Lexmark T522 Service Manual

Lexmark T522 - Optra Laser Printer Manual

Lexmark T522 manual content summary:

  • Lexmark T522 | Service Manual - Page 1
    Lexmark™ T52x 4520-xxx • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Lexmark T522 | Service Manual - Page 2
    U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes point of purchase. Lexmark and Lexmark with diamond design and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or
  • Lexmark T522 | Service Manual - Page 3
    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
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    4520-xxx Transfer Roll Service Check 2-103 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 Service Manual
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    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 Sensor Flag Assembly Removal 4-34 Fuser Lamp Removal 4-35 Fuser Lower Exit Guide Assembly Removal 4-35 High Voltage Power Supply Removal
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    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
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    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 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
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    4520-xxx viii Service Manual
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    4520-xxx Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown: Laser Advisory Label Notices and Safety Information ix
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    4520-xxx Class 1 Laser Statement Label x Service Manual
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    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
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    laser de Classe I. Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d'un laser son système laser sont conçus laser supérieurs à des rayonnements de Classe I . Avvertenze sui prodotti laser 795 nanometri. Il sistema laser e la stampante sono
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    de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico. Declaração sobre Laser 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
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    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
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    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 milliwatt som ndning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd. Notices and Safety Information xv
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    betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling . Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat prescrites. xvi Service Manual
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    4520-xxx Japanese Laser Notice Chinese Laser Notice Notices and Safety Information xvii
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    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
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    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
  • Lexmark T522 | Service Manual - Page 20
    nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. • Die personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias. xx Service Manual
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    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 informações de seguran
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    4520-xxx Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas. xxii Service Manual
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    and service checks used to isolate failing field replaceable units (FRUs). • "Diagnostic Aids" contains tests and checks used to locate or repeat symptoms of printer problems. Printer operation information is provided to enhance the tests and checks. • "Repair Information" provides instructions for
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    4520-xxx xxiv Service Manual
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    personal computers and to most computer networks. The Lexmark T laser printers are available in the following models: Model Name Lexmark T522 Lexmark T522n Lexmark T520 Lexmark T520n Type 4520-210 Non network 4520-220 Network 4520-001 Non network 4520-002 Network General Information 1-1
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    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
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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
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    Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Photoconductor Power-On Reset Power-On Self Test Raster Imaging Processor Read Only Memory Synchronous Dual Random Access Memory Static Random Access Memory Used Parts Return Volts
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    error code that provides the user with information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error message is displayed, go to the "User Error Messages" on page 2-25. If your machine completes the "Power-On Self Test (POST)" on page 2-35 without an
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    4520-xxx Service Error Codes Service Error Codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition. Error Code Action 900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash
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    the paper and POR the printer. If the error continues, go to the "Input Tray(s) Service Check" on page 2-62. 917 Transfer Roll Indicates a problem in the transfer roll area. Go to the "Transfer Roll Service Check" on page 2-103. 920 Fuser Error Indicates that the fuser is below temperature when
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    for correct installation and secure ground. If no problem is found, replace the FRUs in the following order: 1. Controller board 2. Engine board 3. Interconnect board Note: The controller software also can cause a 939 error code. Contact your next level for software support. 2-4 Service Manual
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    Failure 954 NVRAM Failure Action The low voltage power supply zero crossover test failed. • Check the power 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 defective code overlay card, a code upgrade
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    Card is installed in slot x but cannot establish communications with it. 978 - Bad checksum while programming Network Card x. Replace Network Card x. 979 - Flash parts failed while programming Network Card x. If the printer is a network model, replace the controller board. 2-6 Service Manual
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    error detected by the specified device. Invalid command received by the specified device. Invalid command parameter received by the specified device. Note: Service Errors 980 thru 984 can be one of the following: engine board, duplex, tray x (1,2,3,4 or 5), envelope feeder or output bin
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    troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit an example of how the printer shows a duplex unit sub error code. Byte 1
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    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 sensor. *Check the area of the transfer plate and input to the fuser for anything that might cause the paper to
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    media size): *Multi sheet feeding. *A tray size sensing problem. *The media feeding from the paper source is slipping or media is slipping in input to the printer. The input sensor was covered during POST by a piece feeding correctly from a paper source above the detected source. 2-10 Service Manual
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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 84 xx 17 84 xx 18 84 xx 19 The option Tray pass thru sensor was never deactivated. (x-1=media size) (x-2=media source) (x-3=media source where paper jam was detected) *Check the pass
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    beyond the sensor, or the flag and sensor are not operating properly. Go to the "Envelope Feeder Service Check" on page 2-48. The envelope feeder pass thru sensor was never activated. (x1=Media flag are operating correctly, go to the "Envelope Feeder Service Check" on page 2-48. 2-12 Service Manual
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    and tray parts for correct operation. If no problem is found, go to the "Input Tray(s) Service Check" on page 2-62. This code indicates that the media activated the input sensor before the printer EP was ready. (x1=Leading Edge of Media State, x2=Trailing Edge of Media State) The transfer servo
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    printer (could run the print test from the diagnostic test menu). If the media stops over the narrow media sensor again, check the flag and sensor for correct operation. The fuser exit sensor may be bouncing. *This error can be caused by a failing exit sensor or system board. 2-14 Service Manual
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    sensor was never activated by the leading edge of the media fed through the printer. *This error can be displayed after a 201 paper jam. *This can be caused by a defective fuser exit sensor assembly. 8E xx 02 x1 x2 8E xx 06 x1 8E xx 07 x1 8E xx 08 8E xx
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    come up to speed. 8E xx 13 x1 Late feeding from a paper source interfered with the next pick x2 retry. (x-1=Media Size)(x-2=Media Source) 2-16 Service Manual
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    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 Explanation 920 Service - Fuser Error (Under temperature while printing) EN 08 xx yy - 1 EN- zz - - 2
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    yy=The temperature that the fuser wants to reach. 924 Service - Fuser Error (Open Thermistor Failure) EN 18 xx -- - 1 EN -- 00 -- -2 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
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    Data - Note: xx can be any value Explanation 925 Service - Fuser Error (Wrong Fuser Lamp Installed) Note: The Sub Error Codes below are only previous wrong lamp detected. yy=Actual Temperature zz=The temperature that the fuser was trying to reach. Envelope Feeder Sub Error Codes First 6 Bytes
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    pass thru sensor to ensure it is operating correctly. If the sensor test fails, go to the "Envelope Feeder Service Check" on page 2-48. 84 xx 1E x1 x2 If the test passes, look for anything that might cause . *Check to see if the envelope actuates the pass thru sensor flag. 2-20 Service Manual
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    15 18 3D Explanation No duplex error. No problem was reported to the engine by the duplex system card. The leading edge of the sheet of paper never arrived at the input sensor. The duplex unit engine board never received media notification from the printer. The trailing edge of the sheet of paper
