Lexmark T52x Service Manual

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Lexmark™ T52x

• Table of Contents

•Start Diagnostics

• Safety and Notices

• Trademarks

4520-xxx

•Index

• Manuals Menu

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark International, Inc., registered in the United States and/or ot her countries.

4520-xxx

Edition: July 2001

The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERN ATIONAL, 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 all o w di sc la im er o f e x pres s o r impl i ed wa r ran ti es i n c ertai n t ra ns act i ons ; t he refore , t hi s statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the info rmation herein; these changes will be incorporated in later editions. Improvements or changes in the products or the p rograms describ ed may be made at any time.

Comments may be addressed to Le xmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriat e without incurring any obligation to yo u. 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 wi th diamond design and MarkNet are trademarks of Lexmark International , Inc., register ed in the U nited St ates and/or oth er countries.

Image Quick and Optra Forms are trad emarks of Lexmark International, In c. Other trademarks are the property of their respective owners .

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 an d in applicable FAR pro visions: Lexmark International, Inc., Lexington, KY 40550.

P/N: 12G3967

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Contents

Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . . . ix

Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxiii

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Tools Required for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Diagnostic Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

User Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . 2-35

Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Check . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Envelope Feeder Service Check . . . . . . . . . . . . . . . . . . . 2-48

Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Fuser Solenoid Service Check. . . . . . . . . . . . . . . . . . . . . 2-60

Input Sensor Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-61

Input Tray(s) Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-62

High-Capacity Feeder Input Tray Service Check . . . . . . . 2-66

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . . 2-79

Options Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

Output Bin Sensor Standard Tray Service Check . . . . . . 2-83

Paper Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-84

Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-86

Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-88

Smart Contact Assembly Service Check . . . . . . . . . . . . 2-100

Serial Port Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-101

Toner Sensor Service Check . . . . . . . . . . . . . . . . . . . . . 2-102

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Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . 2-103

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Duplex Quick Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Duplex Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Duplex Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Parallel Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . 3-16

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Printer Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-18

Maintenance Pag e Count . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Setting Configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Restore EP Factory Defaults. . . . . . . . . . . . . . . . . . . . . . 3-21

Print Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Print Test with RIP (Controller Board) Removed. . . . . . . 3-24

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-24

Autocompensator Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Autoconnect System, Paper Tray Options, En velope Fee der 3-26

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Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Repair Informatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printhead Assembly Adjustmen t. . . . . . . . . . . . . . . . . . . . . 4-4

Paper Alignment Assembly Adjustment . . . . . . . . . . . . . . . 4-5

Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Covers Removals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Center Pan Assembly Removal . . . . . . . . . . . . . . . . . . . . 4-16

Controller Board Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Deve loper Dr i v e Assem b ly Remo val . . . . . . . . . . . . . . . . 4-18

Duplex Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Front Cover Assembly Removal. . . . . . . . . . . . . . 4-19

Dupl e x Front C o v e r Door Remova l . . . . . . . . . . . . . . . . . 4-19

Duplex Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

EMC Shields Removals . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Engine Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Main Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Frames Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Fuser Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Fuser Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Fuser Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Fuser Detack Housing Assembly Removal . . . . . . . . . . . 4-32

Fuser Transfer Plate Removal . . . . . . . . . . . . . . . . . . . . . 4-32

Fuser Envelope Conditioner Solenoid Removal. . . . . . . . 4-33

Fuser Narrow Media Sensor/Flag Assembly Removal. . . 4-34

Fuser Exit S e n sor Flag Assem b ly Removal . . . . . . . . . . . 4-3 4

Fuser Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Fuser Lower Exit Guide Assembly Removal . . . . . . . . . . 4-35

High Voltage Power Supply Removal. . . . . . . . . . . . . . . . 4-36

Integrated Tray Compensator Assembly Removal. . . . . . 4-37

Integrated Tray Compensator Pick Roll Asm Removal . . 4-38

Intercon nect Board Assembly Remov al. . . . . . . . . . . . . . 4-39

Low Voltage Power Supply Removal . . . . . . . . . . . . . . . . 4-40

Main Drive Assembly Removal. . . . . . . . . . . . . . . . . . . . . 4-43

Main Drive Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . 4-44

Multipurpose Tray/Lower Deflector Assembly Removal. . 4-45

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Operator Panel Asse mbly Removal. . . . . . . . . . . . . . . . . 4-47

Operator Panel Cable/Cover Switch Removal. . . . . . . . . 4-48

Optional 250/500 Paper Tray Assembly Remov al. . . . . . 4-49

Paper Alignment Assembly Removal . . . . . . . . . . . . . . . 4-50

Paper Deflectors Re mova ls. . . . . . . . . . . . . . . . . . . . . . . 4-52

Paper Input Sensor Removal. . . . . . . . . . . . . . . . . . . . . . 4-53

Paper Size Sensing Board Removal. . . . . . . . . . . . . . . . 4-53

Pick Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Redrive Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . 4-55

Smart Contact Assembly Re mova l . . . . . . . . . . . . . . . . . 4-56

Toner Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Transfer Roll Assembl y Remo va l . . . . . . . . . . . . . . . . . . 4-58

Upper Paper Deflector Assemb l y Remo va l. . . . . . . . . . . 4-58

Upper Front Cover Hinge Assembly Removal. . . . . . . . . 4-59

Upper Front Cover Interlock Switch Assembly Removal. 4-60

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-1

High Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 5-3

Engine Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Engine Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Controller Board - Non Network. . . . . . . . . . . . . . . . . . . . 5-10

Controller Board - Network . . . . . . . . . . . . . . . . . . . . . . . 5-11

Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Envelope Feeder Board. . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Duplex Unit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use This Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 4: Paper Feed (Autocompensator) . . . . . . . . . 7-10

Assembly 5: Paper Feed - Multipurpose Unit . . . . . . . . . 7-12

Assembly 6: Paper Feed - Alignment . . . . . . . . . . . . . . . 7-14

Assembly 7: Paper Feed - Output . . . . . . . . . . . . . . . . . . 7-16

Assembly 8: Integrated Paper Tray - 500 Sheet . . . . . . . 7-18

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Assembly 9: Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 10: Developer Drive. . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 11: Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 12: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 13: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 14: Electronics 1 . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 15: Electronics II . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 16: Electronics III. . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 17: Electronics IV. . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 18: Electronics V . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 19: Electronics VI. . . . . . . . . . . . . . . . . . . . . . . 7-42

Assembly 20: 250-Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-44

Assembly 21: Integrated Paper Tray - 250 Sheet . . . . . . 7-48

Assembly 22: 500-Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-50

Assembly 23: Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Assembly 24: Envelope Feeder . . . . . . . . . . . . . . . . . . . . 7-60

Assembly 25: High-Capacity Feeder . . . . . . . . . . . . . . . . 7-62

Assembly 26: Kiosk - Vertical Paper Adapter. . . . . . . . . . 7-72

Assembly 27: Kiosk - Horizontal Paper Adapter. . . . . . . . 7-74

Assembly 28: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76

Assembly 29: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . 7-78

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Contents vii

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viii S ervice Manual

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Notices and Safety Information

Laser No tices

The following laser notice labels may be affixed to this printer as shown:

Laser Advisory Label

Notices and Safety Information ix

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Class 1 Laser Statement Label

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Laser No tice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (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 I level during normal operation, user maintenance, or prescribed service condition.

Laser

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

Laserprodukt e der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Gallium ars enlaser mit 5 Milliwatt handelt, der Wellen der L änge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipie rt, d a ß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Notices and Safety Information xi

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Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominal e de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825.

I 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 comp resa 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

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Avisos sobre el láse r

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanóme tros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declar açã o so br e La ser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliw a t ts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

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Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. V oor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825.

Laserproduk ten van klasse I 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 zo ontworpen dat bij normaal gebr uik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelli ng mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR S ubchapt er J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milli watin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaa lin toiminnan, käyttäjän tekemien huoltotoim ien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denn a del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwat t so m arbe t a r i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för at t n ågon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll so m utförs av användaren eller annan föreskriven serviceåtgärd.

Notices and Safety Information xv

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Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC

60825. Klasse I-laserprodukte r er ik ke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistem a làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per s obre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Japanese La se r Not i ce

Chinese Laser Notice

Notices and Safety Information xvii

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Korean Laser Notice

Safety Information

•

This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts.

• 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 dur ing disassem bly and ser v icing of this product. Professional service personnel should understand this and take necessary precautions.

