint Restraint Pad Tray Assembly 250 Sheet Option Restraint Side 250 Sheet Tray Wear Strips Label Tray Option Number Clip 250 Tray Wear Finger Autosize Plate Snap In Label Paper Size Knob Paper Size Restraint Back 250 Sheet Tray Slider Autosize 250 Spring Backup Roller Spring Bellcrank 250 Tray Option Bushing Drive Roll T PA on Ra vm Bellcrank Roller Release Parts Catalog 7 47 4520 xxx Assembly 21 Integrated Paper Tray 250 Sheet 7 48 Service Manual 4520 xxx an Units Description 21 1 99A1536 1 Tray Integrated 250 Sheet 2 99A2160 1 Restraint Back 250 Sheet Tray 3 99A1894 1 Restraint Side 250 Sheet Tray 4 99A0119 4 Wear Strips 5 99A1812 1 Label Tray Option Number 6 99A0121 1 Clip 250 Tray Wear 7 99A0126 4 Finger Autosize 8 99A0124 1 Plate Snap In 9 99A0127 1 Slider Autosize 250 10 99A0120 2 Restraint Pad
81. Sub Error Code Data Note Explanation xx can be any value 84 1D The envelope feeder pass thru sensor activated but never x2 deactivated x1 Media Size x2 Media Source This error can be caused by an envelope over the pass thru sensor Remove the envelope and try to feed an envelope If the envelope stops over the pass thru sensor try the following Select the diagnostic test menu select input tray sensor tests select envelope feeder sensor test Check the envelope pass thru sensor to ensure it is operating correctly If the sensor test fails go to the Envelope Feeder Service Check on page 2 48 If the test passes look for anything that might cause the envelope to stop over the sensor 84 xx 1E x1 An envelope never activated the envelope feeder pass thru x2 sensor or the sensor never sensed the presence of an envelope x1 Media Size x2 Media Source Check to make sure the envelope feeds to the pass thru sensor Check to see if the envelope actuates the pass thru sensor flag 2 20 Service Manual 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 Stats Explanation Byte 4 00 No duplex error No problem was reported to the engine by the duplex system card 01 The leading edge of the sheet of paper never arrived at
82. a few Pels missing or broken run the LCD Test on page 3 11 from the hardware tests before continuing with this diagnostic service check Diagnostic Information 2 79 4520 xxx FRU Action 1 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 2 Operator Panel Display blank 5 beeps LED Off Check the voltage at J11 2 on the engine board It measures approximately 5 V dc If incorrect replace the engine board If correct replace the operator panel assembly 3 Operator Panel Display blank 5 beeps LED On Check for ground between J13 4 and ground If correct replace the operator panel assembly If incorrect replace the engine board 4 Operator Panel all diamonds No Beeps Check to make sure a card is not plugged in backward This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps 5 Operator Panel all diamonds 5 Beeps Check the voltage at Pin J11 1 and J11 3 The voltage measures approximately 5 V dc If incorrect replace the FRUs in the following order 1 Operator panel assembly 2 Engine board 2 80 Service Manual 4520 xxx Options Service Check Service Tip When you have a problem with any of the options installed in the options slots on the interconn
83. ackup Tray 21 99A0085 1 Tray Backup Roller Parts Catalog 7 73 4520 xxx Assembly 27 Kiosk Horizontal Paper Adapter 7 74 Service Manual 4520 xxx an Units Description 27 1 99A0231 1 Bail Support 2 99A1647 1 Arm Assembly Pivot 3 99A1819 1 Mounting Frame Assembly 4 99A2409 12 Parts Packet Retainer 5 99A0234 15 Parts Packet Screw 6 99A1705 1 Gear Idler 7 99A1704 2 Gear Idler 8 99A0197 1 Shaft Drive Rear 9 99A0079 1 Tray Assembly Backup Roller 10 99A0208 3 Parts Packet Pulley 11 99A0087 6 Spring Backup Roller 12 99A0086 6 Roller Backup 13 99A1707 1 Tray Assembly Drive Roller 14 99A0907 1 Frame Assembly Right Side 15 99A0232 1 Cover Right 16 99A1820 2 Belt 185G 17 99A0122 2 Shaft Assembly Drive Roller 18 99A0906 1 Frame Assembly Left Side 19 99A0088 1 Cover Backup Tray 20 99A0085 1 Tray Backup Roller Parts Catalog 7 75 4520 xxx Assembly 28 Options Asm Index 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 7 76 Service Manual Part Number 99A1752 99A1753 99A1754 99A1755 99A1756 99A1773 99A1757 99A1758 99A1759 99A1774 99A2486 99A2487 99A2200 99A2488 99A0629 13A0296 13A0297 99A0545 13A0298 99A0923 99A1182 99A2489 Units et 0 1 4 Description 4MB SDRAM DIMM 8MB SDRAM DIMM 16MB SDRAM DIMM 32MB SDRAM DIMM 64MB
84. activate the new setting Note When the printer PORs it does so in the normal mode 3 20 Service Manual 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 Sometimes this is used to help correct print quality problems Fuser Temperature This adjustment can be used to help solve some customer problems with paper curl on low grade papers and or problems with letterheads on some types of media The fuser temperature can be adjusted as follows NORMAL LOWER LOWEST Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5 The factory sets the warm up at 0 or no warm up time This time period lets the backup roll heat up and helps reduce curl in some environments Transfer The transfer can be adjusted to LOW MEDIUM HIGH Print Contrast The print contrast setting controls the developer voltage offset The print contrast can be adjusted to LOW MEDIUM HIGH Charge Roll The charge roll can be adjusted to LOW MEDIUM HIGH Diagnostic Aids 3 21 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 ins
85. age one contains a mixture of graphics and text Pages two and three only contain graphics If duplex is turned On the pages are duplexed otherwise the pages are printed on one side The Print Quality Test pages are printed in English and must always be printed on letter legal or A4 paper Note The print quality test pages can also be printed from the Configuration menu however a cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM Some diagnostic information may be printed on the pages when printing from this menu To run the Print Quality Test Pages Turn the printer off Press and hold Select and Return Turn on the printer Release the buttons once Performing the Self Test displays The printer performs its normal POR cycle then print one copy of the Print Quality Test pages If you want more than one copy perform these steps again ar Go The following is printed Diagnostic EP Setup fuser temperature warm up time transfer print contrast and charge roll settings Contents of the Diagnostic Error Log Printer configuration information printer serial number controller code level engine code level operator panel code level smart option code levels font versions and so on Values for the Quality Menu settings used to print the pages Diagnostic Aids 3 23 4520 xxx Print Test with RIP Controller Board Removed This ser
86. all with the paper out sensor flag positioned in the sensor slot on the paper tray board Paper Tray Paper Out Sensor Flag Removal 1 Remove the paper tray frame assembly 2 Remove the paper tray board 3 Remove the paper out sensor flag Paper Size Spring Comb Removal 1 Remove the paper tray board 2 Remove the paper size spring comb mounting screw and remove the spring comb Repair Information 4 49 4520 xxx Paper Alignment Assembly Removal Remove the upper paper deflector assembly Remove the inner paper deflector assembly Release the input paper sensor from its mounting and remove Remove the left door Remove the paper alignment assembly mounting screws A IRN A 104 4 50 Service Manual 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 B 99A0492 Repair Information 4 51 4520 xxx Paper Deflectors Removals Inner Paper Deflector Assembly Removal aaron gt Remove the paper tray Remove the upper deflector assembly Place the printer on its side Remove the lower deflector assembly Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector Upper Paper Deflector Assembly Remova
87. and check the voltage at J3 3 on the System board The voltage measures approximately 5 V dc If incorrect replace the envelope system board If correct replace the input sensor assembly Diagnostic Information 2 51 4520 xxx 990 Service Error envelopes fail to feed from the hopper FRU Action 1 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 2 Envelope Feeder System Check the voltage on J4 1 The Board voltage measures approximately 24 V If incorrect replace the envelope system board if correct measure the voltage at J4 6 The voltage measures approximately 5 V de If incorrect disconnect J4 and measure the voltage again If incorrect replace the envelope feeder system board If correct replace the D C motor assembly 260 Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls are not rotating FRU Action 1 Main Drive Belt Check the belt for correct installation and for signs of damage Replace as necessary 2 Gears Check all the gears for correct installation and for signs of damage Repair or replace parts as necessary 3 Clutch Latch Assembly Check the clutch latch assembly to make sure it moves freely 4 Master Cam Gear Master Check the master cam gear and Kick Gear ma
88. and slippage of the rollers FRU Action 1 Autocompensator Assembly Check the autocompensator pick arm rollers for any sign of glazing toner or other buildup Clean or replace as necessary Diagnostic Information 2 65 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 Service Tip Check the other paper sources to be sure they are operating correctly The base printer indicates a dead machine condition when the high capacity input tray is installed FRU 1 AC Line Cord AC Jumper HCIT to Printer AC input and Output Receptacles AC Wiring Harness Action If the base printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT check the AC jumper cord If defective replace the cord If not defective check the AC input and output receptacles and wiring harness in the HCIT Repair or replace the receptacles or AC wiring harness as required NOTE Make sure the ground wire is installed correctly from the AC wiring
89. ar l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 xii Service Manual 4520 xxx Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios en los dem s pa ses reune todas las condiciones expuestas en la norma IEC 60825 para productos l ser de Clase I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase 3b de arseniuro de gali
90. aserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse 3b laser som best r av gallium arsenlaserenhet som avgir str ling i bolgelengdeomradet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstraling ut over klasse under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte laser de classe que compleix els requisits d IEC 60825 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un laser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci l ser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites xvi Service Manual 4520 xxx Japanese Laser Notice L 3 icBiy 5 21 77 77 1 1 1 176 1 17 5 0 amp 1 82508
91. be caused by a failing exit sensor or system board 2 14 Service Manual 4520 xxx First 6 Bytes Sub Error Code Data Note Explanation xx can be any value 89 xx The fuser exit sensor bounced Check the exit sensor for correct operation Check the fuser DC cable to J14 on the system board Also the system board may be failing 8D 00 00 The fuser exit sensor was never activated by the leading edge of the media fed through the printer This error can be displayed after a 201 paper jam This can be caused by a defective fuser exit sensor assembly Enter the diagnostic tests menu select base sensor tests select output sensor test and check the fuser exit sensor for correct operation If the test fails check the internal fuser cabling DC autoconnect on the fuser frame fuser DC autoconnect to the system board cable and the cable connection to J14 on the system board 8E xx 02 x1 This error can be caused by the input sensor not being x2 activated by a page that was known to have been picked by a source other than the duplex option Ensure the correct source has been selected and the media is feeding from that source 8E xx 06 The second pick failed from a paper source when paper was in the source and the only sheet in the paper path 8b xx 07 x1 The second pick failed from a paper source when paper was in the source Other sheets may have started to feed but none wer
92. binet Printer Stand Filler Rear Top Piece Printer Stand Table Assembly Large Printer Stand Table Assembly Small 7 78 Service Manual 4520 xxx Assembly 29 Miscellaneous continued Asm Index 29 29 29 29 29 29 Part Number 99A0208 99A0234 99A0394 99A0462 99A1852 99A1853 Units Description Parts Packet Pulley Kiosk Parts Packet Screw Kiosk Grease Packet Nyogel 744 Grease Packet IBM 23 Packaging 4069 250 250 printer Packaging 4069 500 250 printer Parts Catalog 7 79 4520 xxx 7 80 Service Manual 4520 xxx Index A Acronyms 1 4 Adjustment Procedures 4 2 Duplex Motor Drive Belts 4 2 Fuser Solenoid 4 3 Gap Adjustment 4 3 Paper Alignment Assembly 4 5 Printhead Assembly 4 4 B Base Sensor Test 3 16 Button Test 3 11 Connector Locations Controller Board 5 10 Duplex Unit Board 5 18 Engine Board 5 4 Envelope Feeder Board 5 16 Fuser Board 5 12 High Voltage Power Supply 5 3 Interconnect Board 5 14 LVPS 5 1 Network Controller Board 5 11 Controller Board Connectors 5 10 D Diagnostic Aids 3 1 Device Tests 3 2 Disk Test Clean 3 3 Flash Test 3 4 Quick Disk Test 3 2 Diagnostic Mode 3 1 Duplex Tests 3 6 Duplex Feed 1 Test 3 9 Duplex Feed 2 Test 3 9 Duplex Motor Test 3 8 Duplex Quick Test 3 6 Duplex Sensor Test 3 7 Error Log 3 10 Clearing the Error Log 3 10 Viewing the Error Log 3 10 Hardware Tests 3 11 Button Test 3 11 LCD Test 3 11 Parallel W
93. ck for proper mechanical operation of the solenoid and associated hardware link and so on If correct check the resistance of the solenoid between J4 1 and J4 2 on the fuser control board The resistance measures between 5 ohms and 10 ohms If incorrect replace the solenoid assembly 2 LVPS Check the voltage at CN3 18 on the LVPS The voltage measures approximately 42 V dc If incorrect replace the LVPS 3 DC Fuser to Engine Board Check the continuity of the DC fuser to Cable engine board cable If incorrect replace the cable 4 Fuser Control Board Check for continuity between J4 2 and J1 5 and J4 1 and J1 7 on the fuser control board If incorrect replace the fuser control board 5 Interconnect Board If no problems are found with the fuser solenoid LVPS DC cable or fuser Engine Board control board replace the FRUs in the following order 1 Engine board 2 Interconnect board 2 60 Service Manual 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 A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly FRU Action 1 Input Sensor Flag Check the input senso
94. ck the voltage on the board at J4 2 green The voltage measures approximately 5 V dc If incorrect disconnect the cable at J4 and check the voltage again If incorrect replace the high capacity feeder option control board Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Option Control Board Run the sensor diagnostics for tray X X the number that represents the high capacity input tray If the test fails check the voltage at J3 1 gray The voltage measures approximately 24 If incorrect disconnect the paper low switch cable from J3 and measure the voltage again on J3 1 If incorrect replace the high capacity feeder option control board If correct check the cable for a short between pins 1 and 2 on the cable If incorrect replace the cable If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch Diagnostic Information 2 75 4520 xxx Excessive Noise or Vibration FRU Action 1 DC Motor Assembly Check to make sure all the motor plate mounting screws are tight 2 Idler Pulley DC Motor Assembly Check to make sure th
95. ct N A Ground PrtxDin Ground OI AJOJN PrtRxD Connector Locations 5 19 4520 xxx 5 20 Service Manual 4520 xxx 6 Preventive Maintenance This chapter describes procedures for printer preventive mainte nance Following these recommendations can help prevent prob lems and maintain optimum performance Safety Inspection Guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas of the machine Preventive Maintenance 6 1 4520 xxx Scheduled Maintenance
