Lexmark T52X

4520-XXX

Extracted From Service Manual

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Edition: July 2002

The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. ImageQuick and Optra Forms are trademarks of Lexmark International, Inc. Other trademarks are the property of their respective owners. Copyright Lexmark International, Inc. 2001, 2002. All rights reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

P/N: 12G3967

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7. Parts Catalog How to Use This Parts Catalog

SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.

Parts Catalog 7-1

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Assembly 1: Covers

18 17

4 5

16

10

15 14 12

11

13

7-2 Service Manual

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AsmIndex 1-1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 15 16 17 18 18 NS NS NS NS NS Part Number 99A2074 99A1508 99A1506 99A1587 99A1524 99A2435 99A2087 99A2075 99A2011 99A2010 99A2150 99A0007 99A1502 99A1511 99A0004 99A2014 99A2015 99A2060 99A1594 99A1509 99A1510 99A0577 99A0263 99A0263 99A0263 99A0263 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 3 6 5 Description Cover Assembly, Redrive Cap Cover, Fuser Wick Assembly Cover Asm, Laser Assembly Support, Paper Cartridge Load Spring Cartridge Load Spring Smart Contact Assembly Cover, Right Side Hinge, Upper Front Cover Kit, Upper Front Cover with Labels 210/220 Kit, Upper Front Cover with Labels 001/002 Label, TLI/ID/Serial No. - Blank Latch, Upper Cover Cover Assembly, Lower Front Spring, Latch Operator Panel Assembly 110V Operator Panel Assembly 220V Switch, Cover Open w/Operator Panel Cable Assembly Retainer, Cable Cover, Left Door 001/002 1-slot Cover, Left Door 210/220 2-slot Cable Tie Parts Packet, Screw (Left Side Cover Mounting) Parts Packet, Screw (Right Side Cover Mounting) Parts Packet, Screw (Laser Cover) Parts Packet, Screw (Upper Front Cover Mounting)

Parts Catalog 7-3

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Assembly 2: Frame

7-4 Service Manual

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AsmIndex 2-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number 99A1643 99A2063 56P1049 99A1613 99A0062 99A2016 99A0867 99A2017 99A2018 99A2076 99A2077 99A2021 99A2020 99A2022 99A1518 99A0028 99A0585 Units 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 Description Shroud, Fan Fan, Main Sensor, Standard Bin Level with Cable Flag, Output Paper Level Bracket, Level Sensor Duct, Left Stacker Duct, Main Body Guide, Redrive Exit Support, Left Lower Stacker Pan, Drip ITC Pad, Machine Mounting Support, Right Stacker Plate Transfer Plate Assembly Right Sideframe Frame Extension, Right 210/220 Spring, Tray Bias Parts Packet, Contact Kit Contact, Dr Blade/TAR/Developer Roll (3) Contact, PC Drum (1) Contact, Charge Roll (1) Block, Contact Mounting (4) Screw, Contact Mounting (5) Sensor, Toner Cartridge Level Roller, Developer Support Tray Bias Arm Assembly Pan, Center Assembly Spring, Cartridge Hold Down Deflector, Upper PF Deflector, Inner Frame, EP Module Sensor, Input Frame Extension, Left 210/220 Shield, ESD Assembly with label Spring, PA Out Activate

18 19 20 21 22 23 24 25 26 27 28 29

99A0466 99A0039 99A0026 99A2024 99A2019 99A1525 99A1850 99A2065 99A0053 99A1517 99A0549 99A0063

1 2 1 1 2 1 1 1 1 1 1 1

Parts Catalog 7-5

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Assembly 2: Frame (continued)

7-6 Service Manual

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AsmIndex 2 - 30 31 32 33 34 35 NS NS NS NS NS NS Part Number 99A2025 56P1139 99A1896 99A2078 99A0567 99A0556 99A0263 99A1546 99A1596 99A1538 99A1540 99A1541 Units 1 1 1 1 1 1 17 1 1 1 4 1 Description Left Side Frame Board, Input Tray (ITC) Guard, Gear Pan, Motor Drip Link, Gear Release Spring, Counterbalance Parts Packet, Screw Shield, Gear Contact, LSF Ground Contact, RSF Ground Nut Plate, Frame 210/220 Spring, Duplex Ground

Parts Catalog 7-7

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Assembly 3: Printhead

7-8 Service Manual

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AsmIndex 3-1 NS Part Number 99A2026 99A0263 Units 1 3 Description Printhead Assembly (Includes All Cables) Parts Packet, Screw (Printhead Mounting)

Parts Catalog 7-9

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Assembly 4: Paper Feed (Autocompensator)

7-10 Service Manual

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AsmIndex 4-1 2 2 3 4 4 5 6 6 NS Part Number 99A2070 99A2079 99A2157 56P1228 99A1927 99A1930 99A0070 99A1616 99A1609 99A0263 Units 1 1 1 1 1 1 2 1 1 1 Description Sensor, Paper Out Internal Tray Pick Arm Assembly (500) 210/220 Pick Arm Assembly (250) 001/002 Spring Arm Belcrank Spring, Bellcrank Internal 250 Spring, Bellcrank Internal 500 Pick Rolls Flag, Paper Out 500 Tray Flag, Paper Out 250 Tray 001/002 Parts Packet, Screw (Hanger)