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Consignes de Sécurité

•

Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriqu es, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

Norme di sicurezza

Il prodotto è stato progettato , testato e approvato in conformità a

•

severi standard di sicurezza e per l’utiliz zo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.

• Le informazioni 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 è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

Notices and Safety Information xix

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Sicherheitshinweise

•

Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen . Di e s i ch er he i ts r e le vanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Ve rantwortung oder Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produ kt sind

ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinanderne hme ns und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständig e Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

Pautas de Seguridad

Este producto se ha diseñado, verificado y aprobado para

•

cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser conscien te de este peligro y tomar las precauciones necesarias.

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Inform ações de Segurança

•

Este produto foi concebido, testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.

• As inf o rmações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

Informació de Seguretat

Aquest producte està dissenyat, comprovat i aprovat per tal

•

d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés 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

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Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

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Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as special tools and test equipment are listed in this chapter.

• “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 repl aceable 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.

• “Preventiv e Maintenance” contains safety inspection guidelines,

lubrication specifications, and maintenance information to prevent problems and maintain performance.

• “Parts Cata log” contains illustrations and part numbers for

individual FRUs.

Preface xxiii

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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

Model Name T ype

Lexmark T522 4520-210 Non network Lexmark T522n 4520-220 Network Lexmark T520 4520-001 Non network Lexmark T520n 4520-002 Network

T laser printers are available in the following models:

General Information 1-1

4520-xxx

Options

The following options are available. Some options are not available in every country. Contact y our 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 and 500-sheet paper trays of A5, letter, and legal size. 250 Sheet UAT (Universally Adjustable Tray) 400 Sheet UAT (Universally Adjustable Tray) 2000 Sheet High Capacity Feeder Envelope Feeder Duplex Unit - 250 Sheet (For T520 & T520n) Duplex Unit - 500 Sheet (For T522 & T522n) Hard Disk - 5.0 & GB Forms Hard Disk - 5.0 & GB or Larger Vertical Kiosk Presenter Horizontal Kiosk Presenter

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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 the repair.

Tools Required for Service

Flat-blade screwdriver #1 Phillip s scr ewdriver #2 Phillip s scr ewdriver 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 Customer Setup DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotographic Process EPROM Erasable, Programmable Read-Only

Memory ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission

of Radiation LCD Liquid Cr ysta l Display LED Light-Emitting Diode LVP S Low Voltage Power Supply MROM Masked Read Only Memor y NVRAM Nonvolatile Random Access Memory OEM Original Equip men t Manufacturer PC Photoconductor POR Power-On Reset POST Power-On Self Test RIP Raster Imaging Processor ROM Read Only Memory SDRAM Synchronous Dual Random Access

Memory SRAM S t atic Random Ac cess Memo ry UPR Used Parts Return V ac Vol ts alternating current V dc Vol ts direct current

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2. Diagnostic Information

Start

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

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

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

Status Messages” on page 2-22

“Service Error Codes” on

“User

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 cartrid ge, paper jam, option, por t , and so on. If a user error message is displayed, go to the

If your machine completes the

page 2-35 “Symptom T ables” on page 2-36. Locate your symptom and take the

without an error, and you have a symptom, go to the

“User Error Messages” on page 2-25.

“Power-On Self Test (POST)” on

appropriate action. If a service error code appears while you are working on the

machine, go to the

“Service Error Codes” on page 2-2 and take the

indicated action for that error.

Diagnostic Information 2-1

4520-xxx

Servi ce Er ro r Co de s

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 Contact the next support leve l or call Lexmark. 901 Engine Flash Indicates that the flash which the engine board code is

902 General Engine Software

903 Paperport Link Driver Error

904 Interface Violation by the controller software

905 Interface Violation by Paperport Device

906 ControllerEngine Link Driver Error

910 DC Pick Motor DC Pick Motor Stall

911 DC Pick Motor E xcessi ve PWM

programmed into is bad. Replace the engi ne board. These errors indicate an unrecov erable engi ne software

error. Replace the engine boar d.

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.

912 DC Pick Motor below speed

913 DC Pick Motor over speed

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Error Code Action

914 DC Pick Moto r: No encoder feedback

917 Tra nsfer Roll Indicates a problem in the transfer roll are a. Go to t he

920 Fuser Error Indicates that the fuser is below temperature when

921 Fuser Error Indicates that the fuser is below standby temperat ure

922 Fuser Error Fuser failed to reach standby temperat ure. Go to the

923 Fuser Error Fuser is too hot durin g print ing or when printer i s idle. Go

924 Fuser Error An open circuit has been detected in the Fuser

925 Fuser Error Wrong fus er lamp installed. Check the fuser lamp f or the

Check the integ rat ed paper tr a y (tra y 1) f or cor rect pape r loading. Reload the paper and POR the printer. If the error continues, go to the “Input Tray(s) Service Check”

on page 2-62.

“Transfer Roll Service Check” on page 2-103.

printing. Go to the “Fuser Service Check” on page 2-56.

when the prin ter is idle . Go to the “Fus er Service Check”

on page 2-56.

“Fuser Service Check” on page 2-56.

to the “Fuser Service Check” on pag e 2-56.

Thermistor Circuit. Go to the “Fuser Service Check” on

page 2-56.

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 T oner Sensor The toner senso r is no t ope rati ng prope rly, the develo per

930 Printhead Error

drive assembly is not operating properly or the print cartridge is defect ive. Go to the “Toner Sensor Service

Check” on page 2-102.

The wrong printhead 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 Mot or Locks/Lost Hsync

934 - Mirror Mot or Lost Lock

935 - Mirror Mot or unable to reach operating speed.

936-937 Transport Motor

936 - Main Drive Motor init ia l lo ck failure

937 - Main Drive Motor los t lo ck

939 Controller Engine Communications Error

These errors represe nt a prob le m with the printh ead. Go to the “Printhead Service Check” on page 2-87.

Indicates a pr oblem with the main dri ve motor. Go to the

“Main Drive Service Check” on page 2-77.

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 f ound, replace the FRUs in the f oll owing order:

1. Cont rol ler board

2. Engi ne board

3. Interconnect board Note: The control ler s oftwa re a lso can caus e a 939 er ror

code. Contact your next level for software support.

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Error Code Action

940 Service LV Power Supply

941 Controller Code CRC

941 Controller Font CRC

943 Controller Font Version

944 Controller Board Failure

945 Controller Board Failure ASIC Failure

The low voltage power supply zero crossover test failed.

• Check the LVPS for correct installat ion. Ensure that the connector on the LVPS assembly is firmly seated with the c onnector on t he interconnect card connector.

This error ma y al so be caused b y a noisy A C input po we r source.

• Be sure the correct LVPS has been installed.

• If all the above are correct, replace the LVPS

assembly.

A 941 error can be created by a defecti ve code overl ay card, a code upgrade, a defective IPDS or a PRESCRIBE card. These should be checked bef ore replacing t he controller board.

Replace the controller board.

Indicates that the controller code and FONT ROM are incompatible.

Replace the controller board.

946 Controller Board Failure SRAM Failure

947 PQET Error Replace the engine board. 948 PEL Clock

Error 949 Delay Line

Calibration Failure

953 NVRAM Failure

954 NVRAM Failure

Replace the controller board.

Indicates the PEL cl ock chec k fa iled. Replace th e engine board.

Indicates a delay line calibration fa il ure. Replace the engine board.

Indicates the NVRAM chip on th e engine board has failed. Replace the engine board.

Indicates the NVRAM experienced a CRC failure . Replace the engine board.

Diagnostic Information 2-5

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Error Code Action

956 Configur ation IDIndicates a prob lem with the Configur ation ID . This error

occurs because the engi ne received a conf iguration ID from the controller software whic h is not valid for t he level of engine code existing in the printer. Setti ng the configurat ion I D c orrect ly sh ould f i x thi s err or . The ID can be set via the NPA data stream or operator panel.

Note: This error is not gener ated at POR to allow the servicer a method of resetting the configuration ID. However, setting the configuration ID is the only operation th at t he servicer can perform. See “Setting

Configuration ID” on page 3-20.

960 RAM Memory Error

961 RAM in Slot 1 is Bad.

962 RAM in Slot 2 is Bad.

963 RAM in slot 3 is Bad.

964 Emulation Error

965 Emulation Error

975 - 979 Network Card X

Indicates a DRAM Memory Err or on t he co ntrolle r board. Replace the controller board.

Replace the card in Slot 1. If this does not fix the problem, replace the controller board.

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.