96. ctive 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 If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select the Quick Disk Test from the Device Tests menu The power indicator blinks while the test is in progress Quick Disk Test Test Passed message displays if the test passes and the power indicator turns on solid Quick Disk Test Test Failed message displays if the test failed and the power indicator turns on solid 2 Press Go Return or Stop to return to the Device Tests menu 3 2 Service Manual 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 Select Disk Test Clean from the Device Tests menu Files will be lost Go or Stop message displays to warn the user that all contents on the disk will be lost 2 To exit the test immediately and return to the Device Tests menu press Return Stop To continue with the test press Go f go is selected Disk Test Clean BAD 000000 00 message displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 3 The power indicator blinks du
97. e idler pulley is not binding on the pulley shaft Check the pulley for any signs of wear Check the idler pulley shaft on the motor mounting plate for any signs of damage or contamination 3 Drive Pulley Check the drive pulley for any signs of wear binds or damage to the pulley or pulley shaft Make sure the pulley turns freely on the pulley shaft 4 Motor Drive Belt Tray Drive Belt Check the DC motor drive belt for any signs of damage Check to make sure the belt is tracking correctly on the drive pulley idler pulley and motor pulley Check the tray drive belt for any signs of damage Check to make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys 2 76 Service Manual 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 Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come intact with the grease in the gearbox assembly FRU Action 1 Main Dr
98. e in the paper path 8E xx 08 The paper in the output bin was flushed The paper ahead of it in the paper path never made it past the output bin sensor or into the tray 8E xx 09 x1 The second pick from the MPT Tray 1 or feeder failed when paper was in the source Other sheets may be in the paper path x1 Media Source 8E xx 0A x1 The second pick from the MPT Tray 1 or feeder failed when paper was in the source Other sheets may have started to pick but none were in the paper path x1 Media Source Diagnostic Information 2 15 4520 xxx First 6 Bytes Sub Error Code d Data Note Explanation 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 8E xx 13 x1 Late feeding from a paper source interfered with the next pick x2 retry x 1 Media Size x 2 Media Source 2 16 Service Manual 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 Data Note Explanation Xx can be any value 920 Service Fuser Error Under temperature while printing EN 08 xx xx Actual Fuser Temperature 1 yy The temperature that the fuser wants to reach EN 22 2 When 22 00 The Hot Roll took too long to heat zz 01 The Hot Roll fe
99. e redrive assembly mounting latches B and remove the redrive assembly f mem Repair Information 4 55 4520 xxx Smart Contact Assembly Removal Disconnect smart cartridge cable Remove print cartridge Remove transfer plate Unlatch smart cartridge contact assembly A from the right frame assembly Remove smart cartridge contact B 6 Disconnect the smart contact assembly cable C from the engine board 4 56 Service Manual 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 Repair Information 4 57 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 Upper Paper Deflector Assembly Removal 1 Open the multipurpose tray and remove the tray from the two mounting posts 2 Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right 3 Remove the upper deflector assembly 4 58 Service Manual 4520 xxx Upper Front Cover Hinge Assembly Removal 1 2 3 Remove the upper front cover Remove the laser assembly cover Remove the C clips A from the upper front cov
100. eady state control in time 05 The Hot Roll did not reach operating temperature in time 923 Service Fuser Error Fuser over temperature EN 12 xx yy This sub error code is displayed anytime that the Hot Roll has 1 reached a higher than desired temperature EN xx Actual Fuser Temperature 2 yy The temperature that the fuser wants to reach 924 Service Fuser Error Open Thermistor Failure EN 18 xx This code is usually generated when an open circuit check is 1 made of the thermistor circuit in the fuser EN 00 xx Actual Fuser Temperature 2 2 18 Service Manual 4520 xxx First 6 Bytes Sub Error Code Data Note can be any value Explanation 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 This error code is generated anytime an incorrect lamp is zz 1 detected EN 2 xx 00 Lamp detection performed and found an error 01 It took long to do lamp detection and NVRAM detected a previous wrong lamp detected yy Actual Temperature zz The temperature that the fuser was trying to reach Envelope Feeder Sub Error Codes First 6 Bytes Sub Error Code Data Note can be any value Explanation 84 xx 17 There is an envelope in the feeder during POST Diagnostic Information 2 19 4520 xxx First 6 Bytes
101. eck input sensor and flag Diagnostic Information 2 9 4520 xxx First 6 Bytes Sub Error Code 1 Data Note Explanation 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 media feeding from the paper source is slipping or media is slipping in input to the printer 84 xx 04 The input sensor was covered during POST by a piece of media still in the machine when it was turned on Clear the media from the printer the base sensor test input sensor from the diagnostic tests menu to test the input sensor and flag for correct operation 84 xx 05 There was a media at the input sensor too early There was not enough time between printhead start and the printhead mirror motor to lock Possible causes for this error are Paper might be pre staged the paper source tray Paper is picking too fast A defective input sensor 84 00 06 A paper jam has been declared by a smart device Immediate stop homing not allowed 84 00 07 A paper jam has been declared by a smart device Homing was allowed before the stop 84 xx OB x1 The option tray pass thru sensor was never actuated by a x2 x3 piece of media x 1 media size x 2 media source x 3 paper source where paper jam was detected the sensor test for the option tray that is displaying t
102. ect board on a 212 414 616 the 010 and 010 at service level B have only one slot switch the non operating option to one of the other option slots to isolate the failure Flash Memory Option s Run copy the test page and check to see if the option you are checking is listed The printer does not recognize the option being installed if the option is not listed Check to make sure that the Memory card is installed correctly and is not broken or damaged If the Memory card is correctly installed not broken or damaged then run the Flash Test on page 3 4 If the test fails replace the Flash card If the problem continues replace the controller board DRAM Memory Option s This service check is the same as the flash memory option service check with the following exception Run the SDRAM Memory Tesi on page 3 12 from the menu if the SDRAM Memory card is correctly installed and not broken or damaged If the test fails replace the SDRAM card If the problem continues replace the controller board 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 Run the Quick Disk Test on page 3 2 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk Diagnostic Information 2
103. ed by the photoconductor cleaning blade and other parts inside the print cartridge FRU Action 1 Hot Roll Fuser Assembly Check the fuser assembly for signs of toner contamination The hot roll especially might cause toner to be retained and deposited on the page Print Quality Light Print Service Tip Check the toner saver and print darkness settings first if the print is light FRU Action 1 Transfer Roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 Right Side Transfer Roll Check the right side transfer roll arm Arm Assembly assembly bearing for any signs of wear or contamination Also check to HVPS ensure the transfer cable is firmly attached to the bearing If incorrect replace the right side transfer arm assembly Check the connection of the transfer roll assembly cable to the transformer on the HVPS board Check the continuity of the cable from the bearing to the spade terminal on the cable If incorrect replace the right side transfer arm assembly If correct replace the HVPS 3 Printhead A contaminated printhead may be the cause of light print If no other cause is found install a new printhead 2 98 Service Manual 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 car
104. embly Feed a sheet of paper and if the same error occurs after clearing the fuser or the same error occurs when no media is present check the exit sensor assembly internal fuser assembly cabling DC fuser cable to the system board and the cable connection to J14 on the system board TIP Turn the printer off enter the diagnostic tests menu and select the base sensor test Select output sensor and check the sensor for correct operation 89 xx 03 The fuser exit sensor did not detect the trailing edge of the media going through the fuser assembly This failure can be caused by a broken fuser exit sensor flag This may also be caused by erratic operation of exit sensor flag or exit sensor or a defective piece of media 89 xx 04 x1 The fuser exit sensor never actuated from the sheet going through the fuser before the next page begins feeding x 1 Media Size 89 xx 07 The narrow media sensor in the fuser was covered by a sheet of paper when not expected or a piece of media is in the machine during POST This error can occur when 202 paper jam has occurred Remove any piece of media that is over the narrow media sensor Try to feed a piece of paper through the printer could run the print test from the diagnostic test menu If the media stops over the narrow media sensor again check the flag and sensor for correct operation 89 xx OB x1 The fuser exit sensor may be bouncing This error can
105. en J3 1 Stpmtr A to J3 2 Stpmtr A The resistance measures approximately 10 ohms The resistance between J3 3 Stpmtr to 3 4 Stpmtr B measures approximately 10 ohms If the resistance is incorrect replace the stepper motor Check for shorts between windings on pins J3 1 to J3 2 and pins J3 3 to J3 4 If a short is found replace the stepper motor assembly If no short is found replace the duplex system board Diagnostic Information 2 47 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 Service Tip The envelope feeder receives its 5 V dc operating voltage from the 24 V dc bulk at J1 7 If 24 V dc is not present at J1 7 tray 1 is the only tray that is recognized Note If a260 Paper Jam Check Envelope message displays check the Sub Error Codes for 9XX and 2XX Error Codes on page 2 8 Printer does not recognize the envelope feeder as an attached input option FRU Action 1 Envelope Feeder Check to make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer 2 Front Autoconnect on Check the connector for signs of Printe
106. ensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Check these parts for signs of Spring Bevel Gear broken or damaged parts Feedroll Gear Drive Roll contamination on the drive rollers or Assembly Wear Plate wear plate and wear or damage to Drive Shaft Bearings and the drive shaft bearings Check the Skewed Backup Roller drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary Diagnostic Information 2 69 4520 xxx Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Input System Board Run the sensor diagnostics for tray X X the number that represents the high capacity input
107. er Feed 2 84 Parallel Port 2 86 Print Quality 2 88 Printhead 2 87 Serial Port 2 101 Smart Contact Assembly 2 100 Toner Sensor 2 102 Index I 3 4520 xxx Transfer Roll 2 103 Setting Configuration ID 3 20 Setting the Page Count 3 18 Status Messages 2 22 Symptom Tables 2 36 Base Printer 2 36 Duplex Unit 2 38 Envelope Feeder 2 38 High Capacity Feeder 2 37 Paper Trays 2 38 U Unique Tools 1 3 User Line 2 Link Messages 2 32 User Line 2 Messages 2 30 User Status Messages 2 22 V Viewing the Permanent Page Count 3 18 Part Numbers 12G1696 7 77 12G1697 7 77 13A0296 7 76 13A0297 7 76 13A0298 7 76 1339535 7 31 1339537 7 31 1339538 7 31 1339539 7 31 1339540 7 31 1339541 7 31 1339542 7 31 1339543 7 31 1339544 7 31 1339545 7 31 1339546 7 31 1342514 7 31 1342530 7 31 1342534 7 31 1342536 7 31 1374067 7 31 43 5248 7 31 56 0150 7 25 56 0161 7 77 1 4 Service Manual 56P0162 56P0188 56P0189 56P0190 56 191 56 1004 56P1005 56P1049 56P1100 56P1101 56P1139 90A2485 99A0004 99A0007 99A0026 99A0028 99A0039 99A0053 99A0058 99A0062 99A0063 99A0070 99A0071 99A0073 99A0074 99A0075 99A0076 99A0079 99A0081 99A0082 99A0083 99A0084 99A0085 99A0086 99A0087 99A0088 99A0089 99A0104 99A0119 99A0120 99A0121 99A0122 99A0124 99A0125 99A0126 99A0127 99A0134 7 71 7 33 7 33 7 33 7 33 7 33 7 33 1 2 7 27 2 71 7 17 2 4 1 57 1 71 7 3 7 3 7 9 7245 7 51 75
108. er Option installed at J1 on the board Check System Board the cables damaged or loose wires Disconnect the motor Check for a short between each pin and the motor housing If a problem is found replace the motor assembly If no problem is found measure the resistance between the following pins on the motor cable connector Pins 1 brown and pin 2 Yellow The resistance measures between approximately 7 5 and 10 5 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder option system board 2 72 Service Manual 4520 xxx The elevator moves in one direction only FRU Action 1 DC Drive Motor Check the voltages at J1 on the high 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 J1 2 Yellow Approximately 24 V dc Motor Running Reverse J1 1 Brown Approximately 24 V dc J1 2 Yellow Approximately 0 V dc If any of the voltages are incorrect disconnect the motor and measure the resistance between J 1 and J 2 The resistance measures between 7 5 and 10 5 ohms If incorrect replace the motor If correct replace the system board Diagnostic Information 2 73 4520 xxx Paper size switch not selecting paper size that is selected FRU Acti
109. er Setup Reset Maintenance Count screen Diagnostic Aids 3 19 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 However the Configuration ID is the only diagnostic function displayed until a valid ID is entered To set the Configuration ID 1 Enter the Diagnostic mode 2 Select Configuration ID from the Printer Setup menu The current ID displays on the screen The Configuration ID is on a label located inside the printer The label is attached to the top front cover hinge assembly and is visible when the top front cover is open The leftmost digit blinks indicating that it is the first digit to be changed 3 To change the value press either Menu until the value you want is reached Press Select to move to the next digit or press Select again to skip a digit Change each digit as required When the last digit is changed press Select to validate the Configuration ID If the ID is invalid then INVALID ID message displays on Line 2 before the ID redisplays You have to reenter the Configuration ID until a valid ID is verified If the ID is valid then the ID is saved in NVRAM and the printer automatically PORs to
110. er 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 Detach the two springs B from the upper front cover hinges Disconnect the operator panel cable from the operator panel assembly Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket C Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket Remove the upper front cover hinge assembly m Repair Information 4 59 4520 xxx Upper Front Cover Interlock Switch Assembly Removal Remove the upper front cover Remove the operator panel Remove the inner EMC shield Ron 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 4 60 Service Manual 4520 xxx 5 Connector Locations Low Voltage Power Supply Connector CNS Interconnect Board Pin No Signal 1 5 V 2 5 V 3 Ground 4 Ground 5 Ground 6 Ground 7 24 8 24 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc Connector Locations 5 1 4520 xxx POWER SU