Parts Catalog 7-11

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Assembly 5: Paper Feed - Multipurpose Unit

7-12 Service Manual

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AsmIndex 5-1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 NS Part Number 99A0075 99A0071 99A0076 99A0081 99A0083 99A2092 99A1531 99A0263 99A0263 99A0084 99A0082 99A2071 99A0073 99A0263 99A2027 99A0074 99A0267 Units 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 2 Description Screw, Socket Set M4X5 mm Arm Assembly, MPT Pick Roll Assembly Spring Assembly, Separator MPT Pad/Separator Arm Assembly Deflector Assembly, MPT Deflector, Lower Parts Packet, Screw (Lower Deflector Mounting 8 mm) Parts Packet, Screw (Lower Deflector Mounting 12 mm) Flag, MPT Paper Out Plate Assembly, MPT Sensor, MPT Paper Out Screw, Damper Parts Packet, Screw (Frame Mounting) Frame Assembly, MPT with Solenoid Bushing, Pick Roll Shaft Parts Packet, Clip (Pick Roll Shaft)

Parts Catalog 7-13

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Assembly 6: Paper Feed - Alignment

7-14 Service Manual

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AsmIndex 6-1 2 3 4 5 6 NS Part Number 99A0089 99A0263 99A2066 99A0492 99A0565 99A0566 99A0263 Units 1 3 1 1 1 1 2 Description Alignment Assembly Paper Feed Parts Packet, Screw (Paper Feed) Clip, Reference Ground Screw, Paper Reference Adjustment Washer, Reference Adjustment Nut, Paper Reference Adjustment Parts Packet, Screw (Alignment Asm Mounting)

Parts Catalog 7-15

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Assembly 7: Paper Feed - Output

7-16 Service Manual

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AsmIndex 7-1 1 2 NS NS NS Part Number 99A2029 99A2151 99A1644 99A0104 99A1857 99A0263 Units 1 1 1 1 1 2 Description Redrive Assembly, 500 Input/250 Output 210/ 220 Redrive Assembly, 250 Input/250 Output 001/ 002 Door Assembly, Redrive 250 Spring, Upper Diverter Deflector, Upper Redrive Parts Packet, Screw (Duplex Path)

Parts Catalog 7-17

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Assembly 8: Integrated Paper Tray - 500 Sheet

7-18 Service Manual

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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 1 1 1 4 1 1 3 1 1 2 1 Description Latch, Back Restraint Tray Assembly 500 Sheet Restraint, Side Strip, Wear Label, Tray Option Number Plate, 500 Tray Wear Finger, Autosize Plate, Snap-in Slider, Autosize 500 Pad, Restraint Restraint, Back

Parts Catalog 7-19

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Assembly 9: Main Drive

7-20 Service Manual

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AsmIndex 9-1 2 2 3 4 NS NS NS Part Number 99A2030 99A0134 99A1569 99A0275 99A2080 99A0263 99A0263 99A0260 Units 1 1 1 1 1 4 3 2 Description Gearbox, w/Motor Shaft, Power Takeoff 250 Shaft, Power Takeoff 500 Spring, Power Takeoff Shaft Gear, Bevel with Grease Packet Parts Packet, Screw (Gearbox Mounting) Parts Packet, Screw (Motor Mounting) Clip, Cable

Parts Catalog 7-21

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Assembly 10: Developer Drive

7-22 Service Manual

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AsmIndex 10 - 1 2 3 Part Number 99A1544 99A2081 99A0263 Units 1 1 3 Description Developer Drive Assembly Parts Packet, Developer Drive Shaft, Coupler Gear #55 Parts Packet, Screw (Developer Drive Ground)

Parts Catalog 7-23

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Assembly 11: Hot Roll Fuser

7-24 Service Manual

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AsmIndex 11 - 1 1 2 3 Part Number 99A2423 99A2422 99A0725 56P0150 Units 1 1 1 1 Description Fuser Assembly w/115V 630W Lamp Fuser Assembly w/220V 630W Lamp Wiper Assembly, Wet Kit, Fuser Cover Assembly with Thermistor, Thermal Fuse, and L & R Fuser Lamp Contact Assemblies, W/ Fuser Cover Control Card Parts Packet, Screws: Contact Assembly (4) Solenoid Mounting (1) Board Cover Mounting(1) Fuser Cover Assembly (4) Hanger (7) Gear, Upper Redrive Housing, Detack Assembly Hot Roll Backup Roll Envelop Conditioner Solenoid Assembly Screw, Fuser Mounting Parts Packet, Retainer (Backup Roll Bellcrank) Sensor, Narrow Media Sensor, Exit Spring, Redrive Idler Roller, Redrive Idler Lamp, 115V 630W CC Gold Lamp, 220V 630W CC Silver Cover, Fuser Wiper Cavity Grip Ring Gear, Idler

99A0263

5 6 7 8 9 10 11 12 13 14 15 16 16 NS NS NS

99A1520 99A2035 99A2036 99A2038 99A2067 99A1649 99A0267 99A1651 99A1551 99A0897 99A0167 99A2050 99A2051 99A1658 99A2037 99A0148

