Service Manual
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...Center Pan Assembly Removal 4-16 Controller Board Removal 4-17 Developer Drive Assembly Removal 4-18 Duplex Board Removal 4-19 Duplex Front Cover Assembly Removal 4-19 Duplex Front Cover Door Removal 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 ...
...Center Pan Assembly Removal 4-16 Controller Board Removal 4-17 Developer Drive Assembly Removal 4-18 Duplex Board Removal 4-19 Duplex Front Cover Assembly Removal 4-19 Duplex Front Cover Door Removal 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 ...
Service Manual
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...58 4-58 4-59 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 - 4520-xxx Operator Panel Assembly Removal Operator Panel Cable/Cover Switch Removal Optional 250/500 Paper Tray Assembly Removal. . .... . . . 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...
...58 4-58 4-59 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 - 4520-xxx Operator Panel Assembly Removal Operator Panel Cable/Cover Switch Removal Optional 250/500 Paper Tray Assembly Removal. . .... . . . 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...
Service Manual
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... error. Go to temporarily recover from the error condition. Replace the engine board. 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface Violation by Paperport Device 906 ControllerEngine Link Driver Error ... speed 2-2 Service Manual 4520-xxx Service Error Codes Service Error Codes are indications that the flash which the engine board code is programmed into is bad. Error Code Action 900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash Indicates that a Tray 1 paper feed problem has been detected.
... error. Go to temporarily recover from the error condition. Replace the engine board. 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface Violation by Paperport Device 906 ControllerEngine Link Driver Error ... speed 2-2 Service Manual 4520-xxx Service Error Codes Service Error Codes are indications that the flash which the engine board code is programmed into is bad. Error Code Action 900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash Indicates that a Tray 1 paper feed problem has been detected.
Service Manual
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... your next level for correct installation and secure ground. Mirror Motor Locks/Lost Hsync 934 - Main Drive Motor lost lock 939 Controller Engine Communications Error The controller board and the engine board cannot communicate with the printhead. 4520-xxx Error Code Action 931-935 Printhead Error These errors represent a problem with one another. Mirror...
... your next level for correct installation and secure ground. Mirror Motor Locks/Lost Hsync 934 - Main Drive Motor lost lock 939 Controller Engine Communications Error The controller board and the engine board cannot communicate with the printhead. 4520-xxx Error Code Action 931-935 Printhead Error These errors represent a problem with one another. Mirror...
Service Manual
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...defective IPDS or a PRESCRIBE card. Replace the controller board. Replace the engine board. Indicates the PEL clock check failed. Replace the engine board. Indicates the NVRAM chip on the interconnect card connector. Diagnostic Information 2-5 Replace the controller board. Indicates a delay line calibration failure. Indicates the... on the LVPS assembly is firmly seated with the connector on the engine board has failed. A 941 error can be checked before replacing the controller board. Replace the engine board. These should be created by a noisy AC input power source. ...
...defective IPDS or a PRESCRIBE card. Replace the controller board. Replace the engine board. Indicates the PEL clock check failed. Replace the engine board. Indicates the NVRAM chip on the interconnect card connector. Diagnostic Information 2-5 Replace the controller board. Indicates a delay line calibration failure. Indicates the... on the LVPS assembly is firmly seated with the connector on the engine board has failed. A 941 error can be checked before replacing the controller board. Replace the engine board. These should be created by a noisy AC input power source. ...
Service Manual
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... by the specified device. 4520-xxx Error Code 975 - 979 Network Card X 980 Comm 981 982 Comm 983 984 990 991 Card Action The following : engine board, duplex, tray x (1,2,3,4 or 5), envelope feeder or output bin. If the printer is experiencing unreliable communications to identify the exact component failure. X=any card installed in...
... by the specified device. 4520-xxx Error Code 975 - 979 Network Card X 980 Comm 981 982 Comm 983 984 990 991 Card Action The following : engine board, duplex, tray x (1,2,3,4 or 5), envelope feeder or output bin. If the printer is experiencing unreliable communications to identify the exact component failure. X=any card installed in...
Service Manual
Page 49
...is feeding to the duplex unit due to a sensor malfunction in the paper path when in the duplex unit. Paper was reported to the engine by the duplex system card. Note: This error is the most valuable information to help isolate a failing part or assembly in the duplex ... arrived at the input sensor. The sheet of paper trailing edge did not clear the exit sensor in the duplex unit. The duplex unit engine board never received media notification from the printer. Paper was sensed during POST. motor diagnostic test during POST. The exit sensor detected a sheet of...