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    data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready. The printer is flushing corrupted print data and the current print job is being discarded. No button actions are possible while this message is displayed. 2-22 Service Manual
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    out of Ready and enter the TESTS MENU (Busy state). Press Select for the values. Press Menu until Reset Printer is on the second line of the display. Press Select to reset the printer. A directory of the flash and disk contents is processing or printing because Print Directory is selected from the
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    is displayed. The flash memory is being programmed, which means fonts or macros are being written to flash memory. Do not perform any button actions while this message is displayed. The disk is being formatted. No button actions are possible while this message is displayed. 2-24 Service Manual
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    User Error Messages User Error Message 200 Paper Jam Remove Cartridge 201 Paper Jam Remove Cartridge 202 Paper Jam Open Rear Door Explanation Paper is jammed at the printer Input Sensor. Open the printer upper front door and remove the print cartridge to access the paper jam area. Paper is jammed
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    in output bin. Open the rear door to access the jammed pages. Insert Cartridge or Close Door This message displays when the printer front door is open or the print cartridge is missing. If this message cannot be cleared go to "Cover Open Switch/Cable Service Check" on page 2-42. 31 Defective
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    . If pages are allowed to print, then they are not reprinted once a good print cartridge is inserted. If this does not fix the problem, go to the "Smart Contact Assembly Service Check" on page 2-100. The printer determines the paper length is too short to print the formatted data. This occurs when
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    is displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. 53 Unformatted Flash This message is displayed when the printer detects an unformatted flash at power on. Press Go to clear the message. The flash is marked
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    Engine Code CRC Failure 88 Toner Low Explanation This error This error code displays when the printer detects an unformatted disk at power on. Press Go to clear fuser assembly, transfer roller, and charge roll at this interval to maintain the print quality and reliability of the printer. The parts
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    printer to the Ready state. User Message Toner Low Tray X Missing Explanation If the toner cartridge is low, then "Toner Low" displays. The Toner Low condition clears whenever the upper front door is opened, and Toner Tray X Missing status clears whenever Tray X is reinserted. 2-30 Service Manual
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    clears whenever Tray X goes empty, or Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays. Note: The printer cannot detect when the envelope feeder or multipurpose feeder are low. Diagnostic Information 2-31
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    printer is ready to process any link, no messages display. Link messages are listed in the following table. User Message Parallel Serial Serial X Network available. Serial Port, where X=1,2,3, is attached to PCI connector X. Network card X, X=1,2,3, is attached to PCI connector X. LocalTalk Card
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    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
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    printer automatically clears the message once the option is removed. Once the job is complete, turn off the printer and attach the option again. This message displays when the duplex front access cover is not installed. This message displays when the duplex rear door is open. 2-34 Service Manual
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    " appears on the display. 8. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start. 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
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    Paper feed problems - Base printer or Integrated 500 Paper Tray Paper jams at exit of Redrive Assembly - No Duplex Unit installed. Paper jams at exit of Redrive Assembly - Duplex Unit installed. Fuser Solenoid fails 2-94. Go to the "Print Quality - Residual Image" on page 2-98. 2-36 Service Manual
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    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 • The printer does not recognize the high capacity feeder installed. • Paper feed problem with the high capacity feeder. Action Go to the "High-Capacity
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    thru the Duplex Unit. Go to the "Duplex Unit Service Check" on page 2-45. Symptom Table - Envelope Feeder Symptom Envelopes do not feed from the envelope feeder. Envelopes do not feed properly into base printer. Action Go to the "Envelope Feeder Service Check" on page 2-48. 2-38 Service Manual
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    board. Go to "Setting Configuration ID" on page 3-20. Review the following information before performing any service checks. • Paper feed problems (especially paper jams): Go to "Viewing the Error Log" on page 3-10 and check the printer error log for indications of repetitive entries that help to
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    be caused by a damaged or contaminated charge roll. Service Tip: Check to make sure the right charge roll charge roll bearing and remove the roll from the printer. Leave the paper wrapped around the charge roll Check the charge roll for correct installation, toner buildup, marks, cuts or other signs
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    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 roll link assembly kit. If correct, check the right charge roll link
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    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 correctly installed and that the right and left cartridge tracks are not changes as the switch is activated, replace the engine board. 2-42 Service Manual
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    printer for correct operation. If the base printer operates correctly, go to "High-Capacity Feeder Input Tray Service Check" on page 2-66. If the base printer easiest to access is the envelope feeder connector located behind the lower front door. If +5 V dc is present at any of the connectors, go to
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    the LVPS output connector, observe all necessary safety precautions before applying AC power. Measure the voltage on LVPS output connector CN3 (Pin 1, 2, 10 board If correct, turn the printer off and reconnect one cable at a time until you find the defective assembly. Service Tip: A short or low
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    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 1 Fuse F1 on Duplex Unit the duplex system board. If no problem is found, replace the duplex system board. Diagnostic Information 2-45
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    installation and free movement of the sensor flag. Check to make sure the sensor cable is connected to J8 on the system board. If no problem is found, replace the FRUs in the following order: 1. Exit sensor assembly 2. Duplex unit system board 2-46 Service Manual
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    Motor Action Check the stepper motor cable for cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tray. Check for correct installation of the motor cable connector at J3 on the system board. Check for any shorts between each pin of the
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    with this service check, otherwise verify the interconnect card is functioning properly. Service Tip: The page 2-8. Printer does not recognize the envelope feeder as an attached input autoconnect at the front of the printer. Check the connector for signs of front of the printer. If incorrect, check the interconnect
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    4520-xxx FRU 3 Autoconnect on the Envelope Feeder. Action Check for any signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages: J1-3
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    0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the envelope system board. 2-50 Service Manual
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    to display "Load Envelopes" after envelopes are placed in the hopper. Service Tip: The kick rolls rotate during the attempted feed cycles. FRU , remove any envelopes in the hopper, turn the printer off and disconnect J3 from the system board. Turn the printer on and check the voltage at J3-3 on the
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    parts as necessary. Check the clutch latch assembly to make sure it moves freely. Check the master cam gear and master/kick gear to make sure they rotate together. If not, then the tenons on the master kick gear may be sheared off. If incorrect, replace the master kick gear. 2-52 Service Manual
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    to feed from the hopper. Kick rolls are rotating. Check the deflector gap adjustment before continuing this service check. FRU 1 Deflector Gap Adjustment 2 Weight Assembly 3 Envelope Edge Guide Action Check the deflector gap adjustment. The adjustment may be too narrow. Check the weight assembly
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    or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder. Check the deflector the paper path of the feeder and an envelope also stopped in the base printer paper path. FRU 1 Latch Lever Action Check to make sure the tip of
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    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 1 Main Fan 2 Main Fan to Engine Board Cable 3 Error Code 927 (Fan runs
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    and then on again. A 925 service error indicates the wrong fuser lamp is installed. Be sure the correct type of fuser lamp is installed in the printer. If the correct lamp is installed and a 925 error remains, the problem may be due to the following: • The fuser may have reached standby temperature
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    all safety precautions. Measure the AC line voltage between the two connectors on the fuser end of the LVPS to fuser AC cable. If the voltage is incorrect, turn the power off, and remove the LVPS. Measure the AC line voltage between pins CN1-1 and CN1-3 on the board. If correct, check the
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    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