1 1 1 1 1 2 2 1 1 2 4 1 1 1 2 1

Parts Catalog 7-25

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Assembly 12: Transfer

7-26 Service Manual

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AsmIndex 12 - 1 2 3 4 5 6 NS Part Number 99A1015 99A0349 99A0184 99A0185 99A0181 99A1578 99A0267 Units 1 1 1 1 1 1 1 Description Transfer Roll Assembly Arm, Transfer Roll Assembly Right Spring, Transfer Roll Right Shaft, Transfer Pivot Spring, Transfer Roll Left Arm, Transfer Roll Left Parts Packet, Retainer (Pivot Shaft)

Parts Catalog 7-27

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Assembly 13: Charging

7-28 Service Manual

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AsmIndex 13 - 1 2 3 4 NS Part Number 99A0512 99A0513 99A1017 99A1555 99A0263 Units 1 1 1 1 1 Description Link Assembly, Charge Left Kit Link Assembly, Charge Right Kit Roll Assembly, Charge Bushing, Charge Roll Parts Packet, Screw (Charge Roll)

Parts Catalog 7-29

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Assembly 14: Electronics 1

7-30 Service Manual

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AsmIndex 14 - 1 Part Number 1342514 Units 1 Description Power Cord Set, 8 ft. U.S., Canada (LV), Nicaragua, Venezuela, Peru (LV), Bolivia (HV), Colombia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Panama Power Cord Set, 8 ft. U.S., Canada (LV), Nicaragua, Venezuela, Peru (LV), Bolivia, Colombia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Panama, Brazil (LV), AP (English) Italy, 6 ft. Paraguay, Uruguay, Finland, Norway, Sweden Power Cord Set, 6 ft. - APG (LV) Power Cord Set, 8 ft. - U.K., Ireland Power Cord Set, 6 ft. - Israel, Germany Power Cord Set, 6 ft. - Switzerland Power Cord Set, 6 ft. - South Africa Power Cord Set, 6 ft. - Two-Prong Argentina (HV) Power Cord Set, 8 ft. - Chile (HV) Power Cord Set, 8 ft. - Denmark Power Cord Set, 6 ft. - Italy Power Cord Set, 8 ft. - Peru (HV) Power Cord Set, 8 ft. - Straight Argentina (HV) Power Cord Set, 8 ft. - Right Angle Argentina (HV) Power Cord Set - Brazil (HV), Paraguay (HV), Uruguay (HV) Fuse, for 110 V ac LVPS 10 a Fuse, for 110 V ac LVPS 5 a Fuse, for 220 V ac LVPS 6.3 a Fuse, for 220 V ac LVPS 3.15 a LVPS, 110 V ac LVPS, 220 V ac

1339535

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 3

1339538 1342536 1339537 1339539 1339540 1339541 1339546 1342534 1339543 1339542 1374067 1339544 1339545 1342530 99A2082 99A2083 99A2090 99A2091 99A2043 99A2044

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Parts Catalog 7-31

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Assembly 14: Electronics I (continued)

7-32 Service Manual

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AsmIndex 14 - 4 Part Number 99A0263 Units 1 Description Parts Packet, Screw(s): 5 6 6 7 7 8 8 8 8 9 10 10 10 10 99A2045 99A2046 99A2152 56P1005 56P1004 99A2486 99A2200 99A2487 99A2528 99A0426 56P1190 56P1191 56P1192 56P1193 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Controller Board Mtg (2) Controller Board Mtg Front (2) Controller Mtg Ground (1) Engine Board Mtg (6) Engine Board Mtg Top (2) HVPS Mtg INA Cover Mtg (12) Interconnect Board Mtg (2) Interconnect Board Shield Ground (1) Interconnect Shield Mtg (5) Outer Shield Mtg (10) Parallel Connector Mtg (2)

Power Supply, High Voltage Interconnect Board Assembly 2 slot 210/220 Interconnect Board Assembly 1 slot 001/002 Engine Board Assembly 210/220 Engine Board Assembly 001/002 Card Assembly, Bar Code Card Assembly, IPDS and SC5/TNE Card Assembly, Prescribe 5/4/2 Flash Card Assembly, Image Quick Screws, Parallel Connector Mounting Controller Board Assembly (Non Network) 210/220 Controller Board Assembly (Network) 210/220 Controller Board Assembly (Non-Network) 001/002 Controller Board Assembly (Network) 001/002

Parts Catalog 7-33

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Assembly 15: Electronics II

7-34 Service Manual

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AsmIndex 15 - 1 2 3 3 4 4 5 5 6 NS NS NS Part Number 99A0263 99A2084 99A2049 99A2156 99A2094 99A2095 99A0263 99A0263 99A0408 99A1611 99A0227 99A0347 Units 6 1 1 1 1 1 4 6 1 1 1 1 Description Parts Packet, Screw (INA Cover Mounting) Engine Board Shield Assembly Shield, Inner Assembly, 2 Slot 210/220 Shield, Inner Assembly, 1 Slot 001/002 Shield, Outer 2 Slot 210/220 Shield, Outer 1 Slot 001/002 Parts Packet, Screw (Outer Shield Mounting) Parts Packet, Screw (Outer Shield Mounting) Cover, INA Flat (Blank) Shield, Ethernet (Blank) Clip, Two Finger EMC Clip, Six Finger EMC