111. er que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi e La informaci pel manteniment d aquest producte esta orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients Notices and Safety Information xxi 4520 xxx Chinese Safety Information e Lexmark IA Ze Er HERB MARE Ae ATT At ERS Lexmark RI e AP ERS A EA H3 AP MED AMIN IR TEA HR A 81521175 Bikes DAA FRE Korean Safety Information ete ASS 5 Lexmark HA 259 Af Sol 9 01 9251 EFA PSS AA BASS S S H aH Ho et gd SS Lexmarke F Ost MAS A gsc 0 HZA ztet PA ho SA BE MHA o NEIE Ares MAHE e HES HASA Bue 25 47 S4S WALL AME US YHo ANHE Me All 0 AAS SISH Best aas oz P tin Ozone Information This product does not produce measurable amounts of ozone gas xxii Service Manual 4520 xxx Preface This manual is divided into the following chapters General Information contains a general descript
112. erconnect board If correct turn the printer off and reconnect one cable at a time until you find the defective assembly Service Tip A short or low resistance load that is attached to the engine board can cause the LVPS to over current and shut the 5 V dc supply down to 0 V dc 2 44 Service Manual 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 FRU Action 1 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 between the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly no short is found replace the system board 2 Autoconnect Cables Check the autoconnect cables for Connectors damage to the cables or the pins in the connectors If damaged replace the cable s If no damage is found check to make sure the cables are connected to J9 J10 J11 and J12 on the duplex system board If no problem is found replace the duplex System board Diagnostic Information 2 45 4520 xxx POST fails 230 Paper Jam Check Duplex message displays FRU Action 1 Duplex D C Servo Drive Motor Check the D C servo motor cables fo
113. erconnect card connector This error may also be caused by a noisy AC input power source Be sure the correct LVPS has been installed If all the above are correct replace the LVPS assembly 941 Controller Code CRC A 941 error can be created by a defective code overlay card a code upgrade a defective IPDS or a PRESCRIBE card These should be checked before replacing the controller board 941 Controller Font CRC Replace the controller board 943 Controller Font Version Indicates that the controller code and FONT ROM are incompatible 944 Controller Board Failure Replace the controller board 945 Controller Board Failure ASIC Failure Replace the controller board 946 Controller Board Failure SRAM Failure Replace the controller board 947 PQET Error Replace the engine board 948 PEL Clock Error Indicates the PEL clock check failed Replace the engine board 949 Delay Line Indicates a delay line calibration failure Replace the Calibration engine board Failure 953 NVRAM Indicates the NVRAM chip on the engine board has Failure failed Replace the engine board 954 NVRAM Indicates the NVRAM experienced a CRC failure Failure Replace the engine board Diagnostic Information 2 5 4520 xxx Error Code Action 956 957 959 System Board Error codes 956 thru 959 are system board failures Perform a power on reset POR
114. ervice Manual 4520 xxx 202 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 Repair Information 4 31 4520 xxx Fuser Detack Housing Assembly Removal Remove the fuser assembly Remove the fuser cover assembly Remove the fuser lamp Use care when handling the lamp Disengage the hot roll bearing clips to free the fuser frame walls Gently apply outward pressure on the left and right fuser side frames to release the detack housing assembly Fuser Transfer Plate Removal Remove the upper paper deflector Remove the fuser transfer roll Remove the inner paper deflector Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting Remove the fuser transfer plate A 4 32 Service Manual 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 on page 4 3 whenever you replace the fuser solenoid Repair Information 4 33 4520 xxx Fuser Narrow Media Sensor Flag Assembly Removal 1 2 3 6 Remove the fuser assembly
115. es are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair Information 4 1 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 Too little belt tension can result in belt slippage To do the duplex drive belt adjustment 1 2 3 4 Do the removal procedure Duplex Front Cover Door Removal on page 4 19 to access the drive belt idler pulley Loosen the idler pulley mounting screw and position the idler to provide 3 mm 5 mm drive belt deflection Tighten the idler pulley mounting screw being careful to maintain the adjustment Reassemble the duplex unit To do the duplex motor belt adjustment 1 2 3
116. ew Card Asm Mounting 25 99A0392 1 Kit Door Switch Spring and Bumper 26 99A0677 1 Parts Packet Washer Door Switch Spring Mounting 27 99A0676 1 Parts Packet Nut Door Switch Spring Mounting NS 99A0690 1 Cable Optical Sensor Parts Catalog 7 63 4520 xxx Assembly 25 High Capacity Feeder continued 7 64 Service Manual 4520 xxx 115 SEH Units Description 25 28 99A0188 3 Guide Rear Paper use with 99A0219 29 99A0675 6 Parts Packet Screw Top Frame Mounting 30 99A0219 1 Frame Assembly Top with labels 31 99A0675 2 Parts Packet Screw 32 99A0677 2 Parts Packet Washer Top Frame Clamp 33 99A0719 1 Clamp Top Frame Mounting 34 99A0676 2 Parts Packet Nut Base Mounting 35 99A0677 2 Parts Packet Washer Base Mounting 36 99A0675 2 Parts Packet Screw Base Mounting 37 99A0663 1 Pulley Idler 38 99A0664 1 Belt Drive 39 99A1807 1 Cable AC Internal Wiring 40 99A0676 2 Parts Packet Nut 2 56 Switch Mounting 41 99 0653 1 Switch Lower Limit Microswitch 42 99A0676 2 Parts Packet Nut Power Supply Ground 43 99A0677 4 Parts Packet Washer Motor Plate Mtg 44 99A1808 1 Cord AC External Jumper 45 99A0676 2 Parts Packet Nut Power Supply Cover 46 99A0714 1 Cover Power Supply 47 99A0675 2 Parts Packet Screw Power Supply Bd Mtg 48 99A0677 2 Parts Packet Washer Power Supply Board 49 99A0667 1 Power Supply Board 50 99A0715 1 Cable Low Voltage
117. ge is correct check the continuity between J4 1 and J4 3 on the cable If no change in continuity occurs as the switch is activated replace the cover open switch cable assembly If the continuity changes as the switch is activated replace the engine board 2 42 Service Manual 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 Check on page 2 66 If the base printer continues to not operate correctly remove any other attached paper handling options Observe all necessary ESD precautions when removing and handling the controller board engine board or any of the installed option cards or assemblies Note If the LVPS is blowing fuses remove the LVPS from the printer Check the metal LVPS shield for signs of damage that causes the shield to touch components on the LVPS board assembly FRU Action 1 Line Voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 AC Line Cord Check the line cord for any signs of damage If correct check the continuity of the line cord and replace if necessary 3 5 Vdc at any Option Check for 5 V dc on any of the Connector option connectors The easiest to access is the envelope feeder connector located behind the lower front door If 5 V dc is
118. h capacity feeder to be recognized If the voltage is correct check the voltages at J11 3 red and J11 4 red The voltages measure 24 V dc If correct replace the high capacity feeder option system board If incorrect disconnect J8 from the system board and measure the voltages again If incorrect check the LVPS cable and the A C internal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to each pin on the motor connector If you find a short between any pin and the motor housing replace the motor assembly If no shorts are found replace the high capacity feeder option control board Check the voltage at J9 1 light blue The voltage measures approximately 24 V dc If incorrect disconnect the cable at J9 and check the voltage again If the voltage continues to be incorrect replace the high capacity feeder option System board If the voltage measures correctly check the cable If the cable is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board 2 68 Service Manual 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 FRU Action 1 Pass Thru S
119. harness to the frame of the HCIT and the nut and lock washer are tightened 2 66 Service Manual 4520 xxx The base printer does not recognize that the high capacity input tray is installed FRU Action 1 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 Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly 2 Base Printer or option Check the option or base printer mounted above autoconnect for signs of damage Repair the high capacity option autoconnect as necessary 3 LVPS Check the voltages at J11 2 and Option System Board J11 4 The voltage measures 24 V de If the voltage is correct replace the high capacity system board assembly If the voltage is incorrect check the continuity of the AC input cable to the LVPS If correct replace the LVPS assembly If incorrect replace the AC cable to the input of the LVPS Diagnostic Information 2 67 4520 xxx FRU Action 4 High Capacity Feeder Option Control Board Check the voltage on J8 1 green 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 hig
120. he error code and check the pass thru sensor for that tray for correct operation Check for paper picking from the selected paper input source H the error is being detected from a lower paper source see if paper is feeding correctly from a paper source above the detected source 2 10 Service Manual 4520 xxx First 6 Bytes Sub Error Code Xx can be any value Data Note Explanation 84 xx Of x1 2 x3 The option Tray pass thru sensor was never deactivated 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 Check to see if paper has cleared the pass thru area of the option where the paper jam occurred 84 00 10 The main motor ID failed to identify either motor after two tries Possible causes for this error are main drive motor has stalled An incorrect main drive motor gearbox assembly has been installed 84 xx 17 There is an envelope or envelopes in the envelope feeder during warm up An envelope may have partially fed from the envelope feeder Remove any envelopes from the feeder and check the envelope feeder for correct operation 84 xx 18 There is media over the Tray 2 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 2 and see if Tray
121. he fuser control board If correct go to step 3 3 Fuser to Engine Board DC Cable Check the continuity of the cable If incorrect replace the cable If correct go to step 4 2 58 Service Manual 4520 xxx FRU Action 4 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 If correct go to step 5 5 Fuser Hot Roll Examine the fuser assembly for Fuser Hot Roll Bearings signs of overheating or damage Fuser Backup Roll Check the hot roll and backup roll for Bearings signs of excessive toner label glue Fuser Backup Roll labels or other contaminants If Fuser Mechanical Parts problems are found with the hot roll or backup roll replace the failing roll If other problems are found replace the fuser assembly Diagnostic Information 2 59 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 FRU Action 1 Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid can be observed by removing the redrive assembly Che
122. he printer Open the printer rear door to access the jam Paper is jammed around Tray X X tray 1 thru 5 Try opening Tray X If the tray is difficult to remove then you may have to remove the tray above or below tray X to remove the jammed pages Paper is jammed in the multipurpose feeder 260 Paper Jam Check Envelope Feeder Paper is jammed in the envelope feeder 27X Paper Jam Check Output Paper is jammed in output bin Open the rear door to access the jammed pages Insert Cartridge or Close Door This message displays when the printer front door is open or the print cartridge is missing If this message cannot be cleared go to Cover Open Switch Cable Service Check on page 2 42 31 Defective Print Cartridge Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is defective Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print they are not reprinted once a good print cartridge is inserted Note This error indicates the printer was able to read the cartridge ID but the ID did not pass the verification test To pass the verification test the ID read from the print cartridge must match the ID from the last good print cartridge or the same ID must be read from the
123. he sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for any signs of damage or binds If incorrect replace the flag If the flag is operating correctly check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the envelope system board correct check the voltage at J3 2 The voltage changes from 0 to 5 V when the flag is moved in and out of the sensor If incorrect replace the sensor assembly If this does not fix the problem replace the envelope system board 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 FRU Action 1 Envelope Out Hopper Check the envelope out sensor flag Sensor Flag for damage correct installation and operation If incorrect repair or replace the flag 2 Envelope Out Hopper Input Check the sensor to make sure it is Sensor installed correctly and the sensor cable is properly connected to the envelope system board If correct perform the Envelope Feed Sensor Test to check both the sensor and flag If the test fails remove any envelopes in the hopper turn the printer off and disconnect J3 from the system board Turn the printer on
124. heck Bin x Paper is jammed in output bin Generally this message appears when the paper has not cleared the exit sensor in time has jammed in the redrive assembly or has not fed into the output bin Diagnostic Aids 3 29 4520 xxx 3 30 Service Manual 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 Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tabl
125. ignal J1 Engine Board NarMedia ThermGnd HRTherm Ground ThumpA 5 V ThumpB 41 AJ AJ wy ExitSns J2 Thermistor ThermGnd HRTherm J3 Thumper Ground 42 V de J4 Thumper Solenoid ThumpB ThumpA J5 Narrow Media Sensor 5 12 Service Manual 5 V Nar Media Ground 4520 xxx OOOOOOOO Connector Locations 5 13 4520 xxx Interconnect Board Connector Pin No Signal 42 LVPS k 42 V dc Heaton Xeroxing 24 V dc 24 V dc 24 V dc Ground Ground Oo 41 oO ay AJ OJN Ground Ground J3 LVPS Ground Ground Ground Ground 5 V dc 5 V dc N 5 5 V 45 Autoconnect 24 V dc Ground J6 Engine Board N A J7 Controller Board N A J11 INA 1 N A J12 INA 2 N A 5 14 Service Manual 4520 xxx 210 220 BAR CODE AREA 001 002 BAR CODE AREA Connector Locations 5 15 4520 xxx Envel
126. ion Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF Fuser Temperature Set to NORMAL Test the printer using plain paper 20 Ib An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Measure all voltages from the connector to printer ground All voltages measured during the print cycle are measured with the controller board removed while running the print test 2 88 Service Manual 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 FRU Action 1 High Voltage Contacts Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted contaminated or damaged If incorrect replace the contact with one from the HV contact kit Screws are included to attach the contacts to the right side frame in the HV contact kit 3 Charge Roll Conductive Check to make sure the charge roll Bushing bushing is correctly installed in the right charge roll arm 2 HVPS Check the voltages 10 1 thru J10 8 If incorrect replace the engine board 3 HVPS Cable Check
127. ion 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 Diagnostic Information contains a service error code table user status message table user error message table symptom table and service checks used to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Printer operation information is provided to enhance the tests and checks Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains safety inspection guidelines lubrication specifications and maintenance information to prevent problems and maintain performance Parts Catalog contains illustrations and part numbers for individual FRUs Preface 4520 xxx Service Manual 4520 xxx 1 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 Lexmark T522n 4520 220 Network