Indicates a failure within the Downl oad Emulation which is programmed into the code ov erl ay card. The speci fic error is as follows: 964 - Download Emulatio n CRC Failure. Chec ksum Failure. 965 - Download Emulation Outdated, The Download Emulation and the co ntroller code are incom patible. Go to the “Disabling Download Emulations” on page 3-5.

The follo w ing errors indicate a f ailure with the network card in the specified slot. X=any card installed in slots 1,2 or 3. 975 - Unrecognizab le 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 sl ot x but cannot estab lish communications with it. 978 - Bad checksum while programming Netw ork Car d x. Replace Network Card x. 979 - Flash parts failed while programming Network Card x. If the printer is a network model, replace the cont rol ler board.

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Error Code Action

980 <device> Comm

981 <device> The engine protocol violation detected by the specified

982 <device> Comm

983 <device> Invalid command received by the specified device. 984 <device> Invalid command parameter received by the specified

990 <device> Indicates an equipment check condi ti on has occurred in

991 <device> Card

The engine is experiencing unrel iable communications to the specified device.

device. Communicat ions error detected by the specified device.

device. Note: Service Errors 980 thru 984 <device> can be one

of the fol lowing: engine boar d, duplex, tray x (1,2,3,4 or

5), envelope feeder or output bin.

the specified device, but the de vice is unable to identify the exact component failure.

Note: <device> can be one of the following: duplex, tray x (1,2,3,4 or 5), envelope feeder or output bin.

The specifie d device has detect ed an equipment check in its system card.

Note: <device> can be one of the following: duplex, tray x(1,2,3, 4 or 5), envelope feeder or output bi n.

Diagnostic Information 2-7

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Sub Error Codes for 9XX and 2XX Error Codes

The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit.

When a 9XX or 2XX error displays , press and hold Return and press Select to enter for sub error codes. The following is an example of how the printer shows a duplex unit sub error code.

Byte 4 XX XX Byte 8

DU DU

Byte 1 XX XX Byte 5

Byte 2 XX XX Byte 6

Byte 3 XX XX Byte 7

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.

DU DU

2-8 Service Manual

Byte 1 XX XX Byte 5

Byte 2 XX XX Byte 6

Byte 3 XX XX Byte 7

Byte 4 XX XX Byte 8

4520-xxx Base Printer Su b Error Codes

Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem. 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), x=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 : xx can be any value.

Explanation

84 xx 00 x1 x2This code indicates that the input sensor in the printer is still

actuated from th e fir st sheet and the se cond s heet is ready to arrive at the sensor. (x1= medi a size, x2=media source ) *Check the printer i npu t sensor and flag f or correct operat ion.

The flag should oper ate freely. *Check for any signs of debris in the area of the input sensor. *Check the area of the tra nsf er plate and input to the fu ser f or

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 siz e) *The video signal never started within 2 inches after

actuating the input sensor . Check input sensor and fl ag.

Diagnostic Information 2-9

4520-xxx

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

84 xx 02 x1 This error is the most common type of paper jam. Possible

Explanation

causes are (x1=me dia size): *Multi sheet feeding. *A tray size sensing problem. *The media feeding from the paper source is slipping or

media is slipping i n input to the printer.

84 xx 04 The input sensor was covered during POST by a piece of

84 xx 05 There was a media at the input sensor too early. There was

84 00 06 A paper jam has been dec lared by a smart de vi ce . Immedi at e

84 00 07 A paper jam has been declared by a smart device. Homing

84 xx 0B x1 x2 x3

media still in the machine when it was turned on. *Clear the media from the pri nter. *Run the base sensor tes t (i nput sensor) from the di agnostic

tests menu to test the input sensor and flag for correct operation.

not enough time betwe en printhead start and the printhead mirror motor to lock. Possible causes for this error are: *Pape r might be pre-staged in the paper source tra y. *Pape r is picking too fast. *A defective input sensor.

stop homing not allowed.

was allowed before the stop. The option tray pass thru sensor was never actuated by a

piece of media. (x-1=media size) (x-2=media source) (x3=paper source where paper jam was detected) *Run the sensor test for the option tray that is displaying the

error code and check the pass thru sensor for that tray for correct operation.

*Check for paper pick ing from the selected paper input

source.

*If the error is being detected from a lower paper s ource, see

if paper is feeding correctly from a paper source above the detected source.

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4520-xxx

First 6 Bytes Sub Error Code Data - Note : xx can be any value.

Explanation

84 xx 0f x1 x2 x3

84 00 10 The main motor ID failed to identify either motor after two

84 xx 17 There is an envelope or envelopes in the en velope feeder

84 xx 18 There is media over the Tray 2 pass thru sensor during warm-

84 xx 19 There is media over the Tray 3 pass thru sensor during warm-

The option Tray pass thru sensor was never deact ivated. (x-1=media siz e ) (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 ha s cleared the pass thru area of the

option where the paper jam occurred.

tries. P ossible causes for this er ror are: *The main drive motor has stalled. *An incorrect main driv e m otor/gearbox assembly has been

installed.

during warm-up. An env elope may have partially f ed from the envelope feeder. *Remove any envel opes from the feeder and check the

envelope feeder f or correct operation.

up. Check for media ov er the sensor . If no media is present, check the pass thru sensor, fl ag, and cables. *Try running the Input Tray Tests for Tray 2 and see if Tray 2

is feeding paper correctly and all the sensors are working

correctly. *Check to mak e sure t he paper size setting is correct fo r t he

size paper in the tray.

up. Check for media ov er the sensor . If no media is present, check the pass thru sensor, fl ag, 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 mak e sure t he paper size setting is correct fo r t he

size paper in the tray.

Diagnostic Information 2-11

4520-xxx

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

84 xx 1A There is media over the Tray 4 pass thru sensor during warm-

84 xx 1B There is media over the Tray 5 pass thru sensor during warm-

Explanation

up. Check for media over the sensor. If no media is pr esent, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 4 and see if Tray 4

is feedi ng paper correctly and all the sensors are working correctly.

*Check to mak e sure the paper size setting is correct for the

size paper in the tr ay.

up. Check for media over the sensor. If no media is pr esent, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 5 and see if Tray 5

is feedi ng paper correctly and all the sensors are working correctly.

*Check to mak e sure the paper size setting is correct for the

size paper in the tr ay.

84 xx 1C There is media over t he Tray 6 pass thru sensor during warm-

84 xx 1D The env elope f eeder pass thru senso r neve r deactiv ated. The

84 xx 1E x1 x2The envelope feeder pass thru sensor was never activated.

up. Check for media over the sensor. If no media is pr esent, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 6 and see if Tray 6

is feedi ng paper correctly and all the sensors are working correctly.

*Check to mak e sure the paper size setting is correct for the

size paper in the tr ay.

display of this code i ndicates tha t an envelope never cross ed 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.

(x1=Media Size, x2=Media Source) Ensure that envelopes are feeding over the sensor. If an enve lope 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 correct ly, go to the

“Envelope Feeder Service Check” on page 2-48.

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4520-xxx

First 6 Bytes Sub Error Code Data - Note : xx can be any value.

84 xx 20 x1 x2The imaged page is not the e xpected page.

Explanation

(x1=Media Size , x2=Media Source) Check the pass thru sensor to make sure it is operating

properly. If no problem is found, it may be necessary to try a new pass thru sensor.

84 xx 21 x1 x2The smart tray x did not pick a sheet of paper.

84 xx 22 x1 x2This code indic ates that the me dia activated the input sensor

84 xx 23 x1 x2The transfer servo never started.

84 xx 25 This code indic ates that the media has acti vated the input

84 xx 26 This code indic ates that media has activated the input

(x1=Media Size , x2=Media Source) Check tray x auto compensator and tray parts for correct

operation. If no pro blem is foun d, go to the “Input Tray(s)

Service Check” on page 2-62.

before the printer EP was ready. (x1=Leading Edge of Media State, x2=Trailing Edge of Medi a State)

(x1=Media Size , x2=Leading Edge of Media State)

sensor before the printhead has locked. Enough time has elapsed since printhead start to expect a lock. One of the follo wing may be failing: *Printhead Assembl y *System Board *Printhead Cables

sensor; howev e r , the printhea d f ell out of loc k cond ition or not enough time elapsed since the printhead start to expect a stable loc k. The media may have also reached the input sensor early.

Diagnostic Information 2-13

4520-xxx

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

89 00 01 The exit sensor in the fuser is activated by a piece of media

89 xx 03 The fuser exit sensor did not detect the trailing edge of the

Explanation

indicating there is a piece of media in the machine during POST. *Check for media in the exit of the fuser assembly or redrive

assembl y. 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 assem bly 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 tes ts menu, and select the base sensor test. Select output sensor and check the sensor for correct opera ti on.

media going throug h the fuser assembly. *This failure can be caused by a broken fuser exit sensor

flag.

*This may also be caused by erratic operati on of exit sensor

flag or exit sensor or a defective piece of media.

89 xx 04 x1 The fuser ex it sensor never actuated from the sheet going

through the fuser before the ne xt page begins f eeding. (x-1=Media Size)

89 xx 07 The narrow media sens or in the f user was co v ered b y a s heet

of paper when not expected or a piece of media is in th e machine during POST. *This error can occur when a 202 paper jam has occurred. *Remove any piece of media that is over the narrow media

sensor.

*Try to feed a piec e of paper through the printer (co uld run

the print test fro m the diagnostic test menu). If the media stops over the narrow media sensor again, check the flag and sensor for correct operat ion.

89 xx 0B x1 The fuser exit sensor may be bouncing.

*This error can be caused by a failing exit sens or or system

board.

2-14 Service Manual

4520-xxx

First 6 Bytes Sub Error Code Data - Note : xx can be any value.

89 xx 0D The fuser e xit sensor bounced. Check the exit sensor for

Explanation

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

8E xx 02 x1 x2This error can be caused b y the input sensor not bein g

8E xx 06 x1 The second pick failed from a paper source when paper was

8E xx 07 x1 The second pick failed from a paper source when paper was

8E xx 08 The paper in the output bin was flushed. The paper ahead of

edge of the media fed through the printer. *This error can be displayed after a 201 paper jam. *This can be caused by a defectiv e fuser exi t sensor

assembly. Enter the diagnost ic tests menu, select base sensor tests,

select output sensor test and check the fuser exit sensor for correct operat ion. If the test fails, check the internal fuser cabling, DC autoconnect on the fuser frame, fuser DC autoconnect to the sy stem board cable, and the cable connection to J14 on the sy stem board.

activated by a page that was kno wn to ha v e been pic k ed b y a source other than the duplex option . *Ensure the correct source has been select ed and the media

is feeding from that source.

in the source and the only sheet in the paper path.

in the source. Othe r sheets may have started to feed, but none were in the paper path.

it, in the paper path, never m ade 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

8E xx 0A 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= Medi a S ource)

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 Data - N o te: xx can be any value.

8E x1 0B The DC auto compensator failed or stalled when trying to

8E xx 11 It took too long for t he DC auto compensator motor to come

Explanation

feed a sheet of medi a.

up to speed.

8E xx 13 x1 x2Late feedi ng fro m a paper source i nterf ere d with t he nex t pic k

retry. (x-1=Media Size)(x-2=Medi a 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: xx can be any value

920 Service - Fuser Error (Under temperature while printing)

Explanation

EN 08 xx yy

- 1 EN- zz - - 2

921 Service - Fuser Error (Fuser under t em perature while at standby) EN 41 xx yy

-- 1 EN -- zz -- -2

922 Service - Fuser Error (Fuser failed to reach standby temperature)

xx=Actual Fuser Temperature yy=The tempera ture that the fuser wan ts to reach. When zz=00 The Hot Roll took too long to heat up.

zz=01 The Hot Roll fell too far below the desired

temperature while printing.

zz=02 The Hot Roll was too cool while the system was

doing some checking.

zz=03 The Hot Roll was too cool when heat ing to the

desired temperature.

xx=Actual Fuser Temperature yy=The tempera ture that the fuser wan ts to reach. zz=00 The fuser temper ature di d not change enoug h fro m the

fuser lamp temperature at turn on.

01 The fuser te mperatu re rose mor e than d esi red fr om t he

fuser temperature at turn on.

Diagnostic Information 2-17

4520-xxx

First 6 Bytes Sub Error Code Data - Note : xx can be any value

Explanation

EN 42 xx yy

-- 1 EN z1 z2 -- -

- 2

923 Service - Fuser Error (Fuser over temperature) EN 12 xx yy

-- 1 EN -- -- -- -2

924 Service - Fuser Error (Open Thermistor Failure) EN 18 xx -- -

- 1 EN -- 00 -- -2

xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach. zz=00 The fuser temper atur e did not change enough from the

fuser lamp temper ature at turn on.

01 The fuser t emper atur e rose more than des ired f r om the

fuser temperature at turn on.

z2=00 The Hot Roll did not reac h standb y tempe rature in time

during sta nd by.

01 The Hot Roll took to o long t o reac h t he begin ning l amp

detection t em perature.

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 t em perature.’

04 After Hot Roll lamp detection, did not reach steady

state contr ol i n ti m e.

05 The Hot Roll did not reach opera ting temperature i n

time.

This sub error code is display ed anytime t hat the Hot Roll has reached a higher t han desired temperature. xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach.

This code is usually generated when an open circuit check is made of the thermistor circuit in the fuser. xx=Actual Fuser Temperature

2-18 Service Manual

4520-xxx

First 6 Bytes Sub Error Code Data - Note: xx can be any value

925 Service - Fuser Error (Wrong Fuser Lam p Inst alled) Note: The Sub Error Codes belo w are only for an incorrect lamp being installed.

Explanation

EN 07 xx yy zz 1 EN -- -- -- 2

This error code is generated anytime an incorrect lamp is detected. xx=00 Lamp detection performed and found an error.

01 It took long to do lamp detection and NVRAM detected a previous wron g lamp detected. yy=Actual Temperature zz=The tempera tur e that the fuser was trying to reach.

Envelope Feeder Sub Error Codes

First 6 Bytes Sub Error Code Data - Note: xx can be any value

84 xx 17 There is an envelope in the feeder during POST.

Explanation

Diagnostic Information 2-19

4520-xxx

First 6 Bytes Sub Error Code Data - Note : xx can be any value

84 xx 1D x1 x2The envelope feeder pass thru sensor activated but never

84 xx 1E x1 x2An envelope never activated the envelope feeder pass thru

Explanation

deactivated. (x1=Media Siz e)(x2=Media Source) This error can be cau sed 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 men u, select input tr ay sensor

tests, sele ct envelope feeder sens or t e st.

*Check the envelope pass thru sensor to ensure it is

operating correctly. If the sensor test fails, go to the

“Envel ope Feeder Service Check” on page 2-48. If the test passes, look for anything that might cause the

env elope to stop ov er the sensor .

sensor or the sensor neve r sensed the presence of an env elope. (x1=Media Siz e)(x2=Media Source) *Check to mak e sure the envelope fe eds 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.

Status Byte 4

00 No duplex error. No problem was reported to the engine by the

01 The leading edge of the sheet of paper nev er arrived at the input

02 The duplex unit engine board never received media notification

03 The trailing edge of t he sheet of paper nev er cleared the input

04 The leading edge of the sheet of paper nev er arrived at the e xit

05 The duplex logic thinks a sheet of paper is feeding to the duplex

06 The exit sensor detected a sheet of paper too early. 07 The sheet of pape r tr aili ng edge di d not cl ear t he e xi t sensor i n the

Explanation

duplex system card.

sensor.

from the printer.

sensor.

sensor. Note: This error is the most comm on due to the long length of the paper path between the input sensor and the exit sensor.

unit due to a senso r malfu nction in the p aper path when i n f act the printer has not sent a command to send a sheet of paper to the duplex unit .

desired length of time. 08 The feed motor experienced a complete motor stall. 0E The D.C. motor is under speed. The mo tor never reached the

correct operating speed. 13 There is paper left in the duplex unit. Paper was sensed during

the homing operation duri ng 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

Read y The printe r is ready t o

receive and process data.

Ready/Hex The printer is ready and

HEX Trace is ac tive, which is known as HEX Trace Ready.

Busy The prin te r is bus y

receiving or processing data, or printing data.

Note: The printer indicator light blinks while the printer is processing data.

Press Menu to take the printer out of Ready and enter all the Menus exc ept the TESTS MENU (Busy state).

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 th e printer.

Press Stop to take t he printer out of Busy. The Not Ready message is d ispla y ed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to re tu rn to Ready.

Flushing Buffer The printer is flushing

corrupted print data and the current print job is being discarded.

2-22 Service Manual

No button actions are possible whil e this message is displayed.

4520-xxx

User Status M essage Status Action

Printing Menu Settings The printer is processing

or printing a list of current settings menus because Print Menu Settings is se lected from the m e nu.

Printing Directory List A directory of the flash

and disk contents i s processing or printing because Print Directory is selected from the menu.

Press Stop to ta ke the printer out of Ready. The Not Ready message is displ ay ed . No more data is processed, but the printer processes all paper currently in the printer 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 Selec t for the values. Press Menu until Reset Printer is on the second line of the display. Press Select to reset the printer.

Press Stop to ta ke the printer out of Ready. The Not Ready message is displ ay ed . 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 Selec t 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

Per forming Self Tests The printer is running

Not Ready (Press Go )

Resetting Printer The printer is deleting

Formatting Flash (Do Not Power Off)

The printe r i s r e storing factory defaults.

the normal series of start-up tests after it is powered on. When the tests are complete, the printer returns to Ready.

The prin te r is in th e Not Ready state , which means it is not ready to receive or process data. This message displays when Menu is pressed during a print job.

any print jobs in process and restoring all set tings to user defaults.

The flash memory is being formatted.

No button actions are possible whil e this message is displayed.

Press Go to ta ke the printer out of the Not Ready state. Press Menu to ta ke 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.

No button actions are possible whil e this message is displayed.

Program Flash (Do Not Power Off)

Formatting Disk The disk is being

The flash memory is being programmed, which means fonts or macros are being written to flash memory.

formatted.

2-24 Service Manual

Do not perform any button acti ons while this message is displayed.

No button actions are possible whil e this message is displayed.

4520-xxx

User Status M essage Status Action

Programming Disk (Do Not Power Off)

Menus Disabled The printer menus have

Activating M enu Changes

The disk is being programmed, which means font s or macros are being written to disk.

been disabled. T his occurs when Menu is pressed while the pri nter is Ready and Menu Lockout is active. The printer displ ay shows this message for one second and th en returns to the Ready message.

The printer is reset to activate a printer setting changed in the menus.

User Error Messages

No button acti ons are possible whi le this message is displ ay ed .

Note: If information is written to flash memory and to disk at the same time, the Program Flash message is displayed.

No button acti ons are possible whi le this message is displayed.

User Error Message Explanation

200 Paper J am Remove Cartridge

201 Paper J am Remove Cartridge

202 Paper J am Open Rear Door

Paper is jammed at the printer Input Sensor. Open the printer upper front door and remove the print cartridge to access the paper jam are a.

Paper is jammed between the printer input and exit sensors. Open the printer upper front door and remove the print cartridge to access the jam area.

Paper is jammed at the printer exi t sensor. Open 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

260 Paper Jam Check Envelope Feeder

27X Paper Jam Check Output

Insert Cartridge or Close Door

31 Defective Print Cartridge

The paper is most likely jammed in the Duplex Unit. Remov e the du plex front co v er t o acce ss the jam area. If the paper i s jammed in the rear of the duplex, then replace the dupl ex front cover and open the duplex rear door. If the paper is not jammed in the dupl e x unit , then i t may be jammed in the rear of the printer. Open the print er rear door to access the jam.

Paper is jam m ed around Tray X (X=tray 1 thru 5). Tr y opening Tray X. If the tray is difficult to remove, t h en you may have to remove the tr ay abov e or bel ow tray X to remove the jammed pages.

Paper is jammed in the multipurpose feeder.

Paper is jammed in the envelope feeder.

Paper is jamme d in out put bi n. Open t he rear d oor to access the jamm ed pages.

This mess age di spla ys whe n the printe r fr ont d oor is open or the print cartridge is missing. If this message can not be cleared go to “Cover

Open Switch/Cable Service Check” on page 2-42.

Error code 31 is displ ayed when the top front cov er is closed and a defective print cartridge is detected. I t may t ak e the pri nter 10- 20 seconds to determine if the print cartridge is def ective. Depending on the s etti ng of th e Machine Cl ass ID the printer ma y be all owed to print pages durin g this 10-20 sec ond int erval. If page s are allo wed to print, they are not reprinted once a good print cartridge is inserted.

2-26 Service Manual

Note: This error indicates the printer was able to

read the cartridge ID, but the ID did not pass the verifica ti on te s t. To pass the verifica tio n te st , th e ID read from t he print cartridge must mat ch the I D from the last “good” print cartridge or the same ID must be read from the print cartridge twice. The last “good” print cartridge ID is stored in NVRAM.

4520-xxx

User Error Message Explanation

32 Unsupported Print Cartridge

34 Short Paper The printe r determines the paper length is too

36 Resolution Reduced The res olution of the page has been red uced

Error 32 i s displa yed when the top cover is closed and an unsupported print cartridge is detected. It may take the pri nter 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 10-2 0 second interva l. I f pages are al lo wed to print, then they are not r epri nted 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.

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 occu rs if the paper stop is in the incorrect position. Make sure the Paper Siz e setting is correct for the siz e paper that is being used.

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 Coll ati on Memory

38 Memory Full This message is displayed when the printer

39 Complex P age This message is displayed when the page is too

51 Defectiv e Flash This message is displayed when the printer

This message is displayed when the pri nter memory used to store pages is too full to collate the pr in t job.

memory used to store pages is full.

complex t o print .

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 t hat have been requested to be written to flash.

53 Unformatted Fl ash This message is displayed when the printer

detects an unf ormatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operati on continues. Flash operations are not allowed until the flash is formatted.

54 Standard Serial Error This error is displayed when a serial error

54 Serial Option X Error This error is displayed when a serial error

56 Standard Serial Disabled

56 Par allel Port Disabled This error is displa yed when data is sent to the

58 Too Many Trays Attached

58 Too Many Disks Installed

61 Defecti ve Disk This error code is displayed when the printer

(framing or parity) is detected on the standard serial port. This usually indic ates the serial port is not set up correctly.

(framing or parity) is detected on the optional serial port. This usually i ndicates the optional serial port is not set up correctly.

This error is disp layed when data is sent to the printer across the st andard serial port, but the port has been disabled .

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 printe r is re set.

This error code is dis played when t oo man y input trays are attached to the printer.

This error is displayed when too many disks are attach e d to th e p r in te r.

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 wit h 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 hol d the resources that have been requested t o be writ ten to the disk. This message displays for both resource and PostScript Disk oper ators when the disk is full.

63 Unformatted Disk This error code displ ays 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 conti nues. Disk operations are not allowed until the disk is formatted.

80 Scheduled Maintenance

81 Engine Code CRC Failure

88 Toner Lo w This message displays when toner low occurs

The operator panel di spla y s thi s mess age a t each 250K page count interval. It is necessary to replace the fuser assem bly, transfer roller, and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a mainten ance kit. For more information, go to “Scheduled Maintenance” on

page 6-2.

This error displays when the microcode to be programmed in the engine fl ash 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.

and the toner low alarm is activ ated. 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 Not Ready message is displayed. No more data is processed from the host computer. Press Go to return the printer to the Ready stat e .

User Message Explanation

Toner Low If the toner cartridge is low, then “Toner Low”

Tray X Missing If any of the input trays are missing, then “Tray X

displays. The Toner Low condition clears whenev er the upper front door is opened, and Toner Low displays again if the condition exists after the upper front door is closed.

Missing” displ a ys (wher e X des ignate s which Tray (1 through 5) is missing. If multip le trays ar e 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: Tra y 5, Tray 4,...Tray 1.

Note: Tray X Empty status clear s whenever T ray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays. Also note that Empty stat us 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 mul tiple trays are low, they are prioritized in the following order: Tray 5,4,3,2,1.

Note: Tray X Low clears whenever Tray X goes empty, or Tray X is removed . When Tray X is reinserted, it is examined and the appropriate status, if any, displays.

Note: The printer cannot detect when the envelope feeder or mul ti purpose 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

Par allel Standard Parallel Port, if avail able. Serial Standard Serial Port, if avail able. Serial X Serial Port, where X=1,2,3, is attached to PCI

Network X Network card X, X=1,2,3, is attached to PCI

LocalTalk X LocalTalk Card X,X=1,2,3, is attached to PCI

Infrared Standard Infrared port, if availab le. Infrared X Infrared Port X, X=1,2,3, is attached to PCI

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 M essage Explanation

Check Env F eeder Connection

Check Tray X Connection

Check Duplex Connection

Check Env elope Feeder Connection.

Check Tray X (X=1,2,3,4 or 5).

Check Duplex Unit Connection.

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

Insert Duplex Front Cov er This message displ ay s when t he duple x fro nt

Close Duplex Rear Door This message displays when the duplex rear

This messag e displ ay s whe n a printer op tion, Input Tray, or Envelope Feeder, has been attached while the printer is powered on. To use the option, the prin ter must first be powered off and back on again. Data loss results i f print jobs ar e ac tiv e when th e print er is power cycl ed. If a print job is active, then remov e the option and finish the job. The printer automatically clears the mes sage once the option is removed. Once the job is complete, turn off the printer and attach the option again.

access cover is not installed.

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 Tes t. Check for correct POST functioning of the base printer by observing the following:

1. The LED comes on.

2. The operator panel displays one and a half row of pels, and then clears.

3. Diamonds scroll across the display, and then clear.

4. The operator panel displays one and a half row of pels, and then clears.

5. 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.

6. “Performing Self Test” appears on the display.

– The high capacity option elevator tray moves to the

uppermost position if installed.

– The duplex unit is checked if installed.

7. “Busy” appears on the display.

8. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm star t .

9. The main fan turns on.

10. The main drive motor turns on.

11. The developer drive assembly drives the developer shaft in the toner cartridge.

12. The exit rollers turn.

13. The operator panel LED starts blinking.

14. “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

Operator Panel - One or more buttons do no t work.

Operator Panel - Display is blank. Printer sounds 5 beeps .

Operator Panel - Display is blank. Printer does not sound 5 beeps.

Operator Panel continuously displays all diamonds, sounds 5 beeps and does not complete POST.

Paper feed proble ms - Base printer or Integr ated 500 Paper Tray

Paper jams at exit of Redrive Assembly - No Duplex Uni t installed.

Paper jams at exit of Redrive Assembly - Duplex Unit installed.

Fuser Solenoid f ails to operate. Go to the “Fuser Solenoid Service

Check” on page 2-43.

Go to the “Operator Panel Buttons

Service Check” on page 2-79.

Go to the “Operator Panel Service

Check” on page 2-79.

Replace the operator panel assembly.

Go to the “Operator Panel Service

Check” on page 2-79.

Go to the “Paper Feed Service

Check” on page 2-84.

Go to the “Paper Feed Service

Check” on page 2-84.

Go to the “Duplex Unit Service

Check” on page 2-45.

Check” on page 2-60.

Print quality - Black page Go to the “Print Quality - All Black

Print quality - Blank page Go to the “Print Quality - Blank

Print quality - Light print Go to the “Print Quality - Light Print”

Print quality - Background Go to the “Print Quality -

Print quality - Residual image Go to the “Print Quality - Residual

Page” on page 2-89.

Page” on page 2-90.

on page 2-98.

Background” on page2-94.

Image” on page 2-98.

2-36 Service Manual

4520-xxx

Symptom Action

Print quality - Skew Go to the “Paper Feed Servic e

Check” on page 2-84.

Print quality - Banding Go to the “Print Quality - Banding”

Print quality - Random marks Go to the “Print Quality - Random

Print quality - Toner on backside of printed page .

Print quality - Vertical bla c k bands on edge of copy.

Unable to clear a “32-Unsupported Print Cartridge” User Error Message.

on page 2-96.

Marks” on page 2-91.

Go to the “Pr in t Qu al ity - Toner on

backside of printed page” on page 2-99.

Go to the “Pr in t Qu al ity - Bl a ck

bands on outer edges of t he page.” on page 2-96.

Go to the “Smart Contact Assembly

Service Check” on page 2-100.

Symptom Table - High-Capacity Feeder (2000-Sheet)

Symptom Action

• The printer does not recognize the high capacity feeder installed.

• Paper feed problem with the high capacity feeder.

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 proble m with 250 Sheet Paper Tray.

Paper feed proble m with 500 Sheet Paper Tray.

Media fail s to pass thru from the lower atta ched Paper Tray option to the next higher m ounted option.

Go to the “Input Tray(s) Service

Check” on page 2-62.

Symptom Ta ble - Duplex Unit

Symptom Action

• Paper feed problem with Duplex.

• Paper jams at Paper Removal Tray.

• Paper skew s in the Duple x Unit.

• Paper fail s to pass from lower

option thru the D u plex 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.

2-38 Service Manual

Go to the “En velope Feeder Service

Check” on page 2-48.

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

Configuration ID” on page3-20

Review the following information before performing any service checks.

“Setting

• Paper feed problems (especially paper jams): Go to “Viewing the

Error Lo g ” on page 3-10

indications of repetitive entries that help to isolate a problem to a particular area of the printer or option.

and check the printer error log for

• Paper feed problems with error message: Use the “Sub Error

Codes for 9XX and 2XX Error Codes” on page 2-8

the problem.

to help diagnose

• P ri nt quality problems: Go to “Print Quality Test Pages” on

page 3-23

before changing any settings or working on the printer.

and print a test page to help diagnose problems

• Use the resident diagnostics test provided to help isolate a

problem before taking the machine apart or removing any options.

Diagnostic Information 2-39

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

1 Charge Roll Assemb ly Check the charge roll for correct

installation, toner buildup, marks, cuts or other signs of contamination or damage. Replace as necessary.

2 Left Side Charge Roll Link Check the left side charge roll link

assembly for correct assem bly operation. Check for damage to the arm or bearing assembly.

2-40 Service Manual

4520-xxx

FRU Action

3 Right Side Charge Roll Link

Right Charge Roll Bushing

Check the right side charge roll link assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge ro ll li nk as s e mbly kit . If correct, check the right charge roll link assembly bearing for signs of wear or contamination. Excessive contaminati on could cause intermittent char ging of the charge roll. If incorrect, replace the link assembl y. Check for continui t y of the right link assembly from the bearing to the charge roll hi gh voltage contact on the right si de 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 sec u re.

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 cov er open s witch activ ation tab on the toner cartridge is not broken and that t he 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, chec k the voltage at J4-1. If the voltage measures greater than +1.0 V dc, replace the engine bo ard. If the voltage is correct, check the continuit y between J4-1 and J4-3 on the cable. If no change in continuity occurs as the switch is activated, replace the cover open swi tch/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, remov e the option and check the base printer for correct operation. If the base printer operates correctly, go to

Check” on page 2- 66

correctly , remove any other attached paper handling options. Observe all necessar y ESD prec autions 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 me ta l 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 li ne voltage . If the line

“High-Capacity F eeder Input Tray Service

. If the base printer continues to not operate

voltage is incorrect, inform the customer.

2 AC Line Cor d Check the lin e cord for any signs of

3 +5 V dc at any Optio n

Connector

4 +5 V dc at the controller

boar d t e s t po int

5 +5 V dc at the engine board

Test Point

6 LVPS Fuse F1 Remove the LVPS from the printer

damage. If correct, check the continuity of the line cord and replace if necessary.

Check for +5 V dc on any of the option connectors. The easiest to access is the envelope feeder connector located behind the lower front door. If +5 V dc is present at any of t he conn ectors , go t o step 9. I f +5 V dc is not present, go to step 4.

Check for +5 V dc at the +5 V dc test pad located on the controller board. If correct , go to step 9.

Check for +5 V dc at the +5 V dc test point on the engine board. If correct, replace the engine board. If incorrect , go to step 6.

and check fuse F1. Replace the fuse, i f bl own.

Diagnostic Information 2-43

4520-xxx

FRU Action

7 LVPS Fuse F1 - Continues

to blow after LVPS installed in the printer.

8 LVPS CAUTION: Before making any

9 Engine Board Turn the printer off and disconnect

Replace fuse F1 if necessary. T urn the LVPS on/off switch off and connect the AC li ne cord and turn the LVPS on.

CAUTION: Before checking fu s e F 1 turn the LVPS Off and disconnect the AC line cor d. Ch e ck fus e F1 . If the fuse is blown, replace the LVPS.

measurements on the LVPS output connector, observe al l necessary safety precautions before applying AC power. Measur e the voltage on LVPS output connector CN3 (Pin 1, 2, 10, or 11). The voltage measures +5 V dc. If incorrect, repl ace the LVPS.

all the cables fr om the engine board. Check for +5 V dc at the engine board test point. I f incorrect, replace the FRUs in the following order:

1. Engi ne board

2. Interconnect board If correct, turn the printer off and

reconnect one cable at a time until you find the defective assembly.

2-44 Service Manual

Service Tip: A short or low resistance l oad 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.

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

System Board

2 Autoconnect Cables/

Connectors

If fuse F1 is blown, replace the fuse. 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, r eplace the motor assembly. If no short is f ound, repl ace t he sys tem board.

Check the autoconnect cabl es for damage to the cables or the pins in the connectors. If damaged, replace the cable(s). If no damage is f ound, 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

2 Input Sensor, Input Sensor

Flag

3 Paper Exit Sensor and Flag Check the duplex exit sensor for

Check the D.C. servo motor cables for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is f ound, replace the FRUs in the following order:

1. D.C. motor assembl y

2. Dupl ex unit system board Run the Duplex Senso r T e st from the

diagnostics men u. 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 FR Us in t he following order:

1. Inpu t sensor assembly

2. Dupl ex unit system board

correct installation and free movement of the sensor flag. Check to make sure the sensor cable is connected to J8 on the syst em board. If no problem is found, replace the FR Us in t he following order:

1. Exi t sensor assembly

2. Dupl ex 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 steppe r 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 in stallatio n of the motor cab le connector at J3 on th e system board. Chec k f or an y sh orts betw een each pin of the motor cable and the motor housing. If shorts are found, replace the motor. Check the resistance of the stepper motor between J3-1 (Stpmtr A-) to J3-2 (Stpmtr A+). The resistance measures approximately 10 ohms. The resistance between J3-3 (Stpmt r B-) to J3-4 (S tpmtr B +) measures ap proximately 10 ohms. If the resista nce is incorrect, replace the stepper motor. Check for shorts between windin gs on pins J3-1 to J3-2 and pins J3-3 to J3-4. If a short is found, replace the stepper motor assembl y. If no short is found, replace the dupl ex 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 f eeder is f ailing 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 a 260 Paper J am Check Env elope 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

2 Front Autoconnect on

Printer

feeder is cor rectly instal led and mated to th e a utoconnec t at t he fr ont of the printer.

Check the connector for signs of 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 f ront of the printer . If incorrect, check the interconnect board. If correct, reinstall the envelope feeder and cont i n ue with step 3.

2-48 Service Manual

4520-xxx

FRU Action

3 Autoconnect on the

Envelope Feeder.

Check for any signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnec t cabl e at J1 on the envelope system board and measure the following voltages:

J1-3 measures +5 V dc J1-5 measures +5 V dc J1-7 measures +24 V dc

If any of the v oltages are incorrect, replace the autoconnect cable/connector. If the voltages are correct, replace the en vel ope 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 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 en velope syste m board. Perform an envelope feeder sensor test t o check both the sensor and sensor flag.

Note: It may be neces sary to use a small tool to actuate the sensor flag because it is located under the front cover. Be careful not to damage the flag.

If the tes t fails, check t he flag f or 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. If co rrect, check the voltage at J3-2. The v oltage ch anges from 0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembl y. If this does no t fix th e problem, replace the envelope system board.

2-50 Service Manual

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

Sensor Flag

2 Env elo pe Out Hopper Inp ut

Sensor

Check the envelope out sensor flag for dama ge, correct inst allation and operation. If incorrect, repai r or replace the flag.

Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the env elope system board. If correct, perform the En velope 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. T u rn the printer on and chec k the volt age at J3-3 on t he system board. The voltage measures approximately +5 V dc. If incorrect , replace the envelope system board. If correct, replace t he input sensor ass em bly.

Diagnostic Information 2-51

4520-xxx

990 Service Error , envelopes fail to feed from the hopper.

FRU Action

1 D. C . Feed Motor Assembl y Check the motor and motor cabl e f or

2 Envelope Feeder System

Board

any signs of loos e wires or poor connections. Check to make sure the motor cable is connected to the envelope system board.

Check the voltage on J4-1. The voltage measures approximately +24 V dc. If incorrect, repl ace the envelope system board, if correct, measure the vol tage at J4-6. The voltage measures approximately +5 V dc. If incorrect, disconnect J4 and measure the voltage again. If incorrect, replace the envelope feeder system board. If correct, replace the D.C. motor assembl y.

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 fo r correc t inst allat ion

and for si gns of d amage . Rep lace as necessary.

2 Gears Check all the gear s 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/

Kick Gear

Check the master cam gear and master/kick gear to make sur e they rotate together. If not, then the tenons on the master ki ck 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 hoppe r. Kick rolls are rotating.

Check the deflector gap adjustment before continuing this service check.

FRU Action

1 Deflector Gap Adjustment Check the deflect or 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 chec k to make sure the weight assembly rests on all the rear kic k r ollers when the hopper is empty. Replace the weight assembly if it is damaged or does not operate properly.

3 Envelope Edge Guide Check the env elope edge guide to

make sure it is not warped or set too close to th e env el opes i n t he hopper. Replace the edge guide if it is damaged or does not ope rate 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

Rolls

2 Deflector Gap Adjustment Check the deflect or gap adjustment.

Check all the roll s for any s ign s of oi l, grease or ot her c ont aminati on. I f y ou find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder.

The adjustment may be too narrow.

Envelope Feeder multifeeds or may not disp lay a 260 Paper Jam message.

FRU Action

1 Envelopes Check the envelopes being used in

the feeder. Chec k for signs of the envelopes being stuck together or signs of glue. Ch eck 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

incorrectl y inst alled restr ain t roll bias spring. If incorr ect, 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 le ver is cent er ed in th e 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 Manual ly spi n the f an and ch eck th at

it rotates freely. Check the cable connection to the engi ne board, J1 for correct in st a lla ti o n.

2 Main Fan to Engine Board

Cable

3 Error Code 927 (Fan runs) Check the voltage at J1-1 on the

4 Error Code 927

(F an not running)

Check the continuity of the cab le. If incorrect, replace the cable.

engine board. The voltag e measures +5 V dc (static) 0 V dc ( fan running). If incorr ec t, re pl a ce th e main fan. If this does not fix the pro blem, replace the engine board.

Check the voltage at J1-3 on the engine board. The v oltages 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 fai lure . 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 instal led. 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 (Incor rect

Lamp/925 Service Error)

2-56 Service Manual

Install the correct voltage and wattage lamp or fuser ass em bly.

If the corre c t fu s er lamp is instal le d and the 925 error remains, the fuser may have reached stand by temperature t oo quickly. Check that the line voltage is not exce eding the maximum rating for the printer.

4520-xxx

FRU Action

2 Fuser Lamp

Fuser Top Cover Assembly

3 LVPS

LVPS to Fuser AC Cable

Remove t he controller board. Run the Diagnostic Print Test and observe the lamp thr ough the left side frame. If the lamp does not come on, do the following:

• Remove the redri ve assembly.

• Remove the fuser assembly,

disconnect the LVPS to fuser AC cable from t he fuser ass embly a nd remove the fuser.

• Verify that the lamp is installed correc tl y. If correct, ch eck th e continuit y of the fuser top cover assembly by verifying the lam p contacts on the right cont act assembly. If incorrect , check continuity of the fuser lamp. If incorrect replace the lamp. If correct replace the fus er top cover assembly.

Caution: When taking measurements for AC power, observe all safety precaut ions.

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 remov e t he 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 , r eplace the cabl e.

4 Fuser Top Cover Assembly

(Thermal Fuse/Thermistor Assembly)

If the AC line voltage at CN1 is incorrect, check fuse F2. If the fuse is blown, replac e the fuse . If the fuse is not blo wn, replace the LVPS assembly.

Disconnect t he thermistor cab le from the fuser board at J2. Resi stance:

• 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

1Fuser Cover Assembly

(Assembly includes Thermistor and Thermal Fuses.)

2 Fuser Control Boar d Check for continuity bet ween J6-1

3 Fuser to En gine Bo ard DC

Cable

Check for damage to the thermistor assembly. If damage is found, replace the fuser top cover assembly. If no damage is found, check the re sistance 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 , chec k each pin of J6 to ground. If t here is continui ty, replace the fuser cover assem bly

and J1-2 and between J6-2 and J1-3. If incorrect, replace the fuser control boar d. If correct, go to step 3.

Check the continuity of the cable. If incorrect, replace the cable. If correct, go to step 4.

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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 v oltage 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.

5Fuser Hot Roll

Fuser Hot Roll Bearings Fuser Backup Roll Bearings Fuser Backup Roll Fuser Mechanical Parts

Examine the fuser assembly for signs of overheating or damage. Check the hot ro ll and bac kup r oll for signs of excessive toner, label glue, labels or other contaminants. If problems are found with the hot roll or backup r oll, repl ace the failing r oll. 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 envel ope conditioner solenoid adjustment as described in the adjustment section

page 4-3

FRU Action

“Fuser Solenoid Adju stment” on

1 Fuser Envelope Conditioner

Solenoid

2 LVPS Check the voltage at CN3-18 on the

3 DC Fuser to Engine Board

Cable

4 Fuser Control Board Check for contin uity between J4-2 and

5 Interconnect Board

Engine Board

The operation of the fus er sol enoid can be observed by removing the redrive assembly. Check for proper mechanical operation of the solenoid and associated hardware, link and so on. If correct, check the resistance of the solenoid betw een J4-1 and J4-2 on the fuser control board. The resistance measur es be tween 5 ohm s and 10 ohms. If incorrect, replace the solenoid assembly.

LVPS. The voltage measures approximately +42 V dc. If incorrect , replace the LVPS.

Check the c ont inui ty of the DC fuser t o engine board cable. If incorrect, replace the cable.

J1-5 and J4-1 and J1-7 on the fu ser control board. If incorrect, re place the fuser control board.

If no problem s are fou nd wi th the fuser solenoid, LVPS, DC cable or fuser control board, replace the FRUs in the following order:

1. Engi ne board

2. Interconnect board

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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 sensor flag for

damage and proper operation. If a problem is found, repair as necessary.

2 Engine Board Check for approximately +5 V dc at

J10-10 on the engine board. If incorrect , replace the engine board.

3 Input Sensor Cable Check the contin uit y of the input

sensor cable section of the front wiring harness. If incorrect, replace the harness. If correct, replace th e input sensor ass em bly.

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 dam age. 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. Opti on System board

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24X Paper Jam message displays, Paper jammed over the Pass Thru Se nsor. (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 Sens or and Fl ag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Driv e Roll Assembly, Wear Plate, Drive Shaft Bearings and Skew ed Backup Roller

The tray x option system board did not detect a pie ce 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 oper ati on by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor f or correct instal lation and t he flag for proper operat ion. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, repl ace the tray x option pass thru sensor assembly.

Check these parts for signs of broken or damaged parts, contaminati on on the drive rollers or wear plate and wear or damage to the drive shaf t bearings. Check the drive rol l assembly and skewed backu p roller for si gns of wear, slick spots, materi al buildup, and oil or grease on the rol lers. Also check for proper operat ion of the paper aligning assemb ly. 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

Assembly Paper Low Sensor Flag Tray X Option System Board

Run the Tray X Sensor Test and check the sensor for proper operation. If incorrect, check the following:

Paper low sensor flag for smooth and correct oper ation.

Paper low sensor for corr ect installation on the autocompensator housing.

Paper low sensor cable for signs of cuts, pinche d wiring or other damage especially at connector J5 on the system board.

If no problem is found, replace the paper low sensor ass em bly. If thi s 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 2 Paper Out Sensor (On

Option System Board)

correct opera tion and installation. If correct, rep lace the option system board. (The paper out sensor is mounted on the system board).

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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 opti on above tray x. Ch eck for sign s of cuts, pinched wiring or damage to the contacts in the connector. Check the autoconnect cable(s) for correct instal lation at the tray x sy stem board. If c orrect , check the continuity of the autoconnect cable(s). If correct, replace the tray x system board. If incorrect, repl ace 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 and slippage of the rollers.

FRU Action

1 Autocompensator

Assembly

Check the autocompensator pic k 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 Action

1 AC Line Cord

AC Jumper (HCIT to Printer) AC input and Output Receptacles AC Wiring Harness

If the base printer works normally using the AC li ne 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, chec k 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 wi re is installed cor rec tly fro m the A C wiring harness to the frame of the HCIT and the nut and lock w asher are tightened.

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4520-xxx

The base printer does not recognize that the high-capacity input tray is installed.

FRU Action

1 High-Capac it y Feeder

Autoc onnect Mechanical Check

2 Base Printer or option

mounted abo ve

3 LVPS

Option System Board

Check the high capa city feeder input tray to make sure it is mounted correctly and is not pushed down into the fram e assem bly or damaged. Be sure the high capacity feeder input tray autoconnect is properly connect ed to the high capacity f eeder tray option board assembly.

Check the opti on or base printer autoconnect for signs of damage. Repair the high cap acity option autoconnect as necessary.

Check the voltages at J11-2 and J11-4. The vol tage measures +24 V dc, If the voltage is correct, replace the high capacity system board assemb ly. If the voltage is incorrect , check the continuity of the AC input cable to the LVPS. If correct, repl ace 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 autoco nnect system to the high capacity input for the high capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J114(red). The v oltages measure +2 4 V dc. If correct, r eplace the high capacity f eeder opt ion syste m board. If incorrect, disconnect J8 from the system board and measure the voltages agai n. 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 t he voltages are correct, check the stepper motor for shorts from the motor housin g to each pin on the motor connector. If you find a short between any p in and the mot or housing, replace the motor assembly. If no shorts are found, replace the high cap acity feeder option control board.

2-68 Service Manual

Check the voltage at J9-1 (light blue). The voltage measures approximately +24 V dc. If incorrect , disconnect the cable at J9 and che ck the voltage again. If the voltage continues to be i ncorrect, replace the high capacity feeder option system board. If the voltage measures cor rectly, check the cable. If the cable is damaged, replace as necessary. If no prob lem is found with the cable, replace the high capacity feeder option control board.

4520-xxx

24X Paper Jam message displays, Paper jammed over the Pass Thru Se nsor. (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 Sens or and Fl ag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Driv e Roll Assembly, Wear Plate, Drive Shaft Bearings and Skew ed Backup Roller

Diagnostic Information 2-69

4520-xxx

Tray X Paper Low Message disp lay s when Tray X is full or has adequate Paper in the tray.

FRU Action

1 Paper Low Switch

Paper Low Swit ch Cable High Capacity Feed er Input System Board

Run the sensor di agnost ics for tr a y X (X=the number that represents the high capacity input tray). If the test fails , disconn ect the paper l ow s witch 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 boar d. I f the display chang es ch eck t he c ontin uity of the swi tch. If i ncorre ct, r eplace t he switch. If correct, replace the switch cable.

Tray X empty message displays whe n there is paper in the high capacity feeder input tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for 2 Paper Out Sensor

(On Option System Board)

correct opera tion and installation. If correct, replace the high capacity feeder sys tem b oard. ( The pa per out sensor is mounted on the high capacity feeder system boar d).

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The elevator tray fails to stop at the correct position and continues to drive into the bottom frame.

FRU Action

1 Lower Li m it Swit ch

Lower Limit Switch Cable

2 High-Capac it y Feeder

Cont rol Board

Check continuity of the lower limit switch. If incorrect , replace the switch. If correct, check the switch cable. If incorrect , r eplace the cabl e. If correct , re place the high capacity feeder option control board.

Disconnect the lower limit switch cable and check the voltage at J2-1 (orange). The voltage measures approximately +5 V dc. If incorrect, replace the high capacity feeder option contr ol board.

The elevator tray down button does not operate. The tray moves to the uppe r posi t i on.

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 Li m it Swit ch

Lower Limit Switch Cable High-Capacity Feeder Cont rol Board

Check the lower limit switch to make sure it is not closed (normally open). If incorr ec t, re pl a ce th e switch . Check the lower limit switch cable for a short between pins 1 and 2. If incorrect, replace the cable. If correct, r eplace 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

Assembly

2 Wear Strips Check the wear strips for glazing or

Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary.

contaminatio n. Replace as required. It is advisabl e to replace all f our wear strips at t he sa m e 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-

Capacity Feeder Option System Board

Be sure the motor cabl e is correctly installed at J1 on the board. Check the cables, damaged or loose wires. Disconnect the motor. Check for a short between each pin and the motor housing. If a pr ob lem is f ound, replace the motor as sembly. If no problem is f ound, measure the resistance bet ween the following pins on the motor cable connector:

Pins 1 (brown) and pin 2 (Yellow)

2-72 Service Manual

The resistance measures between approximately 7.5 and 10.5 ohms. If incorrect, replace the motor assembly. If correct, rep lace t he hi gh capacity feeder option system board.

Lexmark T52x Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Notices and Safety Information

Preface

1. General Information

2. Diagnostic Information