...is feeding to the duplex unit due to a sensor malfunction in the paper path when in the duplex unit. Paper was reported to the engine by the duplex system card. Note: This error is the most valuable information to help isolate a failing part or assembly in the duplex ... arrived at the input sensor. The sheet of paper trailing edge did not clear the exit sensor in the duplex unit. The duplex unit engine board never received media notification from the printer. Paper was sensed during POST. motor diagnostic test during POST. The exit sensor detected a sheet of...
Service Manual
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... settings or working on the printer. • Use the resident diagnostics test provided to "Setting Configuration ID" on the new engine board. Diagnostic Information 2-39 4520-xxx Service Checks Note: Anytime the engine board is replaced, the Configuration ID must be reset in NVRAM on page 3-20. Go to help isolate a problem before taking...
... settings or working on the printer. • Use the resident diagnostics test provided to "Setting Configuration ID" on the new engine board. Diagnostic Information 2-39 4520-xxx Service Checks Note: Anytime the engine board is replaced, the Configuration ID must be reset in NVRAM on page 3-20. Go to help isolate a problem before taking...
Service Manual
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... between J4-1 and J4-3 on the toner cartridge is correct, check the voltage at J4-3. If the voltage is activated, replace the engine board. 2-42 Service Manual 4520-xxx Cover Open Switch/Cable Service Check FRU 1 Toner Cartridge 2 Cover Open Switch/Cable Assembly Action Check the... toner cartridge to make sure it is incorrect, replace the engine board. It measures approximately +5 V dc. Disconnect the cover open switch for proper mechanical operation. If the voltage is correctly installed and that ...
... between J4-1 and J4-3 on the toner cartridge is correct, check the voltage at J4-3. If the voltage is activated, replace the engine board. 2-42 Service Manual 4520-xxx Cover Open Switch/Cable Service Check FRU 1 Toner Cartridge 2 Cover Open Switch/Cable Assembly Action Check the... toner cartridge to make sure it is incorrect, replace the engine board. It measures approximately +5 V dc. Disconnect the cover open switch for proper mechanical operation. If the voltage is correctly installed and that ...
Service Manual
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... incorrect, go to "High-Capacity Feeder Input Tray Service Check" on the LVPS board assembly. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the option connectors. Check for signs of damage. Remove the LVPS from the printer. If the ...The easiest to access is incorrect, inform the customer. If correct, go to step 4. Replace the fuse, if blown. If correct, replace the engine board. Check the metal LVPS shield for +5 V dc on any signs of damage that causes the shield to touch components on page 2-66. Diagnostic...
... incorrect, go to "High-Capacity Feeder Input Tray Service Check" on the LVPS board assembly. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the option connectors. Check for signs of damage. Remove the LVPS from the printer. If the ...The easiest to access is incorrect, inform the customer. If correct, go to step 4. Replace the fuse, if blown. If correct, replace the engine board. Check the metal LVPS shield for +5 V dc on any signs of damage that causes the shield to touch components on page 2-66. Diagnostic...
Service Manual
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... on the LVPS output connector, observe all the cables from the engine board. If incorrect, replace the FRUs in the printer. 8 LVPS 9 Engine Board Action Replace fuse F1 if necessary. If the fuse is attached to the engine board can cause the LVPS to over-current and shut the +5 V... necessary safety precautions before applying AC power. Interconnect board If correct, turn the LVPS Off and disconnect the AC line cord. Engine board 2. CAUTION: Before checking fuse F1 turn the printer off and reconnect one cable at the engine board test point. Turn the LVPS on . Service Tip...
... on the LVPS output connector, observe all the cables from the engine board. If incorrect, replace the FRUs in the printer. 8 LVPS 9 Engine Board Action Replace fuse F1 if necessary. If the fuse is attached to the engine board can cause the LVPS to over-current and shut the +5 V... necessary safety precautions before applying AC power. Interconnect board If correct, turn the LVPS Off and disconnect the AC line cord. Engine board 2. CAUTION: Before checking fuse F1 turn the printer off and reconnect one cable at the engine board test point. Turn the LVPS on . Service Tip...