128. itioner 6 99A2039 1 Fuser Board Assembly 7 99A1551 1 Sensor Exit 8 99A2033 1 Cover Fuser Assembly with Thermistor 9 99A2062 1 Cable Engine Board to Fuser Board 10 99A1651 1 Sensor Narrow Media 11 99 2061 1 Cable Fuser Fuser to LVPS Parts Catalog 7 43 4520 xxx Assembly 20 250 Sheet Tray 7 44 Service Manual 4520 xxx am bd Units Description 20 1 99A0263 Parts Packet Screw Option Board 2 99A1967 Board Option Tray 3 99A0627 Jumper pin 4 99A0263 Parts Packet Screw Switch Spring 5 99A0063 Spring Switch Activate 6 99A0445 Stud Assembly 250 Frame 7 99A0448 Arm Paper Out 250 8 99A0263 Parts Packet Screw Auto Comp Mounting 9 99A1054 Pick Arm Assembly 10 99A0277 11 99A0263 12 99A0276 13 99A0451 14 99A0282 15 99A0450 16 99A0350 17 99A0679 18 99A0677 19 99A0263 20 99A0070 21 99A1638 22 99A0026 23 99A0419 24 99A0058 25 99A0288 26 99A1666 27 99A0272 28 99A0275 29 99A0280 30 99A0274 31 99A0273 32 99A0279 33 99A0281 Wear Plate Pass Thru 250 Tray Parts Packet Screw Wear Plate Mounting Roll Assembly Drive 500 Dual Roller Skewed Backup Cable 250 Tray Option Retainer Roller Sensor Paper Low Bracket 250 Frame Retention Parts Packet Washer Parts Packet Screw Roll Assembly Pick Base 250 Option Tray Bias Arm Assembly Spring Tray Bias Pad Machine Mounting Sensor Option Pass Thru Label Options Shaft 250 Drive Spring Power Takeoff Bushing Drive
129. ive Assembly Remove the controller board and run Excessive noise or a Diagnostic Print Test in the vibration continuous mode Check the main drive assembly for any excessive noise or vibration Determine if the noise is in the main drive toner cartridge fuser or main drive gearbox Look for any loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary 2 Main Drive Motor Assembly A service error code 936 Transport Excessive noise gears Motor may be displayed Check the ratcheting and so on voltage at J12 6 on the engine board It measures approximately 5 V dc when the motor is not running and goes to 0 V dc when the motor is running If incorrect replace the engine board If this does not fix the problem replace the main drive motor 3 Main Drive Motor Cable Check the continuity of the main drive motor cable If incorrect replace the cable Diagnostic Information 2 77 4520 xxx FRU Action 4 Motor does not turn no gear error code 936 or User message 201 Paper Jam displays Check the voltages at J12 on the engine board 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 static 0 V dc when main drive motor running J12 6 5 V static 2 5 V dc when main drive motor running J12 5 5 V dc static 0 V dc when main drive motor run
130. l 1 2 3 Open the multipurpose tray and remove the tray from the two mounting posts Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right Remove the upper deflector assembly 4 52 Service Manual 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 Remove the two paper size sensing board mounting screws A 3 Remove the paper size sensing board wm LA gt A A 102 Pick Roll Removal 1 Remove the upper paper deflector 2 Release the pick roll retaining tab and slide the pick roll off the shaft Repair Information 4 53 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 B 425 4 54 Service Manual 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 th
131. l assembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Parallel Port Service Check Run the Parallel Wrap Test on page 3 13 Note The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128 and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately three seconds If the test indicates that a problem is detected replace the controller board 2 86 Service Manual 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 Print the error log and see if 201 or 931 errors are logged Service Error Code Explanation 1 Error Code 931 These errors usually indicate a No first HYSNC Signal failure in the HYSNC signal to the Error Code 932 printhead Check the continuity of Lost HYSNC the cables connected to J3 and 48 on the engine board If incorrect replace the defective cable The voltage at J8 1 measures approximately 5 V If incorrect replace the engine board The voltage at J3 7 measures approximately 24 V
132. le Assembly 3 99A0053 1 Sensor Input 4 99A2079 1 Pick Arm Assembly 500 210 220 4 99A2157 1 Pick Arm Assembly 250 001 002 5 99A2071 1 Sensor MPT Paper Out 6 99A2079 1 Pick Arm Assembly 500 210 220 6 99A2157 1 Pick Arm Assembly 250 001 002 7 99A2438 1 MPT Solenoid 8 99A2042 1 Engine Board Assembly 9 99A2055 1 Cable Front Harness 10 99A2045 1 Power Supply High Voltage 11 99A2087 1 Smart Contact Assembly 12 99A0466 1 Sensor Toner Cartridge Level NS 99 2059 1 Cable Deflector Parts Catalog 7 39 4520 xxx Assembly 18 Electronics V 7 40 Service Manual 4520 xxx ae Ebor Units Description 18 1 99 2026 1 Printhead Assembly Includes All Cables 2 99A2056 1 Cable Laser 3 99A2042 1 Engine Board Assembly 4 99A2046 1 Interconnect Board Assembly 5 99A2067 1 Solenoid Assembly Envelope Conditioner 6 99A2039 1 Fuser Board Assembly 7 99A1551 1 Sensor Exit 8 99A2033 1 Cover Fuser Assembly with Thermistor 9 99A2062 1 Cable Engine Board to Fuser Board 10 99A1651 1 Sensor Narrow Media 11 99 2061 1 Cable Fuser Fuser to LVPS Parts Catalog 7 41 4520 xxx Assembly 19 Electronics VI 7 42 Service Manual 4520 xxx Units Description 19 1 99A2026 1 Printhead Assembly Includes All Cables 2 99A2056 1 Cable Laser 3 99A2042 1 Engine Board Assembly 4 99A2046 1 Interconnect Board Assembly 5 99A2067 1 Solenoid Assembly Envelope Cond
133. les NS 99 0263 3 Parts Packet Screw Printhead Mounting Parts Catalog 7 9 4520 xxx Assembly 4 Paper Feed Autocompensator 7 10 Service Manual 4520 xxx eg Units Description 4 1 99A2070 1 Sensor Paper Out Internal Tray 2 99A2079 1 Pick Arm Assembly 500 210 220 2 99A2157 1 Pick Arm Assembly 250 001 002 3 99A0070 2 Pick Rolls 4 99A1616 1 Flag Paper Out 500 Tray 4 99A1609 1 Flag Paper Out 250 Tray 001 002 5 99A1927 1 Spring Bellcrank Internal 250 5 99A1930 1 Spring Bellcrank Internal 500 NS 99 0263 1 Parts Packet Screw Hanger Parts Catalog 7 11 4520 xxx Assembly 5 Paper Feed Multipurpose Unit 7 12 Service Manual 4520 xxx 112 Units Description 5 1 99A0075 1 Screw Socket Set M4X5 mm 2 99A0071 1 Arm Assembly MPT 3 99A0076 1 Pick Roll Assembly 4 99A0081 1 Spring Assembly Separator 5 99A0083 1 MPT Pad Separator Arm Assembly 6 99A2092 1 Deflector Assembly MPT 7 99 1531 1 Deflector Lower 8 99A0263 2 Parts Packet Screw Lower Deflector Mounting 8 mm 8 99A0263 2 Parts Packet Screw Lower Deflector Mounting 12 mm 9 99 0084 1 Flag MPT Paper Out 10 99A0082 1 Plate Assembly MPT 11 99A2071 1 Sensor MPT Paper Out 12 99A0073 2 Screw Damper 13 99A0263 1 Parts Packet Screw Frame Mounting 14 99A2027 1 Solenoid Assembly MPT 15 99A0074 2 Bushing Pick Roll Shaft NS 994 0267 2 Parts Packet Clip
134. lex motor test continues to run until the printer is powered off The power indicator blinks while the test is running The duplex unit runs the motor at a high speed and then a low speed and takes an average of the power required for each speed After all the information is computed the motor turns off DUPLEX MOTOR AA BB CC DD EE FF appears on the printer display To pass the test the following results must display AA 00 BB in the range of 20 through inclusively hex CC in the range of 3A through 5D inclusively hex DD in the range of 11 through 1F inclusively hex Ignore bytes EE and FF If the test fails remove the drive belt from the duplex D C motor and run the motor test again For the duplex D C motor to pass the test the following results must display AA 00 BB the range of 29 through inclusively hex CC in the range of 35 through 51 inclusively hex DD in the range of OC through 13 inclusively hex For the duplex drive system to pass the test the following results must display AA 00 BB in the range of 29 through inclusively hex CC in the range of 3A through 5D inclusively hex DD in the range of 11 through 1F inclusively hex 2 Press Return Stop to exit the test 3 8 Service Manual 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 f
135. ll too far below the desired temperature while printing zz 02 The Hot Roll was too cool while the system was doing some checking zz 03 The Hot Roll was too cool when heating to the desired temperature 921 Service Fuser Error Fuser under temperature while at standby EN 41 xx xx Actual Fuser Temperature yy The temperature that the fuser wants to reach EN zz 22 00 The fuser temperature did not change enough from the 2 fuser lamp temperature at turn on 01 The fuser temperature rose more than desired from the fuser temperature at turn on 922 Service Fuser Error Fuser failed to reach standby temperature Diagnostic Information 2 17 4520 xxx First 6 Bytes Sub Error Code Data Note Explanation xx can be any value EN 42 xx yy xx Actual Fuser Temperature 1 yy The temperature that the fuser wants to reach EN 21 22 22 00 The fuser temperature did not change enough from the 2 fuser lamp temperature at turn on 01 The fuser temperature rose more than desired from the fuser temperature at turn on z2 00 The Hot Roll did not reach standby temperature in time during standby 01 The Hot Roll took too long to reach the beginning lamp detection temperature 02 The Hot Roll reached final lamp detection temperature but took longer than expected 03 The Hot Roll timed out trying to reach the final lamp detection temperature 04 After Hot Roll lamp detection did not reach st
136. lla 770 795 nanometria Laserj rjestelm ja kirjoitin on suunniteltu siten etta kayttaja ei altistu luokan maarityksia voimakkaammalle s teilylle kirjoittimen normaalin toiminnan kayttajan tekemien huoltotoimien tai muiden huoltotoimien yhteydessa VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Ala katso sateeseen VARNING Osynlig laserstralning nar denna del ar ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare ar i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 Laserprodukter i Klass anses ej halsovadliga Skrivaren har en inbyggd laser av Klass 3b som best r av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk f r att n gon person uts tts f r laserstralning ver Klass l niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Notices and Safety Information Xv 4520 xxx Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt samsvar med kravene IEC 60825 Klasse l l
137. mbio di altri produttori Leinformazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Notices and Safety Information xix 4520 xxx Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen Pautas de Seguridad e Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas
138. mbly Repair Information 4 39 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 A 203 3 Pull the LVPS assembly from the right side of the printer 4 40 Service Manual 4520 xxx 4 Press the release latch on the fuser lamp cable connector B and disconnect from the LVPS 5 Remove the fuser assembly Repair Information 4 41 4520 xxx 6 Disconnect the interconnect card cable from the LVPS C 7 Remove the LVPS 4 42 Service Manual 4520 xxx Main Drive Assembly Removal ark 7 8 9 10 Remove the inner EMC shield Remove the gear guard Remove the developer drive assembly Remove the transfer shaft A through the bottom of the printer Remove all cables from the cable clamps B on the main drive assembly Remove the ground screw C and remove the engine board shield Remove the main drive assembly mounting screws D Remove the link from the rear of the main drive assembly Disconnect the cable from the main drive motor Remove the main drive assembly Note Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly D 102 A Repair Information 4 43 4520 xxx Main Drive Motor Removal 1 Remove the main drive assembly 2 Remove the main drive motor mounting screws A 3 Remove
139. mbly 6 Parallel A C Cable Assembly SER PAR 1284C INA Cable Parallel 1284 C B Adapter Parts Catalog 7 77 4520 xxx Assembly 29 Miscellaneous Asm Index 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 Part Number 99A1633 99A0585 99A0267 99A0268 99A0269 99A0299 99A0271 99A0404 99A0413 99A0572 99A0577 99A0675 99A0676 99A0677 99A0083 99A0512 99A0513 99A0702 99A0703 99 0704 99 0705 99 0706 99 0707 99A0710 99 0711 99A0712 Units n ln n sch n n A n n A MA MM lll Description Parts Packet Screw Parts Packet Contact Kit Parts Packet Retainers Parts Packet Springs Paper Feed Parts Packet Duplex Option Fan Mounting Parts Packet Duplex Option Cam Follower Assembly Parts Packet Envelope Option Gears Parts Packet Retainers Envelope Option Parts Packet Screw Duplex Parts Packet 500 Sheet Feeder Option Shaft Bearings Parts Packet Cable Ties 10 each Parts Packet Screw High Capacity Feeder Parts Packet Nuts High Capacity Feeder Parts Packet Washers High Capacity Feeder Parts Kit Multipurpose Tray Parts Kit Charge Roll Link Asm Left Side Parts Kit Charge Roll Link Asm Right Side Printer Stand Caster Non Locking Printer Stand Caster Locking Printer Stand Grommet Wire Printer Stand Lock Cam Printer Stand Storage Shelf Printer Stand Door Assembly Ca
140. mounting 6 Taptite inner redrive deflector mounting 2 202 Les interconnect board to mounting 2 Center engine board mounting 4 controller board to attach 2 interconnect board ground controller board to inner mounting 2 shield controller board back mounting 2 engine board to attach 1 interconnect shield ground lower stacker duct mounting 1 ground cables to ground attach 1 center pan front cable clip main drive mounting 2 gearbox BTM fuser screw mounting 7 M3x8 mm LVPS mounting 2 Taptite auto compensator mounting 1 Repair Information 4 9 4520 xxx Reference Number Screw Type Location Purpose Qty M3x12 mm HVPS board mounting 1 Taptite D Panhead 235 M3x28 mm developer drive ground attach 1 Taptite bottom hole Panhead M3x6 mm stacker duct mounting 1 Taptite Panhead controller to shield mounting 2 Ge ED controller board mounting 2 in pan mounting 2 shield ground attach 1 LVPS mounting 2 fuser cover mounting 2 cable clip mounting 2 outer shield mounting 6 INA cover mounting 4 4 10 Service Manual 4520 xxx Reference N mber Screw Type Location Purpose Qty M3 5x8 mm autocompensator mounting 3 Plastite Thread ES Forming M3 5x10 mm right side cover mounting 1 Plastite Thread Forming right side frame to pan attach 3 324 735 left side frame to pan attach 1 H rt M3x6 mm fuser boa
141. n Test Standard 3 16 Parallel Wrap Test 3 13 Parts Catalog 7 1 Charging 7 28 Covers 7 2 1 2 Service Manual Developer Drive 7 22 Duplex Unit 7 54 Electronics 7 30 Electronics 11 7 34 Electronics 7 36 Electronics 7 38 Electronics 7 42 Envelope Feeder 7 60 Frame 7 4 High Capacity Feeder Hot Roll Fuser 7 24 Integrated Paper Tray 250 Sheet 7 48 Integrated Paper Tray 500 Sheet 7 18 Kiosk Horizontal Paper Adapter 7 74 Kiosk Vertical Paper Adapter 7 72 Main Drive 7 20 Miscellaneous 7 78 Options 7 76 Paper Feed Alignment 7 14 Autocompensator 7 10 Multipurpose Unit 7 12 Output 7 16 Printhead 7 8 Transfer 7 26 250 Sheet Tray 7 44 500 Sheet Tray 7 50 Power On Self Test POST Preventive Maintenance 6 1 Q Quick Disk Test 3 2 R Removal Procedures 4 12 Removals Center Pan Assembly 4 16 Controller Board 4 17 Covers 4 12 Developer Drive Assembly 4 18 Duplex Board 4 19 Duplex Front Cover Assembly 4 19 Duplex Front Cover Door 4 19 7 62 2 35 4520 xxx Duplex Motor 4 20 EMC Shields 4 21 Inner EMC Shield 4 21 Outer EMC Shield 4 22 Engine Board 4 23 Frames 4 25 EP Frame Assembly 4 25 Left Side Frame 4 25 Right Side Frame 4 27 Fuser 4 28 Fuser Board 4 29 Fuser Cover 4 30 Fuser Detack Housing Assembly 4 32 Fuser Envelope Solenoid 4 33 Fuser Exit Sensor Flag Assembly 4 34 Fuser Lamp 4 35 Fuser Lower Exit Guide Assembly 4 35 Fuser Narrow Media Sensor
142. n runs Check the voltage at J1 1 on the engine board The voltage measures 5 V dc static 0 V dc fan running If incorrect replace the main fan If this does not fix the problem replace the engine board 4 Error Code 927 Check the voltage at J1 3 on the Fan not running engine board The voltages are 22 V dc to 24 V dc printer and fan running 12 V dc to 15 V dc printer not running fan running about half speed If incorrect replace the engine board If this does not fix the problem replace the main fan Diagnostic Information 2 55 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 Be sure the correct type of fuser lamp is installed in the printer If the correct lamp is installed and a 925 error remains the problem may be due to the following The fuser may have reached standby temperature too quickly The line voltage may be above the maximum rating for the printer Note A 920 921 or 922 fuser error may be caused by an incorrectly mounted thermistor Service Tip Set the Fuser Temperature to NORMAL before starting this service check FRU Action 1 Fuser Lamp Incorrect Install the correct voltage and Lamp 925 Service Erro