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    Board 5 Fuser Hot Roll Fuser Hot Roll Bearings Fuser Backup Roll Bearings Fuser Backup Roll Fuser Mechanical Parts Action Perform fuser assembly for signs of overheating or damage. Check the hot roll and backup roll for signs of excessive toner, label glue, labels or other contaminants. If problems
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    on the fuser control board. 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 fuser control board, replace the FRUs in the following order: 1. Engine board 2. Interconnect board 2-60 Service Manual
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    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 fuser assembly. FRU 1 Input Sensor Flag 2 Engine Board 3 Input Sensor Cable Action Check the input sensor flag for damage and proper operation. If a problem
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    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 1 Tray X Option System Board or Compensator Assembly the following order: 1. Autocompensator assembly option 2. Option System board 2-62 Service Manual
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    printer displays the value of X for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1) FRU 1 Pass Thru Sensor and Flag Assembly 2 Power x option pass thru sensor assembly. Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate
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    damage especially at connector J5 on the system board. If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the option system board. Tray X Empty message displays when (The paper out sensor is mounted on the system board). 2-64 Service Manual
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    Tray X System Board Action Check the autoconnect from the printer or option above tray x. Check for signs of cuts 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 , toner or other buildup. Clean or replace as necessary.
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    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 of the HCIT and the nut and lock washer are tightened. 2-66 Service Manual
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    the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly. Check the option or base printer autoconnect for signs of damage. Repair the high capacity option autoconnect as necessary. Check the voltages at J11-2 and J11-4. The voltage
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    V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the necessary. If no problem is found with the cable, replace the high capacity feeder option control board. 2-68 Service Manual
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    printer displays the value of X for the paper tray where the error occurs. Example: 242 is a Paper Jam Tray 2) FRU 1 Pass Thru Sensor and Flag Assembly 2 Power x option pass thru sensor assembly. Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate
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    and installation. If correct, replace the high capacity feeder system board. (The paper out sensor is mounted on the high capacity feeder system board). 2-70 Service Manual
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    to stop at the correct position and continues to drive into the bottom frame. FRU 1 Lower Limit Switch Lower Limit Switch Cable 2 tray moves to the upper position. Service Tip: Open the high-capacity feeder front door and check the black rubber bumper attached to the door switch spring. Be sure the
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    Service Tip: Be sure the paper in tray is within specifications. FRU 1 Autocompensator Assembly 2 Wear Strips Action Check the autocompensator pick arm rollers for sign of glazing, toner motor housing. If a problem is found, replace the motor assembly. If no problem is found, measure the
  • Lexmark T522 | Service Manual - Page 101
    4520-xxx The elevator moves in one direction only. FRU 1 DC Drive Motor Assembly High Capacity Feeder System Board Action Check the voltages at J1 on the high capacity system board. The voltages measure as follows: Static (Motor Not Running) J1-1 (Brown): approximately 0 V dc J1-2 (yellow):
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    feeder option control board. Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly. 2-74 Service Manual
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    4520-xxx Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch. FRU 1 High-Capacity Feeder Option Control Board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Action Check the voltage on the board at
  • Lexmark T522 | Service Manual - Page 104
    of damage. Check to make sure the belt is tracking correctly on the drive pulley, idler pulley and motor pulley. Check the tray drive belt for any signs of damage. Check to make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys. 2-76 Service Manual
  • Lexmark T522 | Service Manual - Page 105
    or vibration. Determine if the noise is in the main drive, toner cartridge, fuser or main drive gearbox. Look for any loose or worn parts in the developer drive assembly, main drive gearbox or fuser. Repair as necessary. A service error code 936 - Transport Motor may be displayed. Check the voltage
  • Lexmark T522 | Service Manual - Page 106
    ) 0 V dc (when main drive motor running) If the voltage is incorrect, replace the FRUs in the following order: 1. Main drive motor assembly 2. Engine board 2-78 Service Manual
  • Lexmark T522 | Service Manual - Page 107
    the operator panel cable. If incorrect, replace the cable. If correct, replace the operator panel assembly. Operator Panel Display Service Check Service Tip: The printer has detected a problem with the engine board, operator panel cable or operator panel assembly if POST does not complete and the
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    the operator panel assembly. If incorrect, replace the engine board. Check to make sure a card is not plugged in backward. This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps. Check the voltage at Pin J11-1 and J11-3. The voltage measures
  • Lexmark T522 | Service Manual - Page 109
    page 3-12 from the menu if the SDRAM Memory card is correctly installed and not broken or damaged. If the test fails, replace the SDRAM card. If the problem continues, replace the controller board. Hard Disk Option Service Tip: The Lexmark T printers support one hard disk option. Check to make sure
  • Lexmark T522 | Service Manual - Page 110
    contact your next level of support before replacing the network card. Error Code 977 - Network Card X A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communications with the network card. 2-82 Service Manual
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    , select Sensor Tests and select Standard Bin. Check the sensor and flag for proper operation. If you find no problem with the sensor and flag, continue with the service check. Service Tip: Be sure the flag is correctly installed. The Output Bin Sensor is a normally closed sensor with the sensor
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    any signs of worn rollers, contaminated rollers or binds. Replace the alignment assembly if any problem is found. Check the inner paper deflector for correct installation. If the deflector is bowed wear, scratches or rough spots. Replace the wear strips if a problem is found. 2-84 Service Manual
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    reduce the stack height. Replace both pick rolls if the paper appears to be flat in the tray but there is still a problem. Failures occur mainly near the bottom of the stack of paper. The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly
  • Lexmark T522 | Service Manual - Page 114
    ) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The test provides failure information on the display for approximately three seconds. If the test indicates that a problem is detected, replace the controller board. 2-86 Service Manual
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    not contain any service replaceable parts or components. If service error code 930 displays, the wrong printhead is installed in the printer. Note: A If correct, replace the printhead assembly. These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror
  • Lexmark T522 | Service Manual - Page 116
    Before troubleshooting any print quality problems do the following: • Install another print cartridge if available before proceeding with the service checks. • Use Tray 1 to test for print quality of the base printer. • Replace the charge roll if it is damaged or contaminated. • Replace the transfer
  • Lexmark T522 | Service Manual - Page 117
    Service Tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum. FRU 1 High Voltage Contacts 3 Charge Roll Conductive Bushing 2 HVPS 3 HVPS Cable (Part
  • Lexmark T522 | Service Manual - Page 118
    Section Action Check the print cartridge for any signs of damage, especially the PC drum contact on the cartridge. Check the PC drum contact the following voltages from connector J10 to printer ground: Printer Idle J10-5 measures +24 V dc Printer Printing J10-5 measures +24 V dc If Service Manual
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    previous laser printers. The printer is interlocked through the front top cover interlock switch. Print Quality - Random Marks Service Tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll or transfer roll
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    assembly 2. Main drive gearbox assembly Replace the FRUs in the following order: 1. Toner cartridge 2. Charge roll 3. Developer drive assembly Replace the toner cartridge. Replace the FRUs in the following order: 1. Redrive assembly 2. Fuser assembly Replace the transfer roll. 2-92 Service Manual
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    the redrive assembly. Replace the FRUs in the following order: 1. Alignment assembly 2. Main drive gearbox assembly Replace the FRUs in the following order: 1. Toner cartridge 2. Main drive gearbox assembly Replace the redrive assembly. Replace the alignment assembly. Diagnostic Information 2-93
  • Lexmark T522 | Service Manual - Page 122
    4520-xxx Print Quality - Background Service Tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background. Some problems occur with printers that run a large amount
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    voltages from J10 to printer ground. Printer Idle J10-1 approximately 0 V dc J10-2 approximately 4 V dc J10-4 approximately 0 V dc Printer Printing J10-1 varies 0 is continuity, replace the HVPS. If this does not correct the problem, replace the engine board. If J10-2 voltage is incorrect or if
  • Lexmark T522 | Service Manual - Page 124
    changes or goes away. If this fixes or changes the problem, then check the springs and charge roll link arm assemblies for binds or defective parts. Replace as necessary. Check the charge roll for any signs of toner buildup or other contamination on the outer edges that correspond to the bands