Service Manual
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...it rotates freely. If this does not fix the problem, replace the engine board. Check the voltage at J1-1 on the engine board. Check the voltage at J1-3 on the engine board. Diagnostic Information 2-55 FRU 1 Main Fan 2 Main Fan to Engine Board Cable 3 Error Code 927 (Fan runs) 4 Error Code 927 (... +22 V dc to +24 V dc (printer and fan running) +12 V dc to the engine board, J1 for correct installation. If incorrect, replace the main fan. If incorrect, replace the engine board. Check the continuity of the cable. 4520-xxx Main Fan Service Check Check the cable connections at J1...
...it rotates freely. If this does not fix the problem, replace the engine board. Check the voltage at J1-1 on the engine board. Check the voltage at J1-3 on the engine board. Diagnostic Information 2-55 FRU 1 Main Fan 2 Main Fan to Engine Board Cable 3 Error Code 927 (Fan runs) 4 Error Code 927 (... +22 V dc to +24 V dc (printer and fan running) +12 V dc to the engine board, J1 for correct installation. If incorrect, replace the main fan. If incorrect, replace the engine board. Check the continuity of the cable. 4520-xxx Main Fan Service Check Check the cable connections at J1...
Service Manual
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If incorrect, replace the fuser control board. CAUTION: The fuser may be hot, use caution before removing or servicing. If correct, go to step 4. 2-58 Service Manual If correct, go to the ... to ground. Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit. Note: Check the fuser sub error codes to Engine Board DC Cable Action Check for continuity between J6-1 and J1-2 and between a 923 and 924 error. FRU 1 Fuser Cover Assembly (Assembly includes Thermistor and Thermal...
If incorrect, replace the fuser control board. CAUTION: The fuser may be hot, use caution before removing or servicing. If correct, go to step 4. 2-58 Service Manual If correct, go to the ... to ground. Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit. Note: Check the fuser sub error codes to Engine Board DC Cable Action Check for continuity between J6-1 and J1-2 and between a 923 and 924 error. FRU 1 Fuser Cover Assembly (Assembly includes Thermistor and Thermal...
Service Manual
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...thermistor goes from cold to step 5. Diagnostic Information 2-59 Check the voltage on J16-3 on the engine board. If correct, go to hot. If other contaminants. If incorrect, replace the engine board. Examine the fuser assembly for signs of overheating or damage. If problems are found with the ...for signs of excessive toner, label glue, labels or other problems are found , replace the fuser assembly. 4520-xxx FRU 4 Engine Board 5 Fuser Hot Roll Fuser Hot Roll Bearings Fuser Backup Roll Bearings Fuser Backup Roll Fuser Mechanical Parts Action Perform the print test ...
...thermistor goes from cold to step 5. Diagnostic Information 2-59 Check the voltage on J16-3 on the engine board. If correct, go to hot. If other contaminants. If incorrect, replace the engine board. Examine the fuser assembly for signs of overheating or damage. If problems are found with the ...for signs of excessive toner, label glue, labels or other problems are found , replace the fuser assembly. 4520-xxx FRU 4 Engine Board 5 Fuser Hot Roll Fuser Hot Roll Bearings Fuser Backup Roll Bearings Fuser Backup Roll Fuser Mechanical Parts Action Perform the print test ...
Service Manual
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... the fuser envelope conditioner solenoid adjustment as described in the following order: 1. Engine board 2. FRU Action 1 Fuser Envelope Conditioner Solenoid The operation of the DC fuser to engine board cable. Interconnect board 2-60 Service Manual If incorrect, replace the fuser control board. 5 Interconnect Board Engine Board If no problems are found with the fuser solenoid, LVPS, DC cable or...
... the fuser envelope conditioner solenoid adjustment as described in the following order: 1. Engine board 2. FRU Action 1 Fuser Envelope Conditioner Solenoid The operation of the DC fuser to engine board cable. Interconnect board 2-60 Service Manual If incorrect, replace the fuser control board. 5 Interconnect Board Engine Board If no problems are found with the fuser solenoid, LVPS, DC cable or...
Service Manual
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...defective input sensor or circuit causes the first copy to closed as the sensor flag is found, repair as necessary. FRU 1 Input Sensor Flag 2 Engine Board 3 Input Sensor Cable Action Check the input sensor flag for proper operation. Check the input sensor for damage and proper operation. Service Tip: Run ...a Diagnostic Print Test in and out of the front wiring harness. Check for approximately +5 V dc at J10-10 on the engine board. If correct, replace the input sensor assembly. 4520-xxx Input Sensor Service Check Service Tip: Run the Base Sensor Test. If a problem is...