143. ne board shield mounting screw B from the main drive motor assembly 5 Remove the engine board Note Anytime the engine board is replaced the Configuration ID must be reset in NVRAM on the new engine board Go to Setting Configuration ID on page 3 20 Repair Information 4 23 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 4 24 Service Manual 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 2 3 4 5 6 Remove the engine board Remove the main drive assembly Remove the upper front cover hinge assembly Remove the multipurpose tray lower deflector assembly Remove the paper alignment assembly Remove the left side frame mounting screws A A 102 Repair Information 4 25 4520 xxx 7 Place the printer on its back and remove the left side frame mounting screws A 8 Remove the left side frame A 104 4 26 Service Manual 4520 xxx Right Side Frame Removal 1 Remove the right side cover 2 Remove the LVPS 3 4 Disconnect the autocompensator arm bias spring from the right Remove the multipurpose tray assembly
144. ning J12 4 5 V dc static 5 V dc when main drive motor running J12 1 5 V static 0 V dc when main drive motor running If the voltage is incorrect replace the FRUs in the following order 1 Main drive motor assembly 2 Engine board 2 78 Service Manual 4520 xxx Operator Panel Service Check Operator Panel Buttons Service Check Note Before continuing with this service check do the Button Test on page 3 11 in the diagnostic aids chapter FRU Action 1 Operator Panel Assembly If any button fails the Button Test replace the operator panel assembly 2 Engine Board No buttons work Check the voltage at J11 5 The voltage measures approximately 5 V with the controller board removed If incorrect replace the engine board If correct check the continuity of the operator panel cable If incorrect replace the cable If correct replace the operator panel assembly Operator Panel Display Service Check Service Tip The printer has detected a problem with the engine board operator panel cable or operator panel assembly if POST does not complete and the printer emits 5 beeps and stops ina continuous pattern until the printer is turned off The operator panel cable is an individual cable on some printers and a combination cable assembly with the cover switch cable on later models Note If the operator panel is operating properly except for a Pel or
145. nsor Input Optical 500 Duplex Parts Packet Retainer 6 mm Drive Roll Shaft Assembly Drive 250 Duplex Shaft Assembly Drive 3 Roll 500 Duplex Shaft Assembly Decurl Parts Packet Screw Tensioner Parts Packet Retainer 6 mm Clutch Roll Feet Duplex Base Shaft Assembly Drive 2 Roll 500 Duplex Parts Packet Retainer 6 mm Top Cover Guide Debuckle Pasa an Mi Bae oA 2 4 M M Aa a a a a a on a Parts Catalog 7 59 4520 xxx Assembly 24 Envelope Feeder 7 60 Service Manual 4520 xxx Units Description 24 1 99A0389 1 Paper Weight Assembly 2 99A1694 1 Guide Edge 3 99A1696 1 Cover Top 4 99A0485 1 Sensor Envelope Pass Thru 5 99A0393 1 Clutch Restraint Gear 6 99A1697 1 Cover Right Side 7 99A0390 1 Support Slide Out 8 99A0488 7 Roller Support 9 99A0382 1 Motor Stepper D C 10 99A1666 1 Label Options 11 99A0388 1 Switch Envelope Out 12 99A1700 1 Board Assembly Electronic Control 13 99A0271 1 Parts Packet Gear Kit 14 99A1698 1 Cover Left Side NS 99A0404 1 Parts Packet Retainer 4 mm PP NS 99A0404 3 Parts Packet Retainer Clip 5 mm Shaft NS 99A0404 2 Parts Packet Retainer 6 mm NS 99A0404 3 Parts Packet Retainer 7 mm Shaft NS 99 0384 1 Shaft Drive Pressure Roller NS 9940385 1 Cable Auto Connect Front NS 99A0494 1 Spring Cam Clutch NS 99A0427 1 Label Envelope Orientation Icon NS 99A0469 1 Deflector Guide NS
146. nthead is installed Replace with the correct printhead Diagnostic Information 2 3 4520 xxx Error Code Action 931 935 Printhead Error 932 Printhead Lost Hsync 933 Mirror Motor Locks Lost Hsync 934 Mirror Motor Lost Lock 935 Mirror Motor unable to reach operating speed These errors represent a problem with the printhead Go to the Printhead Service Check on page 2 87 936 937 Transport Motor 936 Main Drive Motor initial lock failure 937 Main Drive Motor lost lock Indicates a problem with the main drive motor Go to the Main Drive Service Check on page 2 77 939 Controller Engine Communications Error The controller board and the engine board cannot communicate with one another The controller board engine board or interconnect board is defective Check each board for correct installation and secure ground If no problem is found replace the FRUs in the following order 1 Controller board 2 Engine board 3 Interconnect board Note The controller software also can cause a 939 error code Contact your next level for software support 2 4 Service Manual 4520 xxx Error Code Action 940 Service LV Power Supply The low voltage power supply zero crossover test failed Check the LVPS for correct installation Ensure that the connector on the LVPS assembly is firmly seated with the connector on the int
147. o de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcapitulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 60825 Os produtos laser da Classe n o 640 considerados perigosos Internamente a impressora cont m um produto laser da Classe 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a opera o normal manuten o feita pelo utilizador ou condi es de assist ncia prescritas Notices and Safety Information xiii 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
148. oblem is found it may be necessary to try a new pass thru sensor 84 xx 21 x1 The smart tray x did not pick a sheet of paper x2 x1 Media Size x2 Media Source Check tray x auto compensator and tray parts for correct operation If no problem is found go to the Input Tray s Service Check on page 2 62 84 xx 22 x1 This code indicates that the media activated the input sensor x2 before the printer EP was ready x1 Leading Edge of Media State x2 Trailing Edge of Media State 84 xx 23 x1 The transfer servo never started x2 x1 Media Size x2 Leading Edge of Media State 84 xx 25 This code indicates that the media has activated the input sensor before the printhead has locked Enough time has elapsed since printhead start to expect a lock One of the following may be failing Printhead Assembly System Board Printhead Cables 84 xx 26 This code indicates that media has activated the input sensor however the printhead fell out of lock condition or not enough time elapsed since the printhead start to expect a stable lock The media may have also reached the input sensor early Diagnostic Information 2 13 4520 xxx First 6 Bytes Sub Error Code xx can be any value Data Note Explanation 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 Check for media in the exit of the fuser assembly or redrive ass
149. ol board The elevator tray down button does not operate The tray moves to the upper position Service Tip Open the high capacity feeder front door and check the black rubber bumper attached to the door switch spring Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly FRU Action 1 Lower Limit Switch Check the lower limit switch to make Lower Limit Switch Cable sure it is not closed normally open High Capacity Feeder If incorrect replace the switch Control Board Check the lower limit switch cable for a short between pins 1 and 2 If incorrect replace the cable If correct replace the high capacity feeder control board Diagnostic Information 2 71 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 FRU Action 1 Autocompensator Check the autocompensator pick Assembly arm rollers for sign of glazing toner or other buildup Replace as necessary 2 Wear Strips Check the wear strips for glazing or contamination Replace as required It is advisable to replace all four wear strips at the same time The elevator tray does not move up or down The printer recognizes that the option is installed FRU Action 1 DC Drive Motor High Be sure the motor cable is correctly Capacity Feed
150. on 1 Paper Size Switch High Capacity Feeder Option Control Board Check for continuity between the common pin J5 1 and the pin of the paper size selected 5 1 Black Common Lead 5 2 Blue 5 5 3 Green Executive 5 4 Yellow A4 5 5 Orange Letter 5 6 Red Legal 5 7 Brown A5 If any position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board 24X Paper Jam Check Tray X Message displays when Tray X is empty No Tray X Message displays FRU Action 1 High Capacity Feeder Option Control Board Check the voltages on the board at J4 1 red and J4 3 blue The voltages measure approximately 5 V dc If incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly 2 74 Service Manual 4520 xxx Tray X Empty message displays Tray does not respond to loading paper No response from the front door switch FRU Action 1 High Capacity Feeder Option Control Board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Che
151. on and the base printer stops when you remove an option The printer no longer recognizes the option and deletes associated messages Each installed option below the base printer provides an electrical autoconnect to the option attached below it We do not recommend to attach or Hot Plug any options with the base printer power turned on Duplex Unit The duplex unit interface is a six pin autoconnector that provides a 24 V 24 V return serial interface transmit signal serial interface receive signal and two ground pins The duplex unit receives the 24 V dc from the base printer for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex unit through a ground spring attached to the frame and base of the printer The ground connection is automatically made when the option is installed below the printer The paper input sensor is located in the rear of the duplex unit under the input paper guide The paper exit sensor is located on the left frame assembly Option Microcode The options are Smart Options or options that have a system board The option system board has a microprocessor that controls the option mechanism A software architecture is provided that controls the option and communicates information such as paper path status sensor status motor status and so on to the base printer 3 26 Service Manual 4520 x
152. on page 2 77 FRU Action 1 Alignment Assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly for any signs of worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is found 2 Inner Deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly replace the deflector Autocompensator fails to feed paper Failures occur randomly throughout the stack of paper FRU Action 1 Pass Thru Sensor Check the pass thru sensor for correct installation and operation 2 Autocompensator The autocompensator pick roll shaft Assembly assembly is not providing enough torque if the pick rollers are not picking the paper correctly Replace the autocompensator assembly 3 Wear Strips in Tray X Check the wear strips for excessive problem is found wear scratches or rough spots Replace the wear strips if a problem is found 2 84 Service Manual 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 Replace both pick rolls if the paper appea
153. ope Feeder Board Connector Pin No Signal J1 N A Ground Tx EOC Ground Rx EOC 24 V dc Return Ou oy AJ OJN 24 V dc J2 Ground Paper Present wl m 5 V dc J3 Ground Paper Present m 5 V dc J4 5 16 Service Manual Motor Phase B Motor Phase A Motor Phase B Motor Phase A 4520 xxx Connector Locations 5 17 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 1 Motor 2 Motor J2 DC Motor 1 5 V Sensor Sensor Encoder Board 2 Tach 3 Ground J3 Stepper Motor 1 STPMOTA 2 STPMOTA A 3 STPMOTB 4 STPMOTB J4 Fan 1 24 V de 2 Fan On J5 Paper Input Sensor 1 5 V dc Sensor 2 Input 3 Ground J6 Rear Cover Open Switch 1 Top Cover Open 2 Ground J7 Jam Removal Tray Open 1 Front Drawer Open Switch 2 Ground J8 Paper Exit Sensor 1 5 V dc Sensor 2 Exit 3 Ground 5 18 Service Manual 4520 xxx Connector Pin No Signal J9 Autoconnect Option Below Ground PrtxDout Ground AJOJN PrtRxd J10 Autoconnect Option Below 24 V dc Ground J11 Printer Autoconnect 24 V dc Ground J12 Printer Autoconne
154. option system board did Assembly not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Check these parts for signs of Spring Bevel Gear broken or damaged parts Feedroll Gear Drive Roll contamination on the drive rollers or Assembly Wear Plate wear plate and wear or damage to Drive Shaft Bearings and the drive shaft bearings Check the Skewed Backup Roller drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary Diagnostic Information 2 63 4520 xxx Tray X Low message displays when Tray X is full or has adequate paper in the tray FRU Action 1 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 Paper low sensor flag for smooth and cor
155. our entries display at a time 2 To move to the next screen press Menu to move forward or backward 3 Press Return Stop to exit the Error Log Clearing the Error Log To clear the Error Log 1 Select Clear Log from the Error Log menu 2 Select YES to clear the Error Log or NO to exit the Clear Log menu If YES is selected the Empty Error Log displays on the screen 3 Press Return Stop to exit the Clear Log menu 3 10 Service Manual 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 Serial 3 Wrap if available LCD Test To run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test continually executes the LCD display test 2 Press Return Stop to cancel the test Button Test To run the Button Test 1 Select Button Test from the Diagnostic menu With no buttons pressed several OP Open appear on the display 2 Press each button one at a time and a CL Closed displays in place of an OP The proper operation of each button can be checked 3 Press Return Stop to cancel the test Diagnostic Aids 3 11 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 memo
156. ower On Self Test 2 35 NEE edo RO Pe EPA 2 36 Service s Ee er aos aad 2 39 Charge Roll Service Check 2 40 Cover Open Switch Cable Service Check 2 42 Dead Machine Service Check 2 43 Duplex Unit Service 2 45 Envelope Feeder Service 2 48 Fuser Service Check 2 56 Fuser Solenoid Service 2 60 Input Sensor Service 2 61 Input Tray s Service 2 62 High Capacity Feeder Input Tray Service Check 2 66 Main Drive Service Check 2 77 Operator Panel Service 2 79 Options Service 2 81 Output Bin Sensor Standard Tray Service Check 2 83 Paper Feed Service 2 84 Parallel Port Service 2 86 Printhead Service 2 87 Print Quality Service 2 88 Smart Contact Assembly Service Check 2 100 Serial Port Service 2 101 Toner Sensor Service 2 102 Contents iii 4520 xxx Transfer Roll Service 2 103 BE leie
157. p 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 Check the sensor and flag for proper operation If you find no problem with the sensor and flag continue with the service check Service Tip Be sure the flag is correctly installed The Output Bin Sensor is a normally closed sensor with the sensor flag down Therefore unless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message is not displayed FRU Action 1 Engine Board Check the voltage at J6 1 It measures 5 V dc when the flag is in Printer fails to display the sensor and 0 V dc when the flag Remove Paper Standard is out of the sensor If the voltage Bin message Output Bin does not change replace the sensor Sensor Test fails cable assembly If this does not fix the problem replace the engine board 2 Output Bin Sensor Flag Check to make sure the correct flag is installed Check the flag for damage or improper operation If incorrect replace the flag Note A broken or improper operating sensor flag causes a Remove Paper Standard Bin message to display before POST completes and cannot be cleared Diagnostic Information 2 83 4520 xxx Paper Feed Service Check If you have a 936 Transport Motor Error go to the Main Drive Service Check
158. poor contact between the smart cartridge contacts in the upper front cover and the smart chip Also check for proper seating of the smart cartridge cable to the engine board FRU Action Smart Contact Assembly Check the voltage on the smart cartridge contact The voltage Engine Board measures approximately 3 8 V dc when not writing data to the system board If data is being written the voltage measures approximately 0 V If incorrect disconnect the cable from J21 on the engine board and check the voltage on J21 1 The voltage measures approximately 45 V dc f incorrect replace the engine board If correct replace the smart cartridge contact assembly 2 100 Service Manual 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 The test provides failure information on the display for approximately three seconds If the test indicates a problem replace the controller board Diagnostic Information 2 101 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 FRU Action 1 Developer Drive As
159. present at any of the connectors go to step 9 If 5 V dc is not present go to step 4 4 5 Vdc atthe controller Check for 5 V dc at the 5 V dc test board test point pad located on the controller board If correct go to step 9 5 5V dc atthe engine board Check for 5 V dc at the 5 V dc test Test Point point on the engine board If correct replace the engine board If incorrect go to step 6 6 LVPS Fuse F1 Remove the LVPS from the printer and check fuse F1 Replace the fuse if blown Diagnostic Information 2 43 4520 xxx FRU Action 7 LVPS Fuse F1 Continues to blow after LVPS installed in the printer Replace fuse F1 if necessary Turn the LVPS on off switch off and connect the AC line cord and turn the LVPS on CAUTION Before checking fuse 1 turn the LVPS Off and disconnect the AC line cord Check fuse F1 If the fuse is blown replace the LVPS 8 LVPS CAUTION Before making any measurements on the LVPS output connector observe all necessary safety precautions before applying AC power Measure the voltage on LVPS output connector CN3 Pin 1 2 10 or 11 The voltage measures 5 V If incorrect replace the LVPS 9 Engine Board Turn the printer off and disconnect all the cables from the engine board Check for 5 V dc at the engine board test point If incorrect replace the FRUs in the following order 1 Engine board 2 Int
160. r door is open 2 34 Service Manual 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 2 3 The operator panel displays one and a half row of pels and then 12 13 14 The LED comes on The operator panel displays one and a half row of pels and then clears Diamonds scroll across the display and then clear clears The top line of the operator panel displays one square block of pels that turn on one at a time until all sixteen blocks display and then they all turn off Performing Self Test appears on the display The high capacity option elevator tray moves to the uppermost position if installed The duplex unit is checked if installed Busy appears on the display The fuser lamp turns on The fuser takes longer to warm up from a cold start than warm start The main fan turns on 10 11 The main drive motor turns on The developer drive assembly drives the developer shaft in the toner cartridge The exit rollers turn The operator panel LED starts blinking Ready appears on the display Diagnostic Information 2 35 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 buttons do
161. r wattage lamp or fuser assembly If the correct fuser lamp is installed and the 925 error remains the fuser may have reached standby temperature too quickly Check that the line voltage is not exceeding the maximum rating for the printer 2 56 Service Manual 4520 xxx FRU Action 2 Fuser Lamp Fuser Top Cover Assembly Remove the controller board Run the Diagnostic Print Test and observe the lamp through the left side frame If the lamp does not come on do the following Remove the redrive assembly Remove the fuser assembly disconnect the LVPS to fuser AC cable from the fuser assembly and remove the fuser Verify that the lamp is installed correctly If correct check the continuity of the fuser top cover assembly by verifying the lamp contacts on the right contact assembly If incorrect check continuity of the fuser lamp If incorrect replace the lamp If correct replace the fuser top cover assembly D 3 LVPS LVPS to Fuser AC Cable Caution When taking measurements for AC power observe all safety precautions Measure the AC line voltage between the two connectors on the fuser end of the LVPS to fuser AC cable If the voltage is incorrect turn the power off and remove the LVPS Measure the AC line voltage between pins CN1 1 and CN1 3 on the board If correct check the continuity of the LVPS to fuser AC cable If incorrect replace the cable If the AC line
162. r damage to the connector or contacts If you find damage replace the damaged cable connector assembly Remove the envelope feeder and check the voltages at the autoconnect on the front of the printer If incorrect check the interconnect board If correct reinstall the envelope feeder and continue with step 3 2 48 Service Manual 4520 xxx FRU Action 3 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 41 3 measures 5 V 41 5 measures 5 V J1 7 measures 24 V dc If any of the voltages are incorrect replace the autoconnect cable connector If the voltages are correct replace the envelope system board Diagnostic Information 2 49 4520 xxx Operator panel displays 260 Paper Jam immediately when envelope feed is requested POST incomplete FRU Action 1 Pass thru Sensor 2 50 Service Manual 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 Make sure the sensor cable is attached to the envelope system board Perform an envelope feeder sensor test to check both the sensor and sensor flag Note It may be necessary to use a small tool to actuate t
163. r flag for damage and proper operation If a problem is found repair as necessary 2 Engine Board Check for approximately 5 V dc at J10 10 on the engine board If incorrect replace the engine board 3 Input Sensor Cable Check the continuity of the input sensor cable section of the front wiring harness If incorrect replace the harness If correct replace the input sensor assembly Diagnostic Information 2 61 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 FRU Action 1 Tray X Option System Board or Compensator Assembly or Autoconnect Cable Check the autoconect cables and connectors for any signs of damage Replace if necessary Check the cables for continuity If incorrect replace the compensator assembly cable If the cables connectors and connections are good replace the FRUs in the following order 1 Autocompensator assembly option 2 Option System board 2 62 Service Manual 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 FRU Action 1 Pass Thru Sensor and Flag The tray x
164. r panel cable into the operator panel and snap the new cover open switch cable into the bracket assembly Route the cables and toroid through the rectangular window in the cover hinge pivot arm Snap the operator panel into the upper front cover Be sure the toroid is on the opposite end of the cables near the engine board connectors Route the cables through the printer and down the inside of the engine board shield Plug the cables into the engine board connectors 4 48 Service Manual 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 3 Disconnect the compensator assembly motor cable 4 Remove the three compensator assembly mounting screws and remove the compensator assembly Paper Tray Frame Assembly Removal 1 Remove the compensator assembly 2 Release the paper pass thru sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly Paper Tray Board Removal 1 Remove the paper tray frame assembly 2 Disconnect all cables from the paper tray board 3 Remove the three paper tray board mounting screws and remove the board Note Reinst
165. r 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 D C motor assembly 2 Duplex unit system board 2 Input Sensor Input Sensor Flag Run the Duplex Sensor Test from the diagnostics menu If the test fails check the input sensor cable at J5 on the system board for correct installation If no problem is found replace the FRUs in the following order 1 Input sensor assembly 2 Duplex unit system board 3 Paper Exit Sensor and Flag Check the duplex exit sensor for correct installation and free movement of the sensor flag Check to make sure the sensor cable is connected to J8 on the system board If no problem is found replace the FRUs in the following order 1 Exit sensor assembly 2 Duplex unit system board 2 46 Service Manual 4520 xxx 230 Paper Jam Check Duplex message displays The page is not duplexed and only exits half way out of the redrive FRU Action 1 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 Check for correct installation of the motor cable connector at J3 on the system board Check for any shorts between each pin of the motor cable and the motor housing If shorts are found replace the motor Check the resistance of the stepper motor betwe
166. rap Test 3 13 ROM Memory Test 3 13 SDRAM Memory Test 3 12 Serial Wrap Test 3 13 Input Tray Tests 3 15 Input Tray Feed Test 3 15 Paper Feed Tests Base Sensor Test 3 16 Input Tray Sensor Test 3 15 Output Bin Test Standard Bin 3 16 Print Registration 3 17 Print Tests 3 22 Printer Setup 3 18 Maintenance Page Count 3 19 Restore EP Factory Defaults 3 21 Setting Configuration ID 3 20 Setting the Page Count 3 18 Viewing the Permanent Page Count 3 18 Diagnostic Mode 3 1 Disabling Download Emulations 3 5 Disk Test Clean 3 3 Duplex Option Board Connectors 5 18 Duplex Tests 3 6 E Engine Board Connectors 5 4 Envelope Option Board Connectors 5 16 Error Codes Service Error Codes 2 2 User Error Messages 2 25 ErrorLog 3 10 ESD Sensitive Parts 4 1 F Flash Test 3 4 Index 1 1 4520 xxx Fuser Board 5 12 H Hardware Tests 3 11 HVPS Connectors 5 3 7 42 Input Tray Feed Test 3 15 Input Tray Sensor Test 3 15 Interconnect Board Connectors 5 14 L Laser Notices LCD Test 3 11 Low Voltage Power Supply 5 1 Lubrication Specifications 6 1 LVPS Connectors 5 1 Maintenance Approach 1 3 Maintenance Page Count 3 19 Maintenance Preventive 6 1 Maintenance Scheduled 6 2 Messages Check Device Connection Messages 2 33 Service Error Codes 2 2 User Error Messages 2 25 User Line 2 Link Messages 2 32 User Line 2 Messages 2 30 User Status Messages 2 22 N Network Controller Board Connectors 5 11 O Output Bi
167. rd mounting 1 SEMS Machine ground cable 68 Screw with washer 397 2 3 M3 5x12 mm printhead to EP frame mounting 3 Plastite Thread Forming with washer 425 Repair Information 4 11 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 Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Covers Removals Left Door Removal 1 Open the upper and bottom front covers 2 Press the two left door latch buttons A and open the left door 3 Release the left door from the rear hinges and remove the door 4 12 Service Manual 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 B 324 Repair Information 4 13 4520 xxx 3 Remove the redrive assembly 4 Remove the right side cover mounting screw B 5 Remove the right side cover B 324 4 14 Service Manual 4520 xxx Upper Front Cover Removal 1 Raise the
168. rect operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector J5 on the system board If no problem is found replace the paper low sensor assembly If this does not correct the problem replace the option system board Tray X Empty message displays when Tray X has paper in the tray FRU Action 1 Paper Out Sensor Flag Check the paper out sensor flag for correct operation and installation If 2 Paper Out Sensor On correct replace the option system Option System Board board The paper out sensor is mounted on the system board 2 64 Service Manual 4520 xxx Printer does not recognize Tray X is installed FRU Action 1 Autoconect Cables Tray X System Board Check the autoconnect from the printer or option above tray x Check for signs of cuts pinched wiring or damage to the contacts in the connector Check the autoconnect cable s for correct installation at the tray x system board If correct check the continuity of the autoconnect cable s If correct replace the tray system board If incorrect replace the cable Paper from Tray X does not reach the Pass Thru Sensor Service Tip Check the media in tray x to make sure it is within specifications Some types of labels foil material and slick papers can cause misfeeds
169. ried through the printer on the backside of the paper FRU Action 1 Hot Roll Fuser Assembly Toner is being carried out on the backside of the media This problem is generally caused by a toner buildup on the fuser hotroll or backup roll Check the fuser hotroll and backup roll for any noticeable buildup of toner Repair as necessary 2 Transfer Roll Transfer Plate Check the transfer roll for any signs Assembly of toner buildup or loose toner around the area of the transfer plate assembly Clean the area and run another copy If the problem continues replace the FRUs in the following order 1 HVPS 2 Engine board Diagnostic Information 2 99 4520 xxx 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 Check to make sure the smart cable is properly connected to J21 on the engine board Check the print cartridge for any signs of damage or improper installation of the smart chip Also be sure there is proper contact between the smart chip on the cartridge and the smart contact assembly Service Tip An intermittent 32 Unsupported Cartridge User Error Message can be caused by
170. ring the test The test can be canceled anytime during the test by pressing Return Stop Once the test is complete the power indicator turns on solid and a message displays xxxx Bad Blocks yyyyyy Usable message displays if fewer than 2000 bad blocks are detected xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks xxxx Bad Blocks Replace Disk message displays if more than 2000 bad blocks are detected The disk cannot be recovered because too many bad blocks exist on the disk 4 Press Go or Return Stop to return to the Device Tests menu Diagnostic Aids 3 3 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 Select Flash Test from the Device Tests menu The power indicator blinks while the test is running Flash Test Test Passed message displays if the test passes and the power indicator turns on solid Flash Test Test Failed message displays if the test fails and the power indicator turns on solid 2 Press Go or Return Stop to return to the Device Tests menu 3 4 Service Manual 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 O
171. river until it touches the back of the reference plate and tighten the nut with a 5 5 mm wrench The reference adjustment screw can be adjusted without loosening the nut Turn the screw clockwise a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want Repair Information 4 5 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 Turn the screw a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want 4 6 Service Manual 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 You must install the correct screw type in each location during reassembly Reference Number Screw Type Location Purpose Qty M3 5x8 mm right
172. roblem It may take several tries before improvement is noticed Note This setting has no effect when duplexing Repair Information 4 3 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 It is necessary to perform a registration adjustment before locking down the three printhead mounting screws To perform the registration adjustment 1 2 3 Turn the printer off Press and hold Return and Go Turn the printer on and release the buttons when Performing Self Test displays Select Registration from the menu Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamonds horizontal lines that can be used for skew adjustment page count setting printer serial number code levels and print registration settings Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of the test page for equal distance from the top of the page If any adjustment is necessary adjust the left or right printhead mounting screws and check the skew again by running another Quick Test Page This
173. rom the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 1 Feeding message displays while the paper is feeding through the printer Duplex Feed 1 Clear Paper message displays when the paper reaches paper stop position 1 and the power indicator turns on solid Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop position 2 To run the Duplex Feed 2 Test Select Duplex Feed 2 from the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 2 Feeding message displays while the paper is feeding through the printer Duplex Feed 2 Clear Paper message displays when the paper reaches the duplex paper stop position 2 and the power indicator turns on solid Diagnostic Aids 3 9 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 H an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log menu The Error log displays on three screens as only f
174. rs to be flat in the tray but there is still a problem Failures occur mainly near the bottom of the stack of paper The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper Also the autocompensator motor may be failing If this problems continues replace the autocompensator assembly Double Feeding Paper Note If double feeding paper occurs mostly from the bottom of the stack check for missing or damaged restraint pads in the tray FRU Action Paper Paper is usually the primary cause of a double feeding paper problem Flex the paper before placing the paper in the tray Edge welded paper is the most common cause of double feeding Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding 2 Autocompensator Make sure the counterbalance spring is not missing loose or broken at the top of the autocompensator arm assembly If you find a problem replace the autocompensator assembly Diagnostic Information 2 85 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 If you find a problem replace the pick rol
175. rts envelopes then the page is printed from Tray 1 Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet If adjustment is necessary the Top Margin Offset must be adjusted first The range of the adjustment is 25 to 25 The Duplex Top Margin Offset range is 20 to 20 Adjustment of this setting lets you shift up or down the position of the Top Margin Changing this parameter by 1 unit moves the margin 1 100 inch A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin 3 Press Return Stop to exit the test Check the Top Margin Offset of the base printer 3 6 Service Manual 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 Duplex input sensor Duplex exit sensor Press Return Stop to exit the test Diagnostic Aids 3 7 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 dup
176. ry can be set and read correctly To run the SDRAM Memory Test 1 Select SDRAM Memory Test from the menu The power indicator blinks indicating the test is in progress 2 Press Return Stop to exit the test P represents the number times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 represents the number times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display If the test fails the message SDRAM Error displays for approximately three seconds and the failure count increases by 1 3 12 Service Manual 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 The power indicator blinks indicating the test is in process The test runs continuously 2 Press Return Stop to exit the test Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the test fails one of the following messages displays for approximately three seconds ROM Checksum Error or ROM Burst Read Error
177. s Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions xviii Service Manual 4520 xxx Consignes de S curit Ce produit a t concu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utilisation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Norme di sicurezza prodotto stato progettato testato e approvato in conformit a severi standard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabile per l utilizzo di parti di rica
178. s Packet Contact Kit Contact Dr Blade TAR Developer Roll 3 Contact PC Drum 1 Contact Charge Roll 1 Block Contact Mounting 4 Screw Contact Mounting 5 18 99A0466 1 Sensor Toner Cartridge Level 19 99A0039 2 Roller Developer Support 20 99A0026 1 Tray Bias Arm Assembly 21 99A2024 1 Pan Center Assembly 22 99A2019 2 Spring Cartridge Hold Down 23 99A1525 1 Deflector Upper PF 24 99A1850 1 Deflector Inner 25 99A2065 1 Frame EP Module 26 99A0053 1 Sensor Input 27 99A1517 1 Frame Extension Left 210 220 28 99A0549 1 Shield ESD Assembly with label 29 99A0063 1 Spring PA Out Activate Parts Catalog 7 5 4520 xxx Assembly 2 Frame continued 7 6 Service Manual 4520 xxx a Ear Units Description 2 30 99A2025 1 Left Side Frame 31 56P1139 1 Board Input Tray ITC 32 99A1896 1 Guard Gear 33 99A2078 1 Pan Motor Drip 34 99A0567 1 Link Gear Release 35 99A0556 1 Spring Counterbalance NS 99 0263 17 NS 9941524 1 Spring Cartridge Load NS 99A1546 1 Shield Gear NS 99A1596 1 Contact LSF Ground NS 99A1538 1 Contact RSF Ground NS 99A1540 4 Nut Plate Frame 210 220 NS 99A1541 1 Spring Duplex Ground Parts Catalog 7 7 4520 xxx Assembly 3 Printhead 7 8 Service Manual 4520 xxx Part index Number Units Description 3 1 99A2026 1 Printhead Assembly Includes All Cab
179. se Sensor Test The operator panel displays OP for open and CL for closed 2 Manually toggle the sensors by hand to verify that each sensor switches from open to closed 3 16 Service Manual 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 4 5 Select Registration from the Diagnostic menu The Top margin sign value pair blinks This indicates it is the margin value being changed To select the margin value to be changed press Select until the margin value pair you want to change is blinking To change the margin value press Menu When the value you want is displayed press Select to save the value To exit the Registration menu press Return To verify the margin values are correct you must print the Quick Test Page from the registration screen Press Go to print the test page While printing the Quick Test Page the Quick Test Printing message displays Once the Quick Test Page completes printing the Registration screen displays again Print the Quick Test Page on letter or A4 paper Diagnostic Aids 3 17 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
180. sembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code Toner Sensor Check the developer drive assembly for correct installation any sign of worn loose or broken parts 2 Front Harness Cable Check the toner sensor portion of the front harness cable to make sure it is properly seated into the toner sensor correct at both the sensor and engine board J10 check the continuity of the cable If incorrect replace the cable Toner Sensor The toner sensor cable is part of the front harness and part of connector J10 on the engine board Check the voltage at J10 11 It reads approximately 5 V If incorrect replace the engine board correct check the voltage at J10 12 It reads approximately 5 V dc with the controller board removed from the printer If incorrect replace the engine board If correct replace the toner sensor assembly A bad ground connection between J10 13 on the engine board and pin 3 on the toner sensor results in a 929 service error 2 102 Service Manual 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
181. serprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daB im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemaBer Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Notices and Safety Information xi 4520 xxx Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 relatives aux produits laser de Classe l Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien p
182. side frame Remove the toner sensor mounting screw A disconnect the sensor cable and remove the toner sensor Remove the right side frame mounting screws B and remove the right side frame Remove the smart cartridge contact assembly mounting screw A 102 B 102 CAUTION Be sure the fuser assembly has cooled before working on any of the fuser FRUs Repair Information 4 27 4520 xxx Fuser Removal Remove the redrive assembly Remove the ground screw B Remove the fuser mounting screws A Disconnect the AC fuser lamp connector from the LVPS Disconnect the DC fuser cable from the engine board Remove the fuser 4 28 Service Manual 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 B Repair Information 4 29 4520 xxx Fuser Cover Removal 1 2 Remove the fuser assembly Note the thermistor cable routing and disconnect the cable from the fuser board Disconnect the AC fuser lamp cable from the top left side of the fuser cover Remove the two screws A from the right side fuser lamp contact cover Remove screw B that attaches the fuser lamp contact to the fuser cover on each end of the cover Detent the latch C and remove the cover Detent the latch C and remove the cover 4 30 S
183. spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no more than ten to fifteen grams on the stack This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose Poor gear efficiency can cause the arm to generate higher normal forces If the pick assembly is noisy replacement may be required The arm must pivot freely through its full range of motion On 500 sheet trays there are wrap springs located on the pivot arbors of the arm These springs aid to prevent the arm from bouncing If the arm appears to be binding or sticky near the bottom of the tray these springs may be the problem Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at bottom until the pick assembly can be replaced However the counterbalance spring is not to be considered an adjustment for feeding problems Diagnostic Aids 3 25 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 opti
184. ss data This message displays when Menu is pressed during a print job Press Go to take the printer out of the Not Ready state Press Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Resetting Printer The printer is deleting any print jobs in process and restoring all settings to user defaults No button actions are possible while this message is displayed Formatting Flash Do Not Power Off The flash memory is being formatted No button actions are possible while this message is displayed Program Flash Do Not Power Off The flash memory is being programmed which means fonts or macros are being written to flash memory Do not perform any button actions while this message is displayed Formatting Disk The disk is being formatted No button actions are possible while this message is displayed 2 24 Service Manual 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 Program Flash message is displayed Menus Disabled The printer menus have No button actions are
185. ster kick gear to make sure they rotate together If not then the tenons on the master kick gear may be sheared off If incorrect replace the master kick gear 2 52 Service Manual 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 FRU Action 1 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow 2 Weight Assembly Check the weight assembly to make sure it moves up and down freely without any binds Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty Replace the weight assembly if it is damaged or does not operate properly 3 Envelope Edge Guide Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper Replace the edge guide if it is damaged or does not operate properly Diagnostic Information 2 53 4520 xxx 260 Paper Jam displays envelope stops in feeder paper path FRU Action 1 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 2 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be
186. sually indicates the optional serial port is not set up correctly 56 Standard Serial Disabled This error is displayed when data is sent to the printer across the standard serial port but the port has been disabled 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset 58 Too Many Trays Attached 58 Too Many Disks Installed This error code is displayed when too many input trays are attached to the printer This error is displayed when too many disks are attached to the printer 61 Defective Disk This error code is displayed when the printer detects a defective disk This error may occur at power on or during disk format and write operations While this message displays Press Go to clear the message The disk is marked defective and normal printer operations continue Disk operations are not allowed with a defective disk The Format Disk menu is not shown 2 28 Service Manual 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
187. t check the right charge roll link assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame If incorrect replace the link assembly Make sure the charge roll bushing is installed and operating correctly Note The screw that attaches the charge roll lead to the contact must be secure Diagnostic Information 2 41 4520 xxx Cover Open Switch Cable Service Check FRU Action 1 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 spring 2 Cover Open Switch Cable Assembly Check the cover open switch for proper mechanical operation If incorrect repair as necessary Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4 3 It measures approximately 5 V dc If the voltage is incorrect replace the engine board If the voltage is correct check the voltage at J4 1 If the voltage measures greater than 1 0 V replace the engine board If the volta
188. t Ready message is displayed No more data is processed from the host computer Press Go to return the printer to the Ready state User Message Explanation Toner Low If the toner cartridge is low then Toner Low displays The Toner Low condition clears whenever the upper front door is opened and Toner Low displays again if the condition exists after the upper front door is closed Tray X Missing If any of the input trays are missing then Tray X Missing displays where X designates which Tray 1 through 5 is missing If multiple trays are missing they are prioritized in this order Tray 1 2 then Tray 5 Tray X Missing status clears whenever Tray X is reinserted 2 30 Service Manual 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 Note Tray X Empty status clears whenever Tray X is removed When Tray X is reinserted it is examined and the appropriate status if any displays Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder Tray X Low If any of the input trays are low then Tray X Low displays where X designates which tray 1 through 5 displays If multiple trays are low they are prioritized in the follo
189. t device gt can be one of the following duplex tray x 1 2 3 4 or 5 envelope feeder or output bin Diagnostic Information 2 7 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 9 or 2 error displays press and hold Return and press Select to enter for sub error codes The following is an example of how the printer shows a duplex unit sub error code Byte 1 Byte 2 Byte 3 Byte 4 DU XX XX XX XX DU XX XX XX XX Byte 5 Byte 6 Byte 7 Byte 8 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 1 Press and hold Return and press Select to enter for sub error codes 2 The first screen of information is displayed Write down the information 3 Continue pressing Return and Select until each screen of information is obtained 4 When the last screen displays the original message displays The following is an example of how the printer shows a duplex unit sub error code Byte 1 Byte 2 Byte 3 Byte 4 DU XX XX XX XX DU XX XX XX XX Byte 5 Byte 6 Byte 7 Byte 8 2 8 Service Manual 4520 xxx Base Printer Sub Error Codes Each status byte has a different level of
190. t the other end of the lamp therefore care must be used when removing the lamp from the fuser Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp Use the following table to identify and install the correct lamp Description Fuser Lamp 115V 630W Fuser Lamp 220 630W Fuser Lower Exit Guide Assembly Removal Remove the fuser assembly Remove the fuser cover assembly Remove the fuser detack housing assembly Disconnect the sensors from the fuser board Gently apply outward pressure on the left and right fuser side frames to release the lower exit guide assembly Repair Information 4 35 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 Disconnect the transfer roll cable from the HVPS board Warning Use care when disconnecting the cable from the transformer on the HVPS The cable and connector can be easily damaged 6 Remove the HVPS mounting screw B 7 Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS 235 4 36 Service Manual 4520 xxx Integrated Tray Compensator Assembly Removal 1