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    cable harness. If there is continuity, replace the HVPS. If this does not correct the problem, replace the engine board. Turn the printer off and check the resistance between J10-7 and printer ground. The resistance measures approximately 0 ohms. If incorrect, make sure the engine board is mounted
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    cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade and other parts inside the print cartridge. FRU 1 Hot Roll Fuser Assembly Action Check the fuser assembly for signs of toner the right side transfer arm assembly. If correct
  • Lexmark T522 | Service Manual - Page 127
    Service Tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper. FRU 1 Hot Roll Fuser Assembly 2 Transfer Roll Transfer Plate Assembly Action Toner is being carried out on the backside of the media. This problem
  • Lexmark T522 | Service Manual - Page 128
    Lexmark 4520 print cartridge is correctly installed in the printer. The cartridge is easily identified by the contact board on the right side rear of the cartridge. Install another print cartridge before attempting to troubleshoot the printer smart cartridge contact assembly. 2-100 Service Manual
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    1329048) and invoking the Serial Post Diagnostic Test. The test helps isolate the printer from the serial cable and host. The test provides failure information on the display for approximately three seconds. If the test indicates a problem, replace the controller board. Diagnostic Information 2-101
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    The toner sensor cable is part of the front harness and part printer. If incorrect, replace the engine board. If correct, replace the toner sensor assembly. A bad ground connection between J10-13 on the engine board and pin 3 on the toner sensor results in a 929 service error. 2-102 Service Manual
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    for damage, toner or foreign material buildup. Service Tip: The transfer roll assembly is part of the Maintenance Kit and is replaced when a '80 Scheduled Maintenance" message displays. Ask the customer if they have replaced the transfer roll recently. CAUTION: Make sure the printer is powered off
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    the printer runs the print test. If the voltage is incorrect, check the continuity of line J10-3 in the front cable harness to the HVPS. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If the problem continues, replace the engine board. 2-104 Service
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    Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostic Mode To enter the Diagnostic Mode: 1. Turn
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    Quick Disk Test from the Device Tests menu. • The power indicator blinks while the test is in progress. • "Quick Disk Test/Test Passed the test passes and the power indicator turns on solid. • "Quick Disk Test/Test Failed" message displays if the test failed and the power indicator turns on solid. 2.
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    /BAD:000000 00%" message displays. The screen updates periodically indicating the percentage of test completed and the number of bad blocks found. 3. The power indicator blinks during the test. The test can be canceled anytime during the test by pressing Return/Stop. • Once the test is complete, the
  • Lexmark T522 | Service Manual - Page 136
    Flash Test from the Device Tests menu. • The power indicator blinks while the test is running. • "Flash Test/Test Passed" message displays if the test passes and the power indicator turns on solid. • "Flash Test/Test Failed" message displays if the test fails and the power indicator turns on solid. 2. Press
  • Lexmark T522 | Service Manual - Page 137
    Emulation Outdated. Time stamps indicate the download emulation and RIP code are incompatible. To help resolve Download Emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations. To Disable the Download Emulation: 1. Turn the
  • Lexmark T522 | Service Manual - Page 138
    by 1 unit moves the margin 1/100 inch. A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin. 3. Press Return/Stop to exit the test. Check the Top Margin Offset of the base printer. 3-6 Service Manual
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    This test is used to determine whether or not the Duplex sensors and switches are working correctly. Select Sensor Test from the Duplex Tests menu. Manually actuate each of the duplex sensors. When the sensor/ switch is closed, CL (closed) displays, when the sensor/switch is open, OP (Open) displays
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    test continues to run until the printer is powered off. • The power indicator blinks while the test is running. • The duplex unit runs the motor at a hex) Ignore bytes EE and FF. If the test fails, remove the drive belt from the duplex D.C. motor and run the motor test again. For the Service Manual
  • Lexmark T522 | Service Manual - Page 141
    is feeding. • "Duplex Feed 1/Feeding" message displays while the paper is feeding through the printer. • "Duplex Feed 1/Clear Paper" message displays when the paper reaches paper stop position 1 and the power indicator turns on solid. Duplex Feed 2 Test This test feeds a blank sheet of paper to
  • Lexmark T522 | Service Manual - Page 142
    Log The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 the screen. 3. Press Return/Stop to exit the Clear Log menu. 3-10 Service Manual
  • Lexmark T522 | Service Manual - Page 143
    4520-xxx Hardware Tests Select the following Hardware Tests from this menu: • LCD Test • Button Test • DRAM Memory Test • ROM Memory Test • Parallel Wrap (if available) • Serial Wrap (if available) • Serial 1 Wrap (if available) • Serial 3 Wrap (if available) LCD Test To run the LCD Test: 1. Select
  • Lexmark T522 | Service Manual - Page 144
    memory can be set and read correctly. To run the SDRAM Memory Test: 1. Select SDRAM Memory Test from the menu. The power represents the number of times the memory test has failed and finished with errors count is reached, the test is stopped, the power indicator is turned on solid, and the final
  • Lexmark T522 | Service Manual - Page 145
    is used to check the validity of the controller board code and fonts. To run the ROM Memory Test: 1. Select ROM Memory Test from the menu. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in process. The test runs continuously. 2. Press Return/Stop to
  • Lexmark T522 | Service Manual - Page 146
    Wrap or Serial 3 Wrap. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is running. 3. This test runs continuously unless canceled by maximum count is reached the test stops. The power indicator goes on solid and the final results display. 4. Press Return/Stop to
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    the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser P = Input Tray Pass Thru Sensor 2. Once this message displays, the servicer can manually actuate each sensor. The tray empty sensor can be actuated by hand,
  • Lexmark T522 | Service Manual - Page 148
    Test This test is used to determine if the sensors located inside the printer are working correctly. The following sensors can be checked: Toner Optical Sensor Input Sensor Output Sensor (Fuser Exit) Narrow Media Sensor Front Door Sensor (Upper Front Cover) To run the Base Sensor Test: 1. Select the
  • Lexmark T522 | Service Manual - Page 149
    Margin: -20 to +20 Each increment causes approximately .55 mm shift in the bottom margin. Top Margin: -25 to +25 Left Margin: -25 to +25 Right Margin: -10 to +10 To set Print Registration: 1. Select Registration from the Diagnostic
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    the Page Count This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer NVRAM Memory where the page count is stored the menu. 2. Press Return/Stop to exit the Diagnostic menu. 3-18 Service Manual
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    4520-xxx Maintenance Page Count This counter is reset by the servicer after a "80 Scheduled Maintenance" message displays (300K copies) and a maintenance kit is installed . When the reset operation is complete, the menu returns to the Printer Setup Reset Maintenance Count screen. Diagnostic Aids 3-19
  • Lexmark T522 | Service Manual - Page 152
    : 1. Enter the Diagnostic mode. 2. Select Configuration ID from the Printer Setup menu. • The current ID displays on the screen. The Configuration ID NVRAM and the printer automatically PORs to activate the new setting. Note: When the printer PORs it does so in the normal mode. 3-20 Service Manual
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    with paper curl on low grade papers and or problems with letterheads on some types of media. The fuser temperature can be adjusted as follows: NORMAL, LOWER, LOWEST Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from
  • Lexmark T522 | Service Manual - Page 154
    the diagnostic Print Tests is to verify that the printer can print on media from each of the side of the paper, regardless of the duplex setting or the presence of a duplex unit. If a source is selected that contains envelopes, an envelope test pattern is printed. Feed problems. 3-22 Service Manual
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    printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality test consists of fuser temperature, warm up time, transfer, print contrast and charge roll settings. • Contents of the Diagnostic Error Log. • Printer configuration information: - printer
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    panel menus and their values. • A list of the installed options and features such as RAM memory cards, optional input paper trays, envelope feeder, duplex unit, output bins, flash or disk. • Printer information such as serial number, page count, installed RAM, engine code level, RIP code level
  • Lexmark T522 | Service Manual - Page 157
    arbors of the arm. These springs aid to prevent the arm from bouncing. If the arm appears to be binding or sticky near the bottom of the tray these springs may be the problem. Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at
  • Lexmark T522 | Service Manual - Page 158
    or "Hot Plug" any options with the base printer power turned on. Duplex Unit The duplex unit interface is a six pin autoconnector that provides a below the printer. The paper input sensor is located in the rear of the duplex unit under the input paper guide. The paper printer. 3-26 Service Manual
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    assembly, left and right lamp brackets and cover. This is a complete assembly and the parts cannot be individually replaced as in previous Lexmark laser printers. The thermal fuse (two fuses in series) protects the fuser assembly and surrounding parts from ignition in the event of a failure in the