...defective input sensor or circuit causes the first copy to closed as the sensor flag is found, repair as necessary. FRU 1 Input Sensor Flag 2 Engine Board 3 Input Sensor Cable Action Check the input sensor flag for proper operation. Check the input sensor for damage and proper operation. Service Tip: Run ...a Diagnostic Print Test in and out of the front wiring harness. Check for approximately +5 V dc at J10-10 on the engine board. If correct, replace the input sensor assembly. 4520-xxx Input Sensor Service Check Service Tip: Run the Base Sensor Test. If a problem is...
Service Manual
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... If there are equally spaced horizontal lines across the page, go to come intact with any of the main drive motor cable. on the engine board. Check the continuity of the gears to "Print Quality - A service error code 936 - Check the voltage at J12-6 on page 2-...displayed. Evenly spaced horizontal lines or marks." Warning: Whenever the gearbox assembly is usually caused by a defective motor assembly or engine board. If incorrect, replace the engine board. Do not allow any metal or other material come in contact with the grease in the main drive, toner cartridge, ...
... If there are equally spaced horizontal lines across the page, go to come intact with any of the main drive motor cable. on the engine board. Check the continuity of the gears to "Print Quality - A service error code 936 - Check the voltage at J12-6 on page 2-...displayed. Evenly spaced horizontal lines or marks." Warning: Whenever the gearbox assembly is usually caused by a defective motor assembly or engine board. If incorrect, replace the engine board. Do not allow any metal or other material come in contact with the grease in the main drive, toner cartridge, ...
Service Manual
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... turn, no gear error code 936 or User message 201 Paper Jam displays. Main drive motor assembly 2. Action Check the voltages at J12 on the engine board. Pin number and voltage: J12-11 = +24 V dc J12-8 = +5 V dc (static) 0 V dc (when main drive motor running) J12-7= + 5 V dc (static) 0 V dc (when main drive motor... main drive motor running) J12-1 = + 5 V dc (static) 0 V dc (when main drive motor running) If the voltage is incorrect, replace the FRUs in the following order: 1. Engine board 2-78 Service Manual
... turn, no gear error code 936 or User message 201 Paper Jam displays. Main drive motor assembly 2. Action Check the voltages at J12 on the engine board. Pin number and voltage: J12-11 = +24 V dc J12-8 = +5 V dc (static) 0 V dc (when main drive motor running) J12-7= + 5 V dc (static) 0 V dc (when main drive motor... main drive motor running) J12-1 = + 5 V dc (static) 0 V dc (when main drive motor running) If the voltage is incorrect, replace the FRUs in the following order: 1. Engine board 2-78 Service Manual
Service Manual
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...continuing with the cover switch cable on page 3-11 in a continuous pattern until the printer is turned off. If incorrect, replace the engine board. If correct, replace the operator panel assembly. Note: If the operator panel is an individual cable on some printers and a combination... cable assembly with this service check do the "Button Test" on later models. FRU 1 Operator Panel Assembly 2 Engine Board (No buttons work) Action If any button fails the Button Test, replace the operator panel assembly. Diagnostic Information 2-79 4520-xxx Operator ...
...continuing with the cover switch cable on page 3-11 in a continuous pattern until the printer is turned off. If incorrect, replace the engine board. If correct, replace the operator panel assembly. Note: If the operator panel is an individual cable on some printers and a combination... cable assembly with this service check do the "Button Test" on later models. FRU 1 Operator Panel Assembly 2 Engine Board (No buttons work) Action If any button fails the Button Test, replace the operator panel assembly. Diagnostic Information 2-79 4520-xxx Operator ...
Service Manual
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..., replace the operator panel assembly. It measures approximately +5 V dc. If correct, replace the operator panel assembly. If incorrect, replace the engine board. Check the voltage at J11-2 on the operator panel with no beeps. The voltage measures approximately +5 V dc. Check the continuity of... the cable at the engine board (J11) and at the operator panel. Check for proper installation of the operator panel cable. Engine board 2-80 Service Manual This condition causes the printer to make sure a card is ...
..., replace the operator panel assembly. It measures approximately +5 V dc. If correct, replace the operator panel assembly. If incorrect, replace the engine board. Check the voltage at J11-2 on the operator panel with no beeps. The voltage measures approximately +5 V dc. Check the continuity of... the cable at the engine board (J11) and at the operator panel. Check for proper installation of the operator panel cable. Engine board 2-80 Service Manual This condition causes the printer to make sure a card is ...