191. talled options is listed in the following order in the menu Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multipurpose Feeder if installed Envelope Feeder if installed For each input source selected you have the following choices Single prints the Print Test Page once Continuous continue printing the Print Test Page until Return or Stop is pressed The contents of the Print Test Page varies depending on the media installed in the selected input source Note The Print Test Page always prints on one side of the paper regardless of the duplex setting or the presence of a duplex unit If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope To run the Print Test Page 1 Select Print Tests from the Diagnostic menu 2 Select the media source 3 Select Single or Continuous If Single is selected no buttons are active during printing If Continuous is selected Return or Stop can be selected to cancel the test Check each Test Page from each source to assist in Print Quality and Paper Feed problems 3 22 Service Manual 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 P
192. ter Memory memory used to store pages is too full to collate the print job 38 Memory Full This message is displayed when the printer memory used to store pages is full 39 Complex Page This message is displayed when the page is too complex to print 51 Defective Flash This message is displayed when the printer detects a defective flash This error may occur at power on or during flash format and write operations Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved Diagnostic Information 2 27 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 Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the flash is formatted 54 Standard Serial Error This error is displayed when a serial error framing or parity is detected on the standard serial port This usually indicates the serial port is not set up correctly 54 Serial Option X Error This error is displayed when a serial error framing or parity is detected on the optional serial port This u
193. the continuity of the HVPS Part of Front cable If incorrect replace the cable Harness Cable assembly correct replace the engine board Engine Board Diagnostic Information 2 89 4520 xxx Print Quality Blank Page FRU Action 1 Print Cartridge Check the print cartridge for any signs of damage especially the PC drum contact on the cartridge 2 High Voltage Contact 3 HVPS Check the PC drum contact on the right side frame for damage PC drum contact wear or contamination If the contact is bent or damaged replace the contact Note Inspect the HVPS PC drum contact on the board for any signs of damage or contamination Check the fuse on the HVPS If open replace the HVPS Check the voltages at J10 on the engine board Measure the following voltages from connector J10 to printer ground Printer Idle J10 5 measures 24 V dc Printer Printing J10 5 measures 24 V dc If the voltages at J10 5 are incorrect replace the engine board 4 Front Cable Harness HVPS Section Check the front cable harness at J10 on the engine board and at CN1 on the HVPS to make sure the harness is connected properly If connected properly check the continuity of the cable harness If there is no continuity replace the front cable harness 2 90 Service Manual 4520 xxx FRU Action 5 Printhead Assembly Generally a 93x service error is posted if
194. 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 Print Quality Random Marks Service Tip The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor charge roll or transfer roll Symptom Action 1 Random Marks Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls Print Quality Blurred or Fuzzy Print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly alignment assembly any feed roller or in the transfer roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding from one of the input paper sources paper trays duplex unit or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary Diagnostic Information 2 91 4520 xxx Print Quality Evenly spaced horizontal lines or marks FRU Action 1 Lines spaced 3 19 mm 12
195. the repair Tools Required for Service Flat blade screwdriver 1 Phillips screwdriver 2 Phillips screwdriver T10 Torx screwdriver 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 General Information 1 3 4520 xxx Acronyms CSU DRAM EDO EP EPROM ESD FRU GB HVPS LASER LCD LED LVPS MROM NVRAM OEM PC POR POST RIP ROM SDRAM SRAM UPR Vac Vdc Customer Setup Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable Programmable Read Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Photoconductor Power On Reset Power On Self Test Raster Imaging Processor Read Only Memory Synchronous Dual Random Access Memory Static Random Access Memory Used Parts Return Volts alternating current Volts direct current 1 4 Service Manual 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
196. too narrow Envelope Feeder multifeeds or may not display a 260 Paper Jam message FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of the envelopes being stuck together or signs of glue Check to make sure the flaps are not interleaved 2 Deflector Check the deflector gap adjustment The adjustment may be too wide 3 Restraint Roll Bias Spring Check for a missing broken or incorrectly installed restraint roll bias spring If incorrect reinstall or replace the spring 260 Paper Jam displays an envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path FRU Action 1 Latch Lever Check to make sure the tip of the latch lever is centered in the opening in the floor of the paper path The latch lever may not be detented on the latch 2 54 Service Manual 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 FRU Action 1 Main Fan Manually spin the fan and check that it rotates freely Check the cable connection to the engine board J1 for correct installation 2 Main Fan to Engine Board Check the continuity of the cable If Cable incorrect replace the cable 3 Error Code 927 Fa
197. tray If the test fails disconnect the paper low switch cable from J3 on the high capacity system board Short pins 1 and 2 together while observing the sensor test on the display If the display does not change replace the high capacity feeder system board If the display changes check the continuity of the switch If incorrect replace the Switch If correct replace the switch cable Tray X empty message displays when there is paper in the high capacity feeder input tray FRU Action 1 Paper Out Sensor Flag 2 Paper Out Sensor On Option System Board Check the paper out sensor flag for correct operation and installation If correct replace the high capacity feeder system board The paper out sensor is mounted on the high capacity feeder system board 2 70 Service Manual 4520 xxx The elevator tray fails to stop at the correct position and continues to drive into the bottom frame FRU Action 1 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 If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High Capacity Feeder Disconnect the lower limit switch Control Board cable and check the voltage at J2 1 orange The voltage measures approximately 5 V If incorrect replace the high capacity feeder option contr
198. 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 These status bytes are designed to help isolate paper jams and paper feed problems in the base printer Legend for Tray Source x 10 MPT x 11 Tray 1 x 12 Tray 2 13 Tray 3 x 14 Tray 4 x 15 Tray 5 x 31 Env Feeder X 40 Manual Legend for Stacker Destination x 91 Stacker 1 x 92 Stacker 2 x 93 Stacker 3 Legend for media size x 1 letter x 2 legal x 3 B5 x 4 A4 x 5 Executive x 6 A5 x 7 Custom x 9 73 4 Env A 9 Env B 10 Env C 8 661 Env D C5 Env E B5 Env F Legal Env First 6 Bytes Sub Error Code Data Note can be any value Explanation 84 xx 00 x1 This code indicates that the input sensor in the printer is still x2 actuated from the first sheet and the second sheet is ready to arrive at the sensor x12media size x2 media source Check the printer input sensor and flag for correct operation The flag should operate freely Check for any signs of debris in the area of the input sensor Check the area of the transfer plate and input to the fuser for anything that might cause the paper to remain over the input sensor 84 xx 01 x1 Video never started on the page x 1 media size video signal never started within 2 inches after actuating the input sensor Ch
199. utdated 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 To Disable the Download Emulation 1 Turn the printer off 2 Press and hold the Go and Menu buttons 3 Turn the printer on and release the buttons once Performing Self Test displays Once the printer is idle the emulation can be downloaded again 4 Program the download emulation into the code overlay card assembly again 5 If these steps do not resolve the problem replace the code overlay card assembly and download the emulation again Diagnostic Aids 3 5 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 You can run one duplexed page Single or continue printing duplexed pages Continues until Return Stop is pressed The paper you choose to print the page on should be either Letter or A4 To run the Duplex Quick Test 1 Select Duplex Quick Test from the menu 2 Select Single or Continuous The single Duplex Quick test cannot be canceled The printer attempts to print the Quick Test Page from the default paper source If the default paper source only suppo
200. vice Error Codes on page 2 2 and take the indicated action for that error Diagnostic Information 2 1 4520 xxx Service Error Codes Service Error Codes are generally non recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition Error Code Action 900 RIP Software 901 Engine Flash Contact the next support level or call Lexmark Indicates that the flash which the engine board code is programmed into is bad Replace the engine board 902 General Engine Software 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface Violation by Paperport Device 906 Controller Engine Link Driver Error These errors indicate an unrecoverable engine software error Replace the engine board 910 DC Pick Motor DC Pick Motor Stall 911 DC Pick Motor Excessive PWM 912 DC Pick Motor below speed 913 DC Pick Motor over speed Error Codes 910 911 912 913 and 914 are indications that a Tray 1 paper feed problem has been detected Go to the Input Tray s Service Check on page 2 62 2 2 Service Manual 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
201. vice 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 The test page consists of horizontal lines spaced approximately one inch apart down the page To run the test Turn the printer off Remove the controller board and inner shield Turn the printer on Press Select to start the test after Start Print Test displays The test is continuous 5 Press Select once again to stop the test Printing Menu Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information A list of all the printer settings contained in the operator panel menus and their values A list of the installed options and features such as RAM memory cards optional input paper trays envelope feeder duplex unit output bins flash or disk Printer information such as serial number page count installed RAM engine code level RIP code level envelope feeder code level tray 1 5 code levels output bin 1 3 code levels operator panel code levels font ROM version and SRAM availability 3 24 Service Manual 4520 xxx Autocompensator Operation
202. voltage at CN1 is incorrect check fuse F2 If the fuse is blown replace the fuse If the fuse is not blown replace the LVPS assembly 4 Fuser Top Cover Assembly Thermal Fuse Thermistor Assembly Disconnect the thermistor cable from the fuser board at J2 Resistance HOT J2 1 J2 2 2 5K ohms COLD 150K ohms to 260K ohms Diagnostic Information 2 57 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 CAUTION The fuser may be hot use caution before removing or servicing FRU Action 1 Fuser Cover Assembly Assembly includes Thermistor and Thermal Fuses Check for damage to the thermistor assembly If damage is found replace the fuser top cover assembly no damage is found check the resistance of the thermistor between pins J6 1 and J6 2 on the cable HOT 2 5K ohms COLD 150K ohms to 260K ohms If the resistance is incorrect replace the fuser top cover assembly If the resistance is correct check each pin of J6 to ground If there is continuity replace the fuser cover assembly 2 Fuser Control Board Check for continuity between J6 1 and J1 2 and between J6 2 and J1 3 If incorrect replace t
203. wheel aligns with the hub on the main drive assembly when reinstalling the assembly A 102 A 237 4 18 Service Manual 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 Remove the two duplex board mounting screws and remove the duplex board Duplex Front Cover Assembly Removal 1 Lift the base printer from the duplex assembly 2 Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6 3 Position the duplex assembly on its side 4 Gently release the three front cover assembly latches from the bottom of the duplex assembly 5 Remove the duplex front cover assembly Duplex Front Cover Door Removal 1 Remove the duplex front cover assembly 2 Holding the front of the assembly away from you open the cover door and gently pry the left side door pivot from the mounting 3 Move the cover door to the left to clear the right door pivot from the mounting and remove the duplex front cover door Repair Information 4 19 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
204. wing order Tray 5 4 3 2 1 Note Tray X Low clears whenever Tray X goes empty or Tray X is removed When Tray X is reinserted it is examined and the appropriate status if any displays Note The printer cannot detect when the envelope feeder or multipurpose feeder are low Diagnostic Information 2 31 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 Serial Standard Serial Port if available Serial X Serial Port where X 1 2 3 is attached to connector X Network X Network card X X 1 2 3 is attached to connector X LocalTalk X LocalTalk Card X X 1 2 3 is attached to PCI connector X Infrared Standard Infrared port if available Infrared X Infrared Port X X 1 2 3 is attached to connector X 2 32 Service Manual 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 Connection
205. xx Fuser Operation Hot Roll Fuser The hot roll fuser is made up of two primary assemblies The first assembly is the top fuser cover which contains the thermistor cable thermal fuse cable assembly left and right lamp brackets and cover 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 The thermistor assembly is designed to keep the temperature of the fuser hot roll within a predetermined temperature by being in contact with the fuser hot roll and changes resistance as the temperature of the hot roll increases The thermistor resistance changes from approximately 150K ohms to approximately 260K ohms as the temperature of the fuser hot roll increases The thermistor is connected to the fuser control board connector J2 1 and J2 2 and from J2 to J1 2 and J1 3 on the fuser control board to J16 2 and J16 3 on the engine board J16 2 THERMGND and J16 3 THERM are connected to module U10 U10 monitors the change in thermistor resistance and sends a signal HEATON from J30 A25 through the interconnect board to CN3 9 on the LVPS to signal the triac to turn the fuser lamp on or off to maintain the correct fuser temperature The voltage drop across the thermistor is proportional to the
206. y Removal 4 18 Duplex Board 4 19 Duplex Front Cover Assembly Removal 4 19 Duplex Front Cover Door Removal 4 19 Duplex Motor 4 20 EMC Shields Removals 4 21 Engine Board Removal eee eee 4 23 Man Fan ee EE 4 24 Frames Removals 22 255 02855 4 25 Fuser EE 4 28 Fuser Board Removal 452239422450 4 29 Fuser Cover 4 30 Fuser Detack Housing Assembly Removal 4 32 Fuser Transfer Plate Hemoval 4 32 Fuser Envelope Conditioner Solenoid Removal 4 33 Fuser Narrow Media Sensor Flag Assembly Removal 4 34 Fuser Exit Sensor Flag Assembly Removal 4 34 Fuser Lamp Removal EE 4 35 Fuser Lower Exit Guide Assembly Removal 4 35 High Voltage Power Supply 4 36 Integrated Tray Compensator Assembly Removal 4 37 Integrated Tray Compensator Pick Roll Asm Removal 4 38 Interconnect Board Assembly Removal 4 39 Low Voltage Power Supply Removal 4 40 Main Drive Assembly Removal 4 43 Main Drive Motor 4 44 Multipurpose Tray Lower Deflector Assembly Removal 4 45 Contents v 4520 xxx Operator Panel Assembly Removal Operator Panel Cable Cover Switch Removal

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