  • Lexmark T522 | Service Manual - Page 160
    exiting the input sensor too late or jamming in the fuser assembly prior to activating the exit sensor flag in time or not at all. Error Message 202 - Paper Jam - Open Rear Door This message indicates the paper is jammed at the printer exit sensor. This can be caused by the paper arriving
  • Lexmark T522 | Service Manual - Page 161
    4520-xxx Error Message 24x (x=Tray 1 through 5) Paper Jam Check Tray x The paper has not cleared the pass thru sensor or reached the pass thru sensor of the option above tray x. Error Message 250 - Paper Jam - Check MP Feeder The paper is jammed in the multipurpose feeder and has not reached the
  • Lexmark T522 | Service Manual - Page 162
    4520-xxx 3-30 Service Manual
  • Lexmark T522 | Service Manual - Page 163
    to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: • Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until you
  • Lexmark T522 | Service Manual - Page 164
    mounting screws but do not remove the motor. 2. Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm (±.5 mm) motor belt deflection. 3. Tighten both mounting screws being careful to maintain the adjustment. 4. Reassemble the duplex unit. 4-2 Service Manual
  • Lexmark T522 | Service Manual - Page 165
    adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the . Select a value and run several copies of the media that displays a curl problem. It may take several tries before improvement is noticed. Note: This setting has no
  • Lexmark T522 | Service Manual - Page 166
    consists of alignment diamonds, horizontal lines that can be used for skew adjustment, page count setting, printer serial number code levels and print registration settings. 6. Check the Quick Test Page for any sign mounting screws being careful not to move the printhead assembly. 4-4 Service Manual
  • Lexmark T522 | Service Manual - Page 167
    out far enough to allow the alignment assembly to be removed from the printer. It is not necessary to completely remove the screw. 4. Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver until it touches the back of the reference plate and tighten the nut
  • Lexmark T522 | Service Manual - Page 168
    left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want. 4-6 Service Manual
  • Lexmark T522 | Service Manual - Page 169
    to service the printer. Each toner level sensor charge roll main drive gearbox EP module to left and right side frame developer drive assembly stacker duct to frame cartridge hold down assembly MPT deflector interconnect board shield ground engine board shield to frame laser
  • Lexmark T522 | Service Manual - Page 170
    Thread Cutting left frame paper alignment assembly mounting 2 toner cartridge guide track mounting 2 left side frame to center attach 3 pan right side frame to attach 2 center pan deflector mounting 2 M3x5 mm INA cover attach 6 Taptite (2 screws per cover) 4-8 Service Manual
  • Lexmark T522 | Service Manual - Page 171
    to attach 1 interconnect shield ground lower stacker duct mounting 1 ground cables to ground attach 1 (center pan - front) cable clip (main drive mounting 2 gearbox, BTM) fuser screw mounting 7 LVPS mounting 2 auto compensator hanger bracket mounting 1 Repair Information 4-9
  • Lexmark T522 | Service Manual - Page 172
    M3x6 mm Taptite Panhead stacker duct controller to shield controller board in pan shield ground LVPS fuser cover cable clip outer shield INA cover mounting 1 mounting 2 mounting 2 mounting 2 attach 1 mounting 2 mounting 2 mounting 2 mounting 6 mounting 4 4-10 Service Manual
  • Lexmark T522 | Service Manual - Page 173
    mounting 1 Plastite Thread Forming right side frame to pan attach 3 left side frame to pan attach 1 M3x6 mm SEMS Machine Screw with washer fuser board ground cable mounting 1 M3.5x12 mm printhead to EP frame mounting 3 Plastite Thread Forming with washer Repair Information 4-11
  • Lexmark T522 | Service Manual - Page 174
    , obstructing the paper path, or restricting mechanical movement. Covers Removals Left Door Removal 1. Open the upper and bottom front covers. 2. Press the two left door latch buttons (A) and open the left door. 3. Release the left door from the rear hinges and remove the door. 4-12 Service Manual
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    4520-xxx Right Cover Removal 1. Open the upper and bottom front covers. 2. Release the cover latch (A) and remove the right cover mounting screw (B). Repair Information 4-13
  • Lexmark T522 | Service Manual - Page 176
    4520-xxx 3. Remove the redrive assembly. 4. Remove the right side cover mounting screw (B). 5. Remove the right side cover. 4-14 Service Manual
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    slots and remove the cover. Note: When removing the cover, hold the upper and lower latch and spring to prevent them from falling into the printer. Repair Information 4-15
  • Lexmark T522 | Service Manual - Page 178
    the fuser wiper cover latch and remove the cover. 5. Remove the paper full sensor flag assembly from the mounting bracket. 6. Remove the mounting screws (A) and remove the cover. Center Pan Assembly Removal 1. Remove the left and right side frames. 2. Remove the pan assembly. 4-16 Service Manual
  • Lexmark T522 | Service Manual - Page 179
    4520-xxx Controller Board Removal 1. Remove the inner EMC shield. 2. Remove the controller board mounting screws (A). 3. Remove the controller board parallel port mounting screws, if installed. 4. Remove the USB port mounting screws (C), if present. 5. Remove the serial port mounting screws if
  • Lexmark T522 | Service Manual - Page 180
    developer drive assembly. Note: Be sure the developer drive assembly wheel aligns with the hub on the main drive assembly when reinstalling the assembly. 4-18 Service Manual
  • Lexmark T522 | Service Manual - Page 181
    the base printer from the duplex assembly. 2. Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable cover assembly latches from the bottom of the duplex assembly. 5. Remove the duplex front cover assembly. Duplex Front Cover Door Removal 1. Remove the
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    assembly latch from the bottom front left side of the duplex assembly. 7. Remove the center drive deflector assembly and the frame assembly from the duplex unit. 8. Remove the two Adjust the "Duplex Motor Drive Belts" on page 4-2 whenever you remove or replace the duplex motor. 4-20 Service Manual
  • Lexmark T522 | Service Manual - Page 183
    4520-xxx EMC Shields Removals Inner EMC Shield Removal 1. Remove the left door. 2. Remove the outer EMC shield. 3. Remove all option boards from the connector board slots. 4. Remove the inner EMC shield mounting screws (A). 5. Remove the ground screw (B). 6.
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    4520-xxx Outer EMC Shield Removal 1. Remove the left door. 2. Loosen the outer EMC shield mounting screws (A) and remove the shield. 4-22 Service Manual
  • Lexmark T522 | Service Manual - Page 185
    4520-xxx Engine Board Removal 1. Remove the inner EMC shield. 2. Disconnect all cables from the engine board. 3. Remove the engine board mounting screws (A). 4. Remove the engine board shield mounting screw (B) from the main drive motor assembly. 5. Remove the engine board. Note: Anytime the engine
  • Lexmark T522 | Service Manual - Page 186
    4520-xxx Main Fan Removal 1. Remove the top rear cover. 2. Remove the inner EMC shield. 3. Note the routing of the main fan cable (A) and disconnect the cable from the engine board at connector J1. 4. Release the four latches (B) and remove the fan from the left side frame. 4-24 Service Manual
  • Lexmark T522 | Service Manual - Page 187
    4520-xxx Frames Removals EP Frame Assembly Removal 1. Remove the left and right side frames. 2. Remove the EP frame assembly. Left Side Frame Removal 1. Remove the engine board. 2. Remove the main drive assembly. 3. Remove the upper front cover hinge assembly. 4. Remove the multipurpose tray/lower
  • Lexmark T522 | Service Manual - Page 188
    4520-xxx 7. Place the printer on its back and remove the left side frame mounting screws (A). 8. Remove the left side frame. 4-26 Service Manual
  • Lexmark T522 | Service Manual - Page 189
    screw (A), disconnect the sensor cable and remove the toner sensor. 6. Remove the right side frame mounting screws (B) and remove the right side frame. 7. Remove the smart cartridge contact assembly mounting screw (C). CAUTION: Be sure the fuser assembly has cooled before working on any of the
  • Lexmark T522 | Service Manual - Page 190
    4520-xxx Fuser Removal 1. Remove the redrive assembly. 2. Remove the ground screw (B). 3. Remove the fuser mounting screws (A). 4. Disconnect the AC fuser lamp connector from the LVPS. 5. Disconnect the DC fuser cable from the engine board. 6. Remove the fuser. 4-28 Service Manual
  • Lexmark T522 | Service Manual - Page 191
    4520-xxx Fuser Board Removal 1. Remove the fuser assembly. 2. Disconnect the cables (A) from the fuser board. 3. Remove the fuser board mounting screws (B). 4. Lift the fuser board from the fuser assembly. Repair Information 4-29
  • Lexmark T522 | Service Manual - Page 192
    cover. 4. Remove the two screws (A) from the right side fuser lamp contact cover. 5. Remove screw (B) that attaches the fuser lamp contact to the fuser cover, on each end of the cover. 6. Detent the latch (C), and remove the cover. 7. Detent the latch (C), and remove the cover. 4-30 Service Manual
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    4520-xxx CAUTION: Take care when removing the screw, as the lamp is under pressure. When the contact is released, damage to the lamp or contact may occur. Repair Information 4-31
  • Lexmark T522 | Service Manual - Page 194
    Removal 1. Remove the upper paper deflector. 2. Remove the fuser transfer roll. 3. Remove the inner paper deflector. 4. Lift the left side of the fuser transfer plate (A) and move the plate to the left to clear the right side from its mounting. 5. Remove the fuser transfer plate. 4-32 Service Manual
  • Lexmark T522 | Service Manual - Page 195
    Solenoid Removal 1. Remove the fuser assembly. 2. Disconnect the solenoid cable from the fuser board. 3. Remove the solenoid mounting screw (A). 4. Disconnect the solenoid link (B). 5. Remove the solenoid from the fuser assembly. Note: Perform the "Fuser Solenoid Adjustment" on page 4-3 whenever
  • Lexmark T522 | Service Manual - Page 196
    lower exit guide assembly, and snap the sensor into place. Be sure the sensor operates correctly. 6. Replace the cable tie on the cable bundle. Fuser Exit Sensor Flag assembly can be removed without removing the lower exit guide assembly. Make sure the narrow media sensor flag is correctly positioned before
  • Lexmark T522 | Service Manual - Page 197
    following table to identify and install the correct lamp. Description Fuser Lamp 115V 630W Fuser Lamp 220V 630W Fuser Lower Exit Guide Assembly Removal 1. Remove the fuser assembly. 2. Remove the fuser cover assembly. 3. Remove the fuser detack housing assembly. 4. Disconnect the sensors from the