Parts Catalog 7-35

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Assembly 16: Electronics III

7-36 Service Manual

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AsmIndex 16 - 1 2 3 4 5 6 7 8 9 Part Number 99A0803 99A2030 56P1139 99A2053 99A2046 99A2052 99A2054 99A2042 56P1049 Units 1 1 1 1 1 1 1 1 1 Description Fan, Main Gearbox, w/Motor Board, Input Tray (ITC) Cable, Auto Connect Bottom Interconnect Board Assembly Cable, Integrated Tray Cable, Main Drive Motor Engine Board Assembly Sensor, Standard Bin Level

Parts Catalog 7-37

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Assembly 17: Electronics IV

7-38 Service Manual

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AsmIndex 17 - 1 1 2 3 4 4 5 6 6 7 8 9 10 11 12 NS Part Number 99A2014 99A2015 99A2060 99A0053 99A2079 99A2157 99A2071 99A2079 99A2157 99A2438 99A2042 99A2055 99A2045 99A2087 99A0466 99A2059 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Operator Panel Assembly 110 V Operator Panel Assembly 220 V Switch, Cover Open w/Operator Panel Cable Assembly Sensor, Input Pick Arm Assembly (500) 210/220 Pick Arm Assembly (250) 001/002 Sensor, MPT Paper Out Pick Arm Assembly (500) 210/220 Pick Arm Assembly (250) 001/002 MPT Solenoid Engine Board Assembly Cable, Front Harness Power Supply, High Voltage Smart Contact Assembly Sensor, Toner Cartridge Level Cable, Deflector

Parts Catalog 7-39

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Assembly 18: Electronics V

7-40 Service Manual

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AsmIndex 18 - 1 2 3 4 5 6 7 8 9 10 11 Part Number 99A2026 99A2056 99A2042 99A2046 99A2067 99A2039 99A1551 99A2033 99A2062 99A1651 99A2061 Units 1 1 1 1 1 1 1 1 1 1 1 Description Printhead Assembly (Includes All Cables) Cable, Laser Engine Board Assembly Interconnect Board Assembly Solenoid Assembly, Envelope Conditioner Fuser Board Assembly Sensor, Exit Cover, Fuser Assembly with Thermistor Cable, Engine Board to Fuser Board Sensor, Narrow Media Cable, Fuser AC Fuser to LVPS

Parts Catalog 7-41

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Assembly 19: Electronics VI

7-42 Service Manual

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AsmIndex 19 - 1 2 3 4 5 6 7 8 9 10 11 Part Number 99A2026 99A2056 99A2042 99A2046 99A2067 99A2039 99A1551 99A2033 99A2062 99A1651 99A2061 Units 1 1 1 1 1 1 1 1 1 1 1 Description Printhead Assembly (Includes All Cables) Cable, Laser Engine Board Assembly Interconnect Board Assembly Solenoid Assembly, Envelope Conditioner Fuser Board Assembly Sensor, Exit Cover, Fuser Assembly with Thermistor Cable, Engine Board to Fuser Board Sensor, Narrow Media Cable, Fuser AC Fuser to LVPS

Parts Catalog 7-43

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Assembly 20: 250-Sheet Tray

7-44 Service Manual

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AsmIndex 20 - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Part Number 99A0263 99A1967 99A0627 99A0263 99A0063 99A0445 99A0448 99A0263 99A1054 99A0277 99A0263 99A0276 99A0451 99A0282 99A0450 99A0350 99A0679 99A0677 99A0263 99A0070 99A1638 99A0026 99A0419 99A0058 99A0288 99A1666 99A0272 99A0275 99A0280 99A0274 99A0273 99A0279 99A0281 Units 3 1 1 1 1 1 1 3 1 1 2 1 1 1 1 1 2 4 4 2 1 1 1 4 1 1 1 1 1 1 1 1 1 Description Parts Packet, Screw (Option Board) Board, Option Tray Jumper, pin Parts Packet, Screw (Switch Spring) Spring, Switch Activate Stud Assembly, 250 Frame Arm, Paper Out 250 Parts Packet, Screw (Auto Comp Mounting) Pick Arm Assembly Wear Plate, Pass Thru 250 Tray Parts Packet, Screw (Wear Plate Mounting) Roll Assembly, Drive 500 Dual Roller, Skewed Backup Cable, 250 Tray Option Retainer, Roller Sensor, Paper Low Bracket, 250 Frame Retention Parts Packet, Washer Parts Packet, Screw Roll Assembly, Pick Base, 250 Option Tray Bias Arm Assembly Spring, Tray Bias Pad, Machine Mounting Sensor, Option Pass Thru Label, Options Shaft, 250 Drive Spring, Power Takeoff Bushing, Drive Shaft Low Gear, Feed Roll Gear, Bevel Bearing, Drive Shaft Cable, 250 Auto Connect Option

Parts Catalog 7-45

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Assembly 20: 250-Sheet Tray (continued)

7-46 Service Manual

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AsmIndex 20 - 34 35 36 37 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 1 2 1 1 4 1 1 4 1 1 1 1 1 1 1 2 1 Description Latch, Back Restraint Restraint Pad Tray Assembly, 250-Sheet Option Restraint, Side 250-Sheet Tray Wear Strips Label, Tray Option Number Clip, 250 Tray Wear Finger, Autosize Plate, Snap-In Label, Paper Size Knob, Paper Size Restraint, Back 250 Sheet Tray Slider, Autosize 250 Spring, Backup Roller Spring, Bellcrank 250 Tray Option Bushing, Drive Roll Bellcrank, Roller Release

Parts Catalog 7-47

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Assembly 21: Integrated Paper Tray - 250 Sheet

7-48 Service Manual

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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 1 1 1 4 1 1 4 1 1 2 1 Description Tray, Integrated 250 Sheet Restraint, Back 250 Sheet Tray Restraint, Side 250 Sheet Tray Wear Strips Label, Tray Option Number Clip, 250 Tray Wear Finger, Autosize Plate, Snap-In Slider, Autosize 250 Restraint Pad Latch, Back Restraint

Parts Catalog 7-49

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Assembly 22: 500-Sheet Tray

7-50 Service Manual

4520-xxx
AsmIndex 22 - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Part Number 99A0350 99A0263 99A0405 99A0070 99A1636 99A0058 99A0419 99A0026 99A0288 99A0895 99A0292 99A1829 99A1583 99A0126 99A0124 99A1952 99A1582 99A0120 99A1576 99A1537 99A1602 99A1601 99A1666 99A1967 99A0447 Units 1 3 1 2 1 4 1 1 1 1 4 1 1 4 1 1 1 2 1 1 1 1 1 1 1 Description Sensor, Paper Low Parts Packet, Screw (Auto Comp Mounting) Pick Arm Assembly Pick Roll Assembly Base, 500 Tray Pad, Base 500 Spring, Tray Bias Tray Bias Arm Assembly Sensor, Option Pass Thru Restraint, Side 500-Sheet Tray Wear Strips Label, Tray Option Number Plate, 500 Tray Wear Finger, Autosize Plate, Snap-In Label, Paper Size Slider, Autosize 500 Restraint Pad Tray Assembly, 500 Sheet Knob, Paper Size Restraint, Back 500-Sheet Tray Latch, Back Restraint Label, Options Board, Tray Shaft, 500 Drive

Parts Catalog 7-51

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Assembly 22: 500-Sheet Tray (continued)

7-52 Service Manual

4520-xxx
AsmIndex 22 - 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 NS NS NS NS Part Number 99A0282 99A1750 99A0276 99A0263 99A0450 99A0451 99A0438 99A0275 99A0263 99A0267 99A0280 99A0446 99A0274 99A0063 99A0286 99A1664 99A0273 99A0279 99A0281 99A1702 99A1645 99A0452 99A1665 99A1667 99A1929 Units 1 1 1 2 1 1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 4 1 2 1 Description Cable, 500 Auto Connect Bottom Wear Plate, Pass Thru Roll Assembly, Drive 500 Parts Packet, Screw (Wear Plate Mounting) Retainer, Roller Roller, Skewed Backup Bearing, Drive Roll Spring, Power Takeoff Parts Packet, Screw (Board Mounting) Parts Packet, Retainer (Aligner Assembly) Bearing, Drive Shaft Low Aligner Assembly, Paper Gear, Feed Roll Spring, Switch Activate Spring, Backup Roller Bellcrank, Roller Release Gear, Bevel Bearing, Drive Shaft Cable, 500 Auto Connect Top Stud Assembly, 500 Frame Arm, Paper Out 500 Washer, Frame Mounting Deflector, Base 500 Bracket, 500 Tray Retention Spring, Bellcrank 500 Option Tray

Parts Catalog 7-53

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Assembly 23: Duplex Unit

7-54 Service Manual

4520-xxx
AsmIndex 23 - 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 20 21 21 22 23 24 25 25 26 27 28 29 Part Number 99A1674 99A0322 99A1693 99A0324 99A0326 99A0323 99A1675 99A0314 99A0413 99A0328 99A0329 99A0321 99A1673 99A0299 99A0312 99A0413 99A1130 99A0413 99A0340 99A1680 99A1579 99A1133 99A1134 99A0342 99A1682 99A1131 99A0341 99A0413 99A1668 99A1677 99A0316 99A0315 99A0325 99A0280 Units 1 1 1 1 3 3 1 2 2 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 Description Cover, Engine Board Main Frame Assembly 250 Duplex Main Frame Assembly 500 Duplex Idler Assembly, Belt Tension Spring, Aligner Guide Assembly, Paper Guide Assembly, Paper Spring, Chassis Ground Parts Packet, Screw (Motor Mount 3 mm) Belt, Motor 114 Gear Pulley, Main Drive 96/54 Gear Motor Assembly, DC Drive Cable, D.C. Motor Tach 250 Duplex Parts Packet, Cam Follower Assembly Kit Actuator Assembly, Deflector Parts Packet, Screw (Actuator Mtg) Guide, Return RH Upper 250 Duplex Parts Packet, Screw (Guide Mounting) Guide, Return RH Lower 250 Duplex Guide, Return RH Lower 500 Duplex Guide, Upper 500 Duplex Tray Assembly, Jam Removal 250 Duplex Tray Assembly, Jam Removal 500 Duplex Guide, LH Lower Return 250 Duplex Guide, LH Lower Return 500 Duplex Guide, Return LH Upper 250 Duplex Sensor, Exit - Optical Parts Packet, Screw (Upper Guide Mtg) Base Assembly, w/Tray Bias 250 Duplex Base Assembly, w/Tray Bias 500 Duplex Shaft, Duplex Drive Spring, Duplex Shaft Gear, Pass Thru Idler Bearing, Drive Shaft Low

Parts Catalog 7-55

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Assembly 23: Duplex Unit (continued)

7-56 Service Manual

4520-xxx
AsmIndex 23 - 30 31 32 33 34 35 36 37 38 39 40 41 NS NS NS NS Part Number 99A0311 99A0274 99A0310 99A0413 99A0317 99A0434 99A0279 99A0191 99A1669 99A1666 99A0413 99A0413 99A1129 99A0627 99A0404 99A0413 Units 1 1 1 4 1 1 1 1 1 1 2 4 1 1 2 2 Description Cable, Auto Connect Bottom Gear, Pass Thru Drive Roll Cable, Auto Connect Top Parts Packet, Screw (Main Frame Assembly Mounting) Gear, Duplex Bevel Pan, Engine Board Drip Bearing, Drive Shaft Fuse,.8A SB Board, System with Jumper 250/500 Duplex Label, Options Parts Packet, Screw Parts Packet, Screw Roller, Duplex Pass Thru Jumper, Engine Board 250 Duplex Parts Packet, Retainer (6 mm Backup Roll) Parts Packet, Screw (M3x6L:G Supradrive)

Parts Catalog 7-57

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Assembly 23: Duplex Unit (continued)

7-58 Service Manual

4520-xxx
AsmIndex 23 - 42 42 43 43 44 44 45 46 47 48 49 50 51 52 53 54 55 56 57 57 58 59 59 60 NS NS NS NS NS NS Part Number 99A1290 99A1280 99A1634 99A1679 99A0435 99A1691 99A1672 99A0332 99A0307 99A0335 99A0334 99A0952 99A0413 99A0330 99A0269 99A0308 99A0404 99A0337 99A0319 99A1676 99A0404 99A0336 99A1692 99A1059 99A0413 99A0404 99A0058 99A1695 99A0404 99A1164 Units 1 1 1 1 1 1 1 1 1 2 2 1 3 1 1 1 2 1 1 1 4 1 1 1 1 2 4 1 1 1 Description Top Cover Assembly, Movable 250 Duplex Top Cover Assembly, Movable 500 Duplex Top Cover Assembly, Fixed 250 Duplex Top Cover Assembly, Fixed 500 Duplex Guide, Lower Entry 250 Duplex Guide, Lower Entry 500 Duplex Guide Assembly, Paper Decurl Guide, Center Drive Upper Air Plenum Spring, Decurl Shaft Bushing, Decurl Shaft Frame Assembly, 250 Duplex Parts Packet, Screw (Outer Frame) Guide Assembly, Center Drive Parts Packet, Fan Mounting Kit Fan, Cooling Duplex Parts Packet, Retainer (5 mm Main Drive) Main Drive Assembly Sensor, Input Optical 250 Duplex Sensor, Input Optical 500 Duplex Parts Packet, Retainer (6 mm Drive Roll) Shaft Assembly, Drive 250 Duplex Shaft Assembly, Drive 3 Roll 500 Duplex Shaft Assembly, Decurl Parts Packet, Screw (Tensioner) Parts Packet, Retainer (6 mm Clutch Roll) Feet, Duplex Base Shaft Assembly, Drive 2 Roll 500 Duplex Parts Packet, Retainer (6 mm Top Cover) Guide, Debuckle

Parts Catalog 7-59

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Assembly 24: Envelope Feeder

7-60 Service Manual

4520-xxx
AsmIndex 24 - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS Part Number 99A0389 99A1694 99A1696 99A0485 99A0393 99A1697 99A0390 99A0488 99A0382 99A1666 99A0388 99A1700 99A0271 99A1698 99A0404 99A0404 99A0404 99A0404 99A0384 99A0385 99A0494 99A0427 99A0469 99A1699 99A0413 99A0484 99A0491 99A0400 99A0489 99A0487 Units 1 1 1 1 1 1 1 7 1 1 1 1 1 1 1 3 2 3 1 1 1 1 1 1 6 1 1 1 1 1 Description Paper Weight Assembly Guide, Edge Cover, Top Sensor, Envelope Pass Thru Clutch, Restraint/Gear Cover, Right Side Support, Slide Out Roller, Support Motor, Stepper D.C. Label, Options Switch, Envelope Out Board Assembly, Electronic Control Parts Packet, Gear Kit Cover, Left Side Parts Packet, Retainer (4 mm PP) Parts Packet, Retainer (Clip 5 mm Shaft) Parts Packet, Retainer (6 mm) Parts Packet, Retainer (7 mm Shaft) Shaft, Drive Pressure Roller Cable, Auto Connect Front Spring, Cam Clutch Label, Envelope Orientation Icon Deflector Guide Guard, Pass Thru Sensor Screw, Top/Motor/Board Belt, Gear Drive Bracket, Stack Limiter Spring, Restraint Roll Shaft Spring, Latch Return Flag, Envelope Out Sensor

Parts Catalog 7-61

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Assembly 25: High-Capacity Feeder

7-62 Service Manual

4520-xxx
AsmIndex 25 - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 NS Part Number 99A0660 99A0675 99A0698 99A0675 99A0691 99A0656 99A0681 99A1818 99A1809 99A0675 99A1829 99A0662 99A0716 99A0676 99A0677 99A0677 99A0657 99A0655 99A0658 99A0650 99A0661 99A1806 99A0677 99A0675 99A0392 99A0677 99A0676 99A0690 Units 1 3 2 4 2 1 3 1 1 3 1 2 1 4 4 4 2 1 2 1 1 1 4 4 1 1 1 1 Description Frame, Printer Support Frame 2 Parts Packet, Screw (Printer Support 2 Frame Mounting) Clamp, Feed Frame Parts Packet, Screw (Feed Frame Clamp) Bearing, Nyliner Leadscrew Top Cover, Side Strip, Wear Strip, Wear Dimple Deflector Assembly Front Parts Packet, Screw (Deflector Mt 8-18 x 7/8 inch) Label, Tray Option Number Transfer Lead Screw Assembly Bearing, Leadscrew Bottom Parts Packet, Nut (6-32 Hinge Mounting) Parts Packet, Washer (Hinge Mounting Flat) Parts Packet, Washer (Hinge Mounting Star) Hinge, Door Door Assembly, Front Magnet, Door Frame Assembly Tray Assembly, Elevator Card Assembly, 2000 Option Control Parts Packet, Washer (Card Asm Mounting) Parts Packet, Screw (Card Asm Mounting) Kit, Door Switch Spring and Bumper Parts Packet, Washer (Door Switch Spring Mounting) Parts Packet, Nut (Door Switch Spring Mounting) Cable, Optical Sensor

Parts Catalog 7-63

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Assembly 25: High Capacity Feeder (continued)

7-64 Service Manual

4520-xxx
AsmIndex 25 - 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Part Number 99A0188 99A0675 99A0219 99A0675 99A0677 99A0719 99A0676 99A0677 99A0675 99A0663 99A0664 99A1807 99A0676 99A0653 99A0676 99A0677 99A1808 99A0676 99A0714 99A0675 99A0677 99A0667 99A0715 99A0685 99A0676 99A0654 99A0651 99A0675 99A0659 99A0695 99A0677 99A0675 Units 3 6 1 2 2 1 2 2 2 1 1 1 2 1 2 4 1 2 1 2 2 1 1 1 2 1 1 3 1 1 2 2 Description Guide, Rear Paper use with 99A0219 Parts Packet, Screw (Top Frame Mounting) Frame Assembly, Top with labels Parts Packet, Screw Parts Packet, Washer (Top Frame Clamp) Clamp, Top Frame Mounting Parts Packet, Nut (Base Mounting) Parts Packet, Washer (Base Mounting) Parts Packet, Screw (Base Mounting) Pulley, Idler Belt, Drive Cable, AC Internal Wiring Parts Packet, Nut (2-56 Switch Mounting) Switch, Lower Limit Microswitch Parts Packet, Nut (Power Supply Ground) Parts Packet, Washer (Motor Plate Mtg) Cord, AC External Jumper Parts Packet, Nut (Power Supply Cover) Cover, Power Supply Parts Packet, Screw (Power Supply Bd Mtg) Parts Packet, Washer (Power Supply Board) Power Supply Board Cable, Low Voltage Power Supply Bushing Parts Packet, Nut - 2-56 Switch, Paper Low Sensor Assembly, Paper Out/Upper Limit Parts Packet, Screw (Support 1 Frame Mtg) Frame, Printer Support 1 Parts Kit, Paper Size Switch Assembly Parts Packet, Washer (Sensor Bracket Mtg) Parts Packet, Screw (Sensor Bracket Mtg)

Parts Catalog 7-65

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Assembly 25: High Capacity Feeder (continued)

7-66 Service Manual

4520-xxx
AsmIndex 25 - 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 Part Number 99A1793 99A1794 99A1795 99A0672 99A0687 99A1796 99A1797 99A1798 99A1799 99A1800 99A1801 99A1802 99A1803 99A1804 99A1804 99A1805 99A0281 99A0279 99A0273 99A0263 99A0276 99A0451 99A0267 99A0675 99A0277 99A0445 99A0280 99A0275 99A0272 99A0446 Units 3 3 1 4 4 1 1 1 1 1 1 1 1 3 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 Description Parts Packet, Screw w/washer (Motor Mt) Parts Packet, Nut & washer (Drive Pulley Plate) Motor Assembly, DC Parts Packet, Foot (Stabilizer) Parts Packet, Mounting Feet Belt, DC Motor Drive Idler Pulley, Belt Tension Plate, Drive Pulley AC Receptacle, Lower AC Pulley, Drive Retainer, C-Clip AC Receptacle, Upper AC Cover, Top LVPS Nut w/lock washer, Top LVPS Cover Mounting Nut w/lock washer, Top LVPS Cover Mounting Grommet, Top LVPS Cover Cable, 250 Auto Connect Bearing, Drive Shaft Gear, Bevel Parts Packet, Screw (Frame Mounting) Roll Assembly, Drive 250 Option Roll, Skew Backup Parts Packet, Retainer (Roller) Parts Packet, Screw (Wear Plate Mounting) Plate Wear, Pass Thru Stud Assembly, 250 Frame Bearing, Drive Shaft Low Spring, Power Takeoff Shaft, 250 Drive Aligner Assembly, Paper

Parts Catalog 7-67

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Assembly 25: High Capacity Feeder (continued)

7-68 Service Manual

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AsmIndex 25 - 90 91 92 93 94 NS NS NS NS NS Part Number 99A0267 99A0274 99A0278 99A1967 99A0263 99A0675 99A0676 99A0677 99A0684 99A0286 Units 1 1 1 1 3 10 6 6 1 1 Description Parts Packet, Retainer (Aligner Assembly) Gear, Feed Roll Bellcrank, Roller Release Card Assembly, 2000 Tray Option Parts Packet, Screw (Tray Option Card Mtg) Parts Packet, Screw (Door to Door Frame Mounting) Parts Packet, Nut Support Frame 1Hex, Support Frame 2, Hex Parts Packet, Washer (Support Frame 1 Star, Support Frame 2 Star) Cable, HCIT-14Pin Flex Spring, Backup Roller

Parts Catalog 7-69

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Assembly 25: High Capacity Feeder (continued)

7-70 Service Manual

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AsmIndex 25 - 95 96 97 98 99 100 101 102 103 104 105 106 NS NS Part Number 99A0263 99A1055 99A0070 99A0692 99A0263 99A0678 99A0288 99A1812 99A1666 99A0677 99A0263 99A0679 99A0717 99A0720 Units 3 1 2 1 1 1 1 1 1 4 4 2 1 1 Description Parts Packet, Screw (Auto Comp Assembly Mounting) Arm Assembly, Pick 2000 Roll Assembly, Pick Base, 2000 Option Parts Packet, Screw (Deflector Mounting) Deflector, Base Sensor, Pass Thru Label, Tray Option Number Label, Options Parts Packet, Washer (Bracket 250 Frame Retention Mounting) Parts Packet, Screw (Bracket 250 Frame Retention Mounting) Bracket, 250 Frame Retention Cable, Paper Low Switch Cable, Lower Limit Switch

Parts Catalog 7-71

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Assembly 26: Kiosk - Vertical Paper Adapter

7-72 Service Manual

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AsmIndex 26 - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part Number 99A0231 99A1646 99A1819 99A0240 99A0234 99A1705 99A1704 99A0197 99A0079 99A0208 99A0087 99A0086 99A1706 99A0125 99A0232 99A1820 99A0226 99A0122 99A0137 99A0088 99A0085 Units 1 1 1 12 16 1 2 1 1 3 6 6 1 1 1 2 1 2 1 1 1 Description Bail, Support Arm Assembly, Pivot Mounting, Frame Assembly Parts Packet, Retainer Parts Packet, Screw Gear, Idler Gear, Idler Shaft, Drive Rear Tray Assembly, Backup Roller Parts Packet, Pulley Spring, Backup Roller Roller, Backup Tray Assembly, Drive Roller Frame Assembly, Right Side Cover, Right Belt, 185G Guide, Paper Exit Shaft Assembly, Drive Roller Frame Assembly, Left Side Cover, Backup Tray Tray, Backup Roller

Parts Catalog 7-73

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Assembly 27: Kiosk - Horizontal Paper Adapter

7-74 Service Manual

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AsmIndex 27 - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number 99A0231 99A1647 99A1819 99A2409 99A0234 99A1705 99A1704 99A0197 99A0079 99A0208 99A0087 99A0086 99A1707 99A0907 99A0232 99A1820 99A0122 99A0906 99A0088 99A0085 Units 1 1 1 12 15 1 2 1 1 3 6 6 1 1 1 2 2 1 1 1 Description Bail, Support Arm Assembly, Pivot Mounting, Frame Assembly Parts Packet, Retainer Parts Packet, Screw Gear, Idler Gear, Idler Shaft, Drive Rear Tray Assembly, Backup Roller Parts Packet, Pulley Spring, Backup Roller Roller, Backup Tray Assembly, Drive Roller Frame Assembly, Right Side Cover, Right Belt, 185G Shaft Assembly, Drive Roller Frame Assembly, Left Side Cover, Backup Tray Tray, Backup Roller

Parts Catalog 7-75

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Assembly 28: Options

AsmIndex 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 Part Number 99A1752 99A1753 99A1754 99A1755 99A1756 99A1773 99A1757 99A1758 99A1759 99A1774 99A2486 99A2487 99A2200 99A2488 99A0629 13A0296 13A0297 99A0545 13A0298 99A0923 99A1182 99A2489 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description 4MB SDRAM DIMM 8MB SDRAM DIMM 16MB SDRAM DIMM 32MB SDRAