Lexmark T52x Service Manual

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
[e-mail]. 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 .

© Copyright Lexma rk Inte r na tion al, Inc. 20 01 .
All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 an d in applicable FAR pro visions: Lexmark International, Inc.,
Lexington, KY 40550.

P/N: 12G3967

4520-xxx

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

Contents iii

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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

Contents v

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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

vi Service Manual

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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

4520-xxx

Class 1 Laser Statement Label

x Service Manual

4520-xxx

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

4520-xxx

Avis relatif à l’utilisation de laser

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

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

1.

xii Service Manual

4520-xxx

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.

Notices and Safety Information xiii

4520-xxx

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.

xiv Service Manual

4520-xxx

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

4520-xxx

Laser-melding

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

60825.
Klasse I-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.

xvi Service Manual

4520-xxx

Japanese La se r Not i ce

Chinese Laser Notice

Notices and Safety Information xvii

4520-xxx

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.

xviii Service Manual

4520-xxx

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

4520-xxx

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.

xx Service Manual

4520-xxx

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

4520-xxx

Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

xxii Service Manual

4520-xxx

Preface

This manual is divided into the following chapters:

• “General Information” contains a general 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

4520-xxx

xxiv Service Manual

4520-xxx

1. General Information

The Lexmark

TM

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

1-2 Service Manual

4520-xxx

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the service error codes,
user status messages, user error messages, service checks, and
diagnostic aids to determine the printer problem and repair the
failure. After you complete the repair, perform tests as needed to
verify 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

1-4 Service Manual

4520-xxx

2. Diagnostic Information

Start

CAUTION: Remove the power cord from the printer or wall outlet
before you connect or disconnect any cable or electronic 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

2-2 Service Manual