  • Lexmark T522 | Service Manual - Page 198
    4520-xxx High Voltage Power Supply Removal 1. Remove the inner paper deflector. 2. Remove the toner sensor cable from the retainer (A) on the front of the HVPS. 3. Remove the right side cover. 4. Disconnect the HVPS cable from the HVPS at connector (C). 5. Disconnect the transfer roll cable from the
  • Lexmark T522 | Service Manual - Page 199
    the paper tray. 2. Remove the left door. 3. Remove the inner EMC shield. 4. Disconnect the compensator motor cable (A) from the engine board. 5. Place the printer on its side. 6. Locate the integrated tray compensator assembly (B) on the bottom of the printer and disconnect the compensator arm bias
  • Lexmark T522 | Service Manual - Page 200
    Pick Roll Assembly Removal 1. Remove the paper tray. 2. Place the printer on its side. 3. Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer. 4. Unsnap the pick roll assembly (D) from its mounting and remove. 4-38 Service Manual
  • Lexmark T522 | Service Manual - Page 201
    the LVPS. 4. Disconnect all cables from the interconnect board. Go to "Interconnect Board" on page 5-14 to identify the correct jumper locations for your printer. 5. Place the printer on its back and remove the mounting screws (A). 6. Remove the interconnect board assembly. Repair Information 4-39
  • Lexmark T522 | Service Manual - Page 202
    4520-xxx Low Voltage Power Supply Removal 1. Remove the right cover. 2. Remove the LVPS mounting screws (A) from the rear of the bottom pan. 3. Pull the LVPS assembly from the right side of the printer. 4-40 Service Manual
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    4520-xxx 4. Press the release latch on the fuser lamp cable connector (B) and disconnect from the LVPS. 5. Remove the fuser assembly. Repair Information 4-41
  • Lexmark T522 | Service Manual - Page 204
    4520-xxx 6. Disconnect the interconnect card cable from the LVPS (C). 7. Remove the LVPS. 4-42 Service Manual
  • Lexmark T522 | Service Manual - Page 205
    Assembly Removal 1. Remove the inner EMC shield. 2. Remove the gear guard. 3. Remove the developer drive assembly. 4. Remove the transfer shaft (A) through the bottom of the printer. 5. Remove all cables from the cable clamps (B) on the main drive assembly. 6. Remove the ground screw (C), and remove
  • Lexmark T522 | Service Manual - Page 206
    4520-xxx Main Drive Motor Removal 1. Remove the main drive assembly. 2. Remove the main drive motor mounting screws (A). 3. Remove the main drive motor. 4-44 Service Manual
  • Lexmark T522 | Service Manual - Page 207
    4520-xxx Multipurpose Tray/Lower Deflector Assembly Removal 1. Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts. Warning: Be
  • Lexmark T522 | Service Manual - Page 208
    4520-xxx 2. Remove the upper deflector. 3. Remove the solenoid mounting screw. 4. Remove the screws (A) mounting the multipurpose tray/lower deflector assembly. 5. Remove the multipurpose tray/lower deflector assembly. 4-46 Service Manual
  • Lexmark T522 | Service Manual - Page 209
    4520-xxx Operator Panel Assembly Removal 1. Remove the upper front cover. 2. Gently press the operator panel lens tab (A) to loosen the operator panel. 3. Disconnect the operator panel cable and remove the operator panel. Repair Information 4-47
  • Lexmark T522 | Service Manual - Page 210
    the cable routing through the printer before you remove the operator panel cable/cover open switch assembly. 1. Remove the left door, left cover, upper front connectors. 8. Route the cables through the printer and down the inside of the engine board shield. 9. Plug the cables into the engine
  • Lexmark T522 | Service Manual - Page 211
    and other paper feed options to access the failing optional paper tray assembly. Paper Tray Compensator Assembly Removal 1. Remove the printer and other paper feed options. 2. Disconnect the compensator assembly bias spring from the tray frame. 3. Disconnect the compensator assembly motor cable
  • Lexmark T522 | Service Manual - Page 212
    1. Remove the upper paper deflector assembly. 2. Remove the inner paper deflector assembly. 3. Release the input paper sensor from its mounting and remove. 4. Remove the left door. 5. Remove the paper alignment assembly mounting screws (A). 4-50 Service Manual
  • Lexmark T522 | Service Manual - Page 213
    4520-xxx 6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame and remove the screw. 7. Remove the paper alignment assembly. Note: Do the "Paper Alignment Assembly Adjustment" on page 4-5 when you reinstall the assembly. Repair Information 4-51
  • Lexmark T522 | Service Manual - Page 214
    pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer and remove the deflector. Upper Paper Deflector Assembly Removal 1. Open the multipurpose tray and remove and slide to the right. 3. Remove the upper deflector assembly. 4-52 Service Manual
  • Lexmark T522 | Service Manual - Page 215
    4520-xxx Paper Input Sensor Removal 1. Remove the inner paper deflector assembly. 2. Disconnect the paper input sensor cable from the input sensor. 3. Release the input paper sensor from its mounting and remove. Paper Size Sensing Board Removal 1. Disconnect the paper size sensing board cable from
  • Lexmark T522 | Service Manual - Page 216
    4520-xxx Printhead Removal 1. Remove the laser assembly cover. 2. Disconnect the printhead cables (A) from the printhead assembly. 3. Remove the printhead mounting screws (B) and " on page 4-4 whenever you remove or replace the printhead assembly or loosen the mounting screws. 4-54 Service Manual
  • Lexmark T522 | Service Manual - Page 217
    4520-xxx Redrive Assembly Removal 1. Remove the redrive door assembly. 2. Remove the redrive exit cover. 3. Remove the redrive assembly mounting screws (A). 4. Release the redrive assembly mounting latches (B) and remove the redrive assembly. Repair Information 4-55
  • Lexmark T522 | Service Manual - Page 218
    Disconnect smart cartridge cable. 2. Remove print cartridge. 3. Remove transfer plate. 4. Unlatch smart cartridge contact assembly (A) from the right frame assembly. 5. Remove smart cartridge contact (B). 6. Disconnect the smart contact assembly cable (C) from the engine board. 4-56 Service Manual
  • Lexmark T522 | Service Manual - Page 219
    4520-xxx Toner Sensor Removal 1. Remove the right side cover. 2. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable and remove the toner sensor. Repair Information 4-57
  • Lexmark T522 | Service Manual - Page 220
    cover and remove the print cartridge. 2. Unsnap the transfer roll assembly from the left pivot arm. 3. Lift the transfer roll assembly toward the left and remove it from the printer. Upper Paper Deflector Assembly and slide to the right. 3. Remove the upper deflector assembly. 4-58 Service Manual
  • Lexmark T522 | Service Manual - Page 221
    4520-xxx Upper Front Cover Hinge Assembly Removal 1. Remove the upper front cover. 2. Remove the laser assembly cover. 3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and remove the pins. Note the pin orientation
  • Lexmark T522 | Service Manual - Page 222
    mounting screw (A) and remove the switch assembly. 5. Note the routing of the interlock switch assembly cable and disconnect the cable on the engine board. 4-60 Service Manual
  • Lexmark T522 | Service Manual - Page 223
    4520-xxx 5. Connector Locations Low Voltage Power Supply Connector CN3 Interconnect Board Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Signal +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V
  • Lexmark T522 | Service Manual - Page 224
    4520-xxx 5-2 Service Manual
  • Lexmark T522 | Service Manual - Page 225
    4520-xxx High Voltage Power Supply Connector CN1 Engine Board Pin No. 1 2 3 4 5 6 7 8 Signal Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT Connector Locations 5-3
  • Lexmark T522 | Service Manual - Page 226
    Return +24 V dc Return ReFREQ LOCKn Start* +24 V dc Return +24 V dc Cover Closed Ground +5 V dc Ground Video* Ground +5 Phead LPOW Ground LADJ* LFB LENA* 5-4 Service Manual
  • Lexmark T522 | Service Manual - Page 227
    J6 Output Level Sensor J8 Printhead HYSNC J10 Cartridge/Sensor/Input Sensor/HVPS Pin No. 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal HOPFULL* Ground Opt2 Ground +5 V dc HsyncID Hsyncin Ground AT Servo (HVPS) Servo OutT (HVPS) TXENABLE (HVPS) Transfer (HVPS) +24 V dc (HVPS) Charge (HVPS
  • Lexmark T522 | Service Manual - Page 228
    4520-xxx Connector J11 Operator Panel J12 Transport Motor J14 Autoconnect (Options) Pin No. 1 2 3 4 5 1 2 4 5 6 7 8 9 10 11 1 2 3 4 Signal FPIRQ Ground I2CCLK +5 V dc I2CDATA ON/OFF Ground +5 V dc MTR1 Dir MTR4 MTR3 +24 V RET +24 V RET +24 V dc RXDIN Ground TxBR Ground 5-6 Service Manual
  • Lexmark T522 | Service Manual - Page 229
    4520-xxx Connector Pin No. J15 Integrated Paper Tray - Paper 1 Size Sensor 2 3 4 5 6 7 8 9 10 J16 Fuser 1 2 3 4 5 6 7 8 J17 MPT Pick 1 2 J18A Auto Compensator 1 2 J18B Auto Compensator 1 2 3 Signal +5 V dc PSIZE2 Ground PSIZE1 +24 V dc Ground POUT +5 V dc Paper Low
  • Lexmark T522 | Service Manual - Page 230
    4520-xxx Connector J19 MPT Paper Out J22 Smart Contact Pin No. 1 2 3 1 2 3 Signal MPFSENSE Ground MPFLED Scart 5 V Ground Ground 5-8 Service Manual
  • Lexmark T522 | Service Manual - Page 231
    4520-xxx Engine Board Connector Locations 5-9
  • Lexmark T522 | Service Manual - Page 232
    4520-xxx Controller Board - Non Network 5-10 Service Manual
  • Lexmark T522 | Service Manual - Page 233
    4520-xxx Controller Board - Network Connector Locations 5-11
  • Lexmark T522 | Service Manual - Page 234
    4520-xxx Fuser Board Connector J1 Engine Board J2 Thermistor J3 Thumper J4 Thumper Solenoid J5 Narrow Media Sensor Pin No. Signal 6 +5 V dc 7 ThumpB 8 ExitSns* 1 ThermGnd 2 HRTherm 1 Ground 2 +42 V dc 1 ThumpB 2 ThumpA 1 +5 V dc 2 Nar Media 3 Ground 5-12 Service Manual
  • Lexmark T522 | Service Manual - Page 235
    4520-xxx Connector Locations 5-13
  • Lexmark T522 | Service Manual - Page 236
    Board Connector J2 LVPS J3 LVPS J5 Autoconnect BTM/FNT J6 Engine Board J7 Controller Board J11 INA 1 J12 INA 2 5-14 Service Manual Pin No. 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 1 2 1 1 1 1 Signal +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground Ground Ground Ground
  • Lexmark T522 | Service Manual - Page 237
    4520-xxx 210/220 001/002 Connector Locations 5-15
  • Lexmark T522 | Service Manual - Page 238
    ) Ground Rx (EOC) +24 V dc Return +24 V dc Ground Paper Present +5 V dc Ground Paper Present +5 V dc Motor - Phase BMotor - Phase AMotor - Phase B+ Motor - Phase A+ 5-16 Service Manual
  • Lexmark T522 | Service Manual - Page 239
    4520-xxx Connector Locations 5-17
  • Lexmark T522 | Service Manual - Page 240
    4520-xxx Duplex Unit Board Note: Duplex connectors J10 and J11 are interchangeable. No problem results if the connectors are switched. Connector J1 Motor J2 DC Motor Sensor V dc Sensor Input + Ground Top Cover Open + Ground Front Drawer Open + Ground +5 V dc Sensor Exit + Ground 5-18 Service Manual
  • Lexmark T522 | Service Manual - Page 241
    4520-xxx Connector J9 Autoconnect, Option Below J10 Autoconnect, Option Below J11 Printer Autoconnect J12 Printer Autoconnect Pin No. 1 2 3 4 1 2 1 2 1 2 3 4 5 Signal Ground PrtxDout Ground PrtRxd +24 V dc Ground +24 V dc Ground N/A Ground PrtxDin Ground PrtRxD Connector Locations 5-19
  • Lexmark T522 | Service Manual - Page 242
    4520-xxx 5-20 Service Manual
  • Lexmark T522 | Service Manual - Page 243
    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover. • Possible safety exposure from any non-Lexmark attachments. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than
  • Lexmark T522 | Service Manual - Page 244
    count interval. It is necessary to replace the fuser assembly, transfer roller and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers: 115 V 630 W Maintenance Kit 99A2420 220 V 630
  • Lexmark T522 | Service Manual - Page 245
    Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. • NS: (Not Shown) in the Asm
  • Lexmark T522 | Service Manual - Page 246
    4520-xxx Assembly 1: Covers 7-2 Service Manual
  • Lexmark T522 | Service Manual - Page 247
    Cable Assembly 1 Cover, Left Door 001/002 1-slot 1 Cover, Left Door 210/220 2-slot 1 Support, Paper 1 Cable Tie 1 Retainer, Cable 5 Parts Packet, Screw (Left Side Cover Mounting) 3 Parts Packet, Screw (Right Side Cover Mounting) 6 Parts Packet, Screw (Laser Cover) 5 Parts Packet, Screw (Upper Front
  • Lexmark T522 | Service Manual - Page 248
    4520-xxx Assembly 2: Frame 7-4 Service Manual
  • Lexmark T522 | Service Manual - Page 249
    , Left Stacker 1 Duct, Main Body 1 Guide, Redrive Exit 1 Support, Left Lower Stacker 1 Pan, Drip ITC 4 Pad, Machine Mounting 1 Support, Right Stacker Plate 1 Transfer Plate Assembly 1 Right Sideframe 1 Frame Extension, Right 210/220 1 Spring, Tray Bias 1 Parts Packet, Contact Kit • Contact, Dr Blade
  • Lexmark T522 | Service Manual - Page 250
    4520-xxx Assembly 2: Frame (continued) 7-6 Service Manual
  • Lexmark T522 | Service Manual - Page 251
    99A0556 99A0263 99A1524 99A1546 99A1596 99A1538 99A1540 99A1541 Units Description 1 Left Side Frame 1 Board, Input Tray (ITC) 1 Guard, Gear 1 Pan, Motor Drip 1 Link, Gear Release 1 Spring, Counterbalance 17 Parts Packet, Screw 1 Spring, Cartridge Load 1 Shield, Gear 1 Contact, LSF Ground 1 Contact
  • Lexmark T522 | Service Manual - Page 252
    4520-xxx Assembly 3: Printhead 7-8 Service Manual
  • Lexmark T522 | Service Manual - Page 253
    4520-xxx AsmIndex 3 - 1 NS Part Number 99A2026 99A0263 Units Description 1 Printhead Assembly 3 Parts Packet, Screw (Printhead Mounting) Parts Catalog 7-9
  • Lexmark T522 | Service Manual - Page 254
    4520-xxx Assembly 4: Paper Feed (Autocompensator) 7-10 Service Manual
  • Lexmark T522 | Service Manual - Page 255
    4520-xxx AsmIndex 4 - 1 2 2 3 4 4 5 5 NS Part Number 99A2070 99A2079 99A2157 99A0070 99A1616 99A1609 99A1927 99A1930 99A0263 Units Description 1 Sensor, Paper Out Internal Tray 1 Pick Arm Assembly (500) 210/220 1 Pick Arm Assembly (250) 001/002 2 Pick Rolls 1 Flag, Paper Out 500 Tray 1
  • Lexmark T522 | Service Manual - Page 256
    4520-xxx Assembly 5: Paper Feed - Multipurpose Unit 7-12 Service Manual
  • Lexmark T522 | Service Manual - Page 257
    99A0073 13 99A0263 14 99A2027 15 99A0074 NS 99A0267 Units Description 1 Screw, Socket Set M4X5 mm 1 Arm Assembly, MPT 1 Pick Roll Assembly 1 Spring Assembly, Separator 1 MPT Pad/Separator Arm Assembly 1 Deflector Assembly, MPT 1 Deflector, Lower 2 Parts Packet, Screw (Lower Deflector Mounting 8 mm
  • Lexmark T522 | Service Manual - Page 258
    4520-xxx Assembly 6: Paper Feed - Alignment 7-14 Service Manual
  • Lexmark T522 | Service Manual - Page 259
    99A2066 99A0492 99A0565 99A0566 99A0263 Units Description 1 Alignment Assembly Paper Feed 3 Parts Packet, Screw (Paper Feed) 1 Clip, Reference Ground 1 Screw, Paper Reference Adjustment 1 Washer, Reference Adjustment 1 Nut, Paper Reference Adjustment 2 Parts Packet, Screw (Alignment Asm Mounting
  • Lexmark T522 | Service Manual - Page 260
    4520-xxx Assembly 7: Paper Feed - Output 7-16 Service Manual
  • Lexmark T522 | Service Manual - Page 261
    NS NS Part Number 99A2029 99A2151 99A1644 99A0104 99A1857 99A0263 Units Description 1 Redrive Assembly, Inner 250 210/220 1 Redrive Assembly, Inner 250 001/002 1 Door Assembly, Redrive 250 1 Spring, Upper Diverter 1 Deflector, Upper Redrive 2 Parts Packet, Screw (Duplex Path) Parts Catalog 7-17
  • Lexmark T522 | Service Manual - Page 262
    4520-xxx Assembly 8: Integrated Paper Tray - 500 Sheet 7-18 Service Manual
  • Lexmark T522 | Service Manual - Page 263
    4520-xxx AsmIndex 8 - 1 2 3 4 5 6 7 8 9 10 11 Part Number 99A1601 99A1576 99A1895 99A0292 99A1812 99A1583 99A0126 99A0124 99A1582 99A0120 99A2093 Units Description 1 Latch, Back Restraint 1 Tray Assembly 500 Sheet 1 Restraint, Side 4 Strip, Wear 1 Label, Tray Option Number 1 Plate, 500 Tray Wear
  • Lexmark T522 | Service Manual - Page 264
    4520-xxx Assembly 9: Main Drive 7-20 Service Manual
  • Lexmark T522 | Service Manual - Page 265
    99A1569 99A0275 99A2080 99A0263 99A0263 99A0260 Units Description 1 Gearbox, w/Motor 1 Shaft, Power Takeoff 250 1 Shaft, Power Takeoff 500 1 Spring, Power Takeoff Shaft 1 Gear, Bevel with Grease Packet 4 Parts Packet, Screw (Gearbox Mounting) 3 Parts Packet, Screw (Motor Mounting) 2 Clip, Cable
  • Lexmark T522 | Service Manual - Page 266
    4520-xxx Assembly 10: Developer Drive 7-22 Service Manual
  • Lexmark T522 | Service Manual - Page 267
    4520-xxx AsmIndex 10 - 1 2 Part Number 99A1544 99A2081 3 99A0263 Units Description 1 Developer Drive Assembly 1 Parts Packet, Developer Drive Shaft, Coupler Gear #55 3 Parts Packet, Screw (Developer Drive Ground) Parts Catalog 7-23
  • Lexmark T522 | Service Manual - Page 268
    4520-xxx Assembly 11: Hot Roll Fuser 7-24 Service Manual
  • Lexmark T522 | Service Manual - Page 269
    NS 99A1658 NS 99A2037 NS 99A0148 Units Description 1 Fuser Assembly w/115V 630W Lamp 1 Fuser Assembly w/220V 630W Lamp 1 Wiper Assembly, Wet 1 Cover, Fuser Assembly with Thermistor, Thermal Fuse, and L & R Fuser Lamp Contact Assemblies 4 Parts Packet, Screws: • Contact Assembly (4) • Solenoid
  • Lexmark T522 | Service Manual - Page 270
    4520-xxx Assembly 12: Transfer 7-26 Service Manual
  • Lexmark T522 | Service Manual - Page 271
    99A0349 99A0184 99A0185 99A0181 99A1578 99A0267 Units Description 1 Transfer Roll Assembly 1 Arm, Transfer Roll Assembly Right 1 Spring, Transfer Roll Right 1 Shaft, Transfer Pivot 1 Spring, Transfer Roll Left 1 Arm, Transfer Roll Left 1 Parts Packet, Retainer (Pivot Shaft) Parts Catalog 7-27
  • Lexmark T522 | Service Manual - Page 272
    4520-xxx Assembly 13: Charging 7-28 Service Manual
  • Lexmark T522 | Service Manual - Page 273
    4520-xxx AsmIndex 13 - 1 2 3 4 NS Part Number 99A0512 99A0513 99A1017 99A1555 99A0263 Units Description 1 Link Assembly, Charge Left Kit 1 Link Assembly, Charge Right Kit 1 Roll Assembly, Charge 1 Bushing, Charge Roll 1 Parts Packet, Screw (Charge Roll) Parts Catalog 7-29
  • Lexmark T522 | Service Manual - Page 274
    4520-xxx Assembly 14: Electronics 1 7-30 Service Manual
  • Lexmark T522 | Service Manual - Page 275
    4520-xxx AsmIndex 14 - 1 Part Number 1342514 1 1339535 1 1339538 1 1342536 1 1339537 1 1339539 1 1339540 1 1339541 1 1339546 1 1342534 1 1339543 1 1339542 1 1374067 1 1339544 1 1339545 1 1342530 2 99A2082 2 99A2083 2 99A2090 2 99A2091 3 99A2043 3 99A2044 Units Description 1 Power Cord Set, 8 ft
  • Lexmark T522 | Service Manual - Page 276
    4520-xxx Assembly 14: Electronics I (continued) 7-32 Service Manual
  • Lexmark T522 | Service Manual - Page 277
    10 99A2158 10 99A2159 Units Description 1 Parts Packet, Screw(s): • Connector Mtg (2) 1 Power Supply, High Voltage 1 Interconnect Network) 210/220 1 Controller Board Assembly (Network) 210/220 1 Controller Board Assembly (Non-Network) 001/002 1 Controller Board Assembly (Network) 001/002 Parts
  • Lexmark T522 | Service Manual - Page 278
    4520-xxx Assembly 15: Electronics II 7-34 Service Manual
  • Lexmark T522 | Service Manual - Page 279
    Number 99A0263 99A2084 99A2049 99A2156 99A2094 99A2095 99A0263 99A0263 99A0408 99A1611 99A0227 99A0347 Units Description 6 Parts Packet, Screw (INA Cover Mounting) 1 Engine Board Shield Assembly 1 Shield, Inner Assembly, 2 Slot 210/220 1 Shield, Inner Assembly, 1 Slot 001/002 1 Shield, Outer 2 Slot
  • Lexmark T522 | Service Manual - Page 280
    4520-xxx Assembly 16: Electronics III 7-36 Service Manual
  • Lexmark T522 | Service Manual - Page 281
    4520-xxx AsmIndex 16 - 1 2 3 4 5 6 7 8 9 Part Number 99A0803 99A2030 99A0128 99A2053 99A2046 99A2052 99A2054 99A2042 99A0138 Units Description 1 Fan, Main 1 Gearbox, w/Motor 1 Board, Input Tray (ITC) 1 Cable, Auto Connect Bottom 1 Interconnect Board Assembly 1 Cable, Integrated Tray 1 Cable, Main
  • Lexmark T522 | Service Manual - Page 282
    4520-xxx Assembly 17: Electronics IV 7-38 Service Manual
  • Lexmark T522 | Service Manual - Page 283
    Part Number 99A2014 99A2015 99A2060 3 99A0053 4 99A2079 4 99A2157 5 99A2071 6 99A2079 6 99A2157 7 99A0072 8 99A2042 9 99A2055 10 99A2045 11 99A2087 12 99A0466 NS 99A2059 Units Power Supply, High Voltage 1 Smart Contact Assembly 1 Sensor, Toner Cartridge Level 1 Cable, Deflector Parts Catalog 7-39
  • Lexmark T522 | Service Manual - Page 284
    4520-xxx Assembly 18: Electronics V 7-40 Service Manual
  • Lexmark T522 | Service Manual - Page 285
    10 11 12 Part Number 99A2026 99A2056 99A2042 99A2046 99A2067 99A2039 99A1551 99A2033 99A2062 99A1651 99A2061 99A2068 Units Description 1 Printhead Assembly 1 Cable, Laser 1 Engine Board Assembly 1 Interconnect Board Assembly 1 Solenoid Assembly, Envelope Conditioner 1 Fuser Board Assembly 1 Sensor
  • Lexmark T522 | Service Manual - Page 286
    4520-xxx Assembly 19: Electronics VI 7-42 Service Manual
  • Lexmark T522 | Service Manual - Page 287
    10 11 NS Part Number 99A2026 99A2056 99A2042 99A2046 99A2067 99A2039 99A1551 99A2033 99A2062 99A1651 99A2061 99A2068 Units Description 1 Printhead Assembly 1 Cable, Laser 1 Engine Board Assembly 1 Interconnect Board Assembly 1 Solenoid Assembly, Envelope Conditioner 1 Fuser Board Assembly 1 Sensor
  • Lexmark T522 | Service Manual - Page 288
    4520-xxx Assembly 20: 250-Sheet Tray 7-44 Service Manual
  • Lexmark T522 | Service Manual - Page 289
    99A0279 99A0281 Units Description 3 Parts Packet, Screw (Option Board) 1 Board, Option Tray 1 Jumper, pin 1 Parts Packet, Screw Drive 1 Spring, Power Takeoff 1 Bushing, Drive Shaft Low 1 Gear, Feed Roll 1 Gear, Bevel 1 Bearing, Drive Shaft 1 Cable, 250 Auto Connect Option Parts Catalog 7-45
  • Lexmark T522 | Service Manual - Page 290
    4520-xxx Assembly 20: 250-Sheet Tray (continued) 7-46 Service Manual
  • Lexmark T522 | Service Manual - Page 291
    38 39 40 41 42 43 44 45 46 NS NS NS NS Part Number 99A1601 99A0120 99A1536 99A0892 99A0119 99A1829 99A0121 99A0126 99A0124 99A1952 99A1537 99A0893 99A0127 99A0286 99A1928 99A0438 99A0278 Units Description 1 Latch, Back Restraint 2 Restraint Pad 1 Tray Assembly, 250-Sheet Option 1 Restraint, Side
  • Lexmark T522 | Service Manual - Page 292
    4520-xxx Assembly 21: Integrated Paper Tray - 250 Sheet 7-48 Service Manual
  • Lexmark T522 | Service Manual - Page 293
    4520-xxx AsmIndex 21 - 1 2 3 4 5 6 7 8 9 10 11 Part Number 99A1536 99A2160 99A1894 99A0119 99A1812 99A0121 99A0126 99A0124 99A0127 99A0120 99A1601 Units Description 1 Tray, Integrated 250 Sheet 1 Restraint, Back 250 Sheet Tray 1 Restraint, Side 250 Sheet Tray 4 Wear Strips 1 Label, Tray Option
  • Lexmark T522 | Service Manual - Page 294
    4520-xxx Assembly 22: 500-Sheet Tray 7-50 Service Manual
  • Lexmark T522 | Service Manual - Page 295
    99A0026 99A0288 99A0895 99A0292 99A1829 99A1583 99A0126 99A0124 99A1952 99A1582 99A0120 99A1576 99A1537 99A1602 99A1601 99A1666 99A1967 99A0447 Units Description 1 Sensor, Paper Low 3 Parts Packet, Screw (Auto Comp Mounting) 1 Pick Arm Assembly 2 Pick Roll Assembly 1 Base, 500 Tray 4 Pad, Base 500
  • Lexmark T522 | Service Manual - Page 296
    4520-xxx Assembly 22: 500-Sheet Tray (continued) 7-52 Service Manual
  • Lexmark T522 | Service Manual - Page 297
    99A0452 99A1665 99A1667 99A1929 Units Description 1 Cable, 500 Auto Connect Bottom 1 Wear Plate, Pass Thru 1 Roll Assembly, Drive 500 2 Parts Packet, Screw (Wear Plate Mounting) 1 Retainer, Roller 1 Roller, Skewed Backup 2 Bearing, Drive Roll 1 Spring, Power Takeoff 3 Parts Packet, Screw (Board
  • Lexmark T522 | Service Manual - Page 298
    4520-xxx Assembly 23: Duplex Unit 7-54 Service Manual
  • Lexmark T522 | Service Manual - Page 299
    99A0316 99A0315 99A0325 99A0280 Units Description 1 Cover, Engine Board 1 Main Frame Assembly 250 Duplex 1 Main Frame Assembly 500 Duplex 1 Idler Assembly, Belt Tension 3 Spring, Aligner 3 Guide Assembly, Paper 1 Guide Assembly, Paper 2 Spring, Chassis Ground 2 Parts Packet, Screw (Motor Mount
  • Lexmark T522 | Service Manual - Page 300
    4520-xxx Assembly 23: Duplex Unit (continued) 7-56 Service Manual
  • Lexmark T522 | Service Manual - Page 301
    38 99A1669 39 99A1666 40 99A0413 41 99A0413 NS 99A1129 NS 99A0627 NS 99A0404 NS 99A0413 Units Description 1 Cable, Auto Connect Bottom 1 Gear, Pass Thru Drive Roll 1 Cable, Auto Connect Top 4 Parts Packet, Screw (Main Frame Assembly Mounting) 1 Gear, Duplex Bevel 1 Pan, Engine Board Drip 1 Bearing
  • Lexmark T522 | Service Manual - Page 302
    4520-xxx Assembly 23: Duplex Unit (continued) 7-58 Service Manual
  • Lexmark T522 | Service Manual - Page 303
    99A0336 99A1692 99A1059 99A0413 99A0404 99A0058 99A1695 99A0404 99A1164 Units Description 1 Top Cover Assembly, Movable 250 Duplex 1 , 250 Duplex 3 Parts Packet, Screw (Outer Frame) 1 Guide Assembly, Center Drive 1 Parts Packet, Fan Mounting Kit 1 Fan, Cooling Duplex 2 Parts Packet, Retainer (5
  • Lexmark T522 | Service Manual - Page 304
    4520-xxx Assembly 24: Envelope Feeder 7-60 Service Manual
  • Lexmark T522 | Service Manual - Page 305
    99A1699 99A0413 99A0484 99A0491 99A0400 99A0489 99A0487 Units Description 1 Paper Weight Assembly 1 Guide, Edge 1 Cover, Top 1 Sensor, Envelope Pass Thru 1 Clutch, Restraint/Gear 1 Cover, Right Side 1 Support, Slide Out 7 Roller, Support 1 Motor, Stepper D.C. 1 Label, Options 1 Switch, Envelope Out
  • Lexmark T522 | Service Manual - Page 306
    4520-xxx Assembly 25: High-Capacity Feeder 7-62 Service Manual
  • Lexmark T522 | Service Manual - Page 307
    23 99A0677 24 99A0675 25 99A0392 26 99A0677 27 99A0676 NS 99A0690 Units Description 1 Frame, Printer Support Frame 2 3 Parts Packet, Screw (Printer Support 2 Frame Mounting) 2 Clamp, Feed Frame 4 Parts Packet, Screw (Feed Frame Clamp) 2 Bearing, Nyliner Leadscrew Top 1 Cover, Side 3 Strip
  • Lexmark T522 | Service Manual - Page 308
    4520-xxx Assembly 25: High Capacity Feeder (continued) 7-64 Service Manual
  • Lexmark T522 | Service Manual - Page 309
    (Power Supply Bd Mtg) 2 Parts Packet, Washer (Power Supply Board) 1 Power Supply Board 1 Cable, Low Voltage Power Supply 1 Bushing 2 Parts Packet, Nut - 2-56 1 Switch, Paper Low 1 Sensor Assembly, Paper Out/Upper Limit 3 Parts Packet, Screw (Support 1 Frame Mtg) 1 Frame, Printer Support 1 1 Parts
  • Lexmark T522 | Service Manual - Page 310
    4520-xxx Assembly 25: High Capacity Feeder (continued) 7-66 Service Manual
  • Lexmark T522 | Service Manual - Page 311
    99A0275 88 99A0272 89 99A0446 Units Description 3 Parts Packet, Screw w/washer (Motor Mt) 3 Parts Packet, Nut & washer (Drive Pulley Plate) 1 Motor Assembly, DC 4 Parts Packet, Foot (Stabilizer) 4 Parts Packet, Mounting Feet 1 Belt, DC Motor Drive 1 Idler Pulley, Belt Tension 1 Plate, Drive Pulley
  • Lexmark T522 | Service Manual - Page 312
    4520-xxx Assembly 25: High Capacity Feeder (continued) 7-68 Service Manual
  • Lexmark T522 | Service Manual - Page 313
    99A0684 NS 99A0286 Units Description 1 Parts Packet, Retainer (Aligner Assembly) 1 Gear, Feed Roll 1 Bellcrank, Roller Release 1 Card Assembly, 2000 Tray Option 3 Parts Packet, Screw (Tray Option Card Mtg) 10 Parts Packet, Screw (Door to Door Frame Mounting) 6 Parts Packet, Nut Support Frame 1Hex
  • Lexmark T522 | Service Manual - Page 314
    4520-xxx Assembly 25: High Capacity Feeder (continued) 7-70 Service Manual
  • Lexmark T522 | Service Manual - Page 315
    99A1055 97 99A0070 98 99A0692 99 99A0263 100 99A0678 101 99A0288 102 99A1812 103 99A1666 104 99A0677 105 99A0263 106 99A0679 NS 99A0717 NS 99A0720 Units Description 3 Parts Packet, Screw (Auto Comp Assembly Mounting) 1 Arm Assembly, Pick 2000 2 Roll Assembly, Pick 1 Base, 2000 Option
  • Lexmark T522 | Service Manual - Page 316
    4520-xxx Assembly 26: Kiosk - Vertical Paper Adapter 7-72 Service Manual
  • Lexmark T522 | Service Manual - Page 317
    99A0085 Units Description 1 Bail, Support 1 Arm Assembly, Pivot 1 Mounting, Frame Assembly 12 Parts Packet, Retainer 16 Parts Packet, Parts Packet, Pulley 6 Spring, Backup Roller 6 Roller, Backup 1 Tray Assembly, Drive Roller 1 Frame Assembly, Right Side 1 Cover, Right 2 Belt, 185G 1 Guide,
  • Lexmark T522 | Service Manual - Page 318
    4520-xxx Assembly 27: Kiosk - Horizontal Paper Adapter 7-74 Service Manual
  • Lexmark T522 | Service Manual - Page 319
    99A0085 Units Description 1 Bail, Support 1 Arm Assembly, Pivot 1 Mounting, Frame Assembly 12 Parts Packet, Retainer 15 Parts Packet, Roller 3 Parts Packet, Pulley 6 Spring, Backup Roller 6 Roller, Backup 1 Tray Assembly, Drive Roller 1 Frame Assembly, Right Side 1 Cover, Right 2 Belt, 185G 2
  • Lexmark T522 | Service Manual - Page 320
    28 28 28 28 28 28 28 28 28 28 Part Number 99A1752 99A1753 99A1754 99A1755 99A1756 99A1773 99A1757 99A1758 99A1759 99A1774 99A2488 99A0629 13A0296 13A0297 99A0545 13A0298 99A0467 99A0923 99A2558 99A2489 Units Description 1 4MB SDRAM DIMM 1 8MB SDRAM DIMM Disk, with Control Board 7-76 Service Manual
  • Lexmark T522 | Service Manual - Page 321
    99A1889 56P0161 56P0162 90A2485 99A1683 99A1684 99A1685 99A1686 Units Description 1 Tray Assembly, 250 Special Media 1 Rib Assembly, 250 Special Media Tray 1 Tray, Universal Adjustable 250 Sheet 1 Cartridge, Empty Shipping (2) 1 Cartridge, Empty Shipping (1) 1 Drive, Forms HD 2.1GB or larger
  • Lexmark T522 | Service Manual - Page 322
    Locking 2 Printer Stand Caster, Locking 1 Printer Stand Grommet, Wire 2 Printer Stand Lock, Cam 1 Printer Stand Storage Shelf 1 Printer Stand Door Assembly, Cabinet 1 Printer Stand Filler, Rear Top Piece 1 Printer Stand Table Assembly, Large 1 Printer Stand Table Assembly, Small 7-78 Service Manual
  • Lexmark T522 | Service Manual - Page 323
    99A1855 Units Description 1 Parts Packet, Pulley - Kiosk 1 Parts Packet, Screw - Kiosk 1 Grease Packet, Nyogel 744 1 Grease Packet, IBM 23 1 Packaging, 4069 250/250 printer 1 Packaging, 4069 500/250 printer 1 Packaging, 4069 500/500 printer 1 Packaging, 4069 500/500 plus 500 printer Parts Catalog
  • Lexmark T522 | Service Manual - Page 324
    4520-xxx 7-80 Service Manual
  • Lexmark T522 | Service Manual - Page 325
    Button Test 3-11 C Connector Locations Controller Board 5-10 Duplex Unit Board 5-18 Engine Board 5-4 Envelope Feeder Board 5-16 Fuser Board 5-12 High Voltage Power Supply 5-3 Interconnect Board 5-14 LVPS 5-1 Network Controller Board 5-11 Controller Board Connectors 5-10 D Diagnostic Aids 3-1 Device
  • Lexmark T522 | Service Manual - Page 326
    4520-xxx Fuser Board 5-12 H Hardware Tests 3-11 HVPS Connectors 5-3 I I 7-42 Input Tray Feed Test 3-15 Input Tray Sensor Test 3-15 Interconnect Board Connectors 5-14 L Laser Notices ix LCD Test 3-11 Low Voltage Power Supply 5-1 Lubrication Specifications 6-1 LVPS Connectors 5-1 M Maintenance
  • Lexmark T522 | Service Manual - Page 327
    34 Fuser Lamp 4-35 Fuser Lower Exit Guide Assembly 4-35 Fuser Narrow Media Sensor/Flag Assembly 4-34 Fuser Transfer Plate 4-32 High Voltage Power Supply 4-36 Integrated Tray Compensator Assembly 4-37 Integrated Tray Compensator Pick Roll Assembly 4-38 Interconnect Board Assembly 4-39 Left Door 4-12
  • Lexmark T522 | Service Manual - Page 328
    4520-xxx Transfer Roll 2-103 Setting Configuration ID 3-20 Setting the Page Count 3-18 Status Messages 2-22 Symptom Tables 2-36 Base Printer 2-36 Duplex Unit 2-38 Envelope Feeder 2-38 High-Capacity Feeder 2-37 7-13 99A0079 7-73, 7-75 99A0081 7-13 99A0082 7-13 99A0083 7-13, 7-78 I-4 Service Manual
  • Lexmark T522 | Service Manual - Page 329
    4520-xxx 99A0084 7-13 99A0085 7-73, 7-75 99A0086 7-73, 7-75 99A0087 7-73, 7-75 99A0088 7-73, 7-75 99A0089 7-15 99A0104 7-17 99A0119 7-47, 7-49 99A0120 7-19, 7-47, 7-49, 7-51 99A0121 7-47, 7-49 99A0122 7-73, 7-75 99A0124 7-19, 7-47, 7-49, 7-51 99A0125 7-73 99A0126 7-19, 7-47, 7-49, 7-51 99A0127 7-47,
  • Lexmark T522 | Service Manual - Page 330
    99A0711 7-78 99A0565 7-15 99A0712 7-78 99A0566 7-15 99A0714 7-65 99A0567 7-7 99A0715 7-65 99A0572 7-78 99A0716 7-63 99A0577 7-3, 7-78 99A0717 7-71 99A0585 7-78 99A0719 7-65 I-6 Service Manual
  • Lexmark T522 | Service Manual - Page 331
    4520-xxx 99A0720 99A0725 99A0799 99A0803 99A0867 99A0892 99A0893 99A0895 99A0897 99A0906 99A0907 99A0909 99A0910 99A0923 99A0952 99A1015 99A1017 99A1054 99A1055 99A1059 99A1129 99A1130 99A1131 99A1133 99A1134 99A1164 99A1280 99A1290 99A1502 99A1506 99A1508 99A1509 99A1510 99A1511 99A1512 99A1517
  • Lexmark T522 | Service Manual - Page 332
    76 7-76 7-76 7-76 7-76 7-76 7-76 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-67 7-63 I-8 Service Manual 99A1807 99A1808 99A1809 99A1812 99A1818 99A1819 99A1820 99A1829 99A1830 99A1850 99A1852 99A1853 99A1854 99A1855 99A1857 99A1889 99A1890 99A1894 99A1895 99A1896 99A1927 99A1928
  • Lexmark T522 | Service Manual - Page 333
    4520-xxx 99A2038 7-25 99A2039 7-25, 7-41 99A2042 7-33, 7-37, 7-39, 7-41, 7-43 99A2043 7-31 99A2044 7-31 99A2045 7-33, 7-39 99A2046 7-33, 7-37, 7-41, 7-43 99A2049 7-35 99A2050 7-25 99A2051 7-25 99A2052 7-37 99A2053 7-37 99A2054 7-37 99A2055 7-39 99A2056 7-41, 7-43 99A2057 7-41, 7-43 99A2059 7-39
  • Lexmark T522 | Service Manual - Page 334
    4520-xxx I-10 Service Manual
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4520-xxx
Lexmark™ T52x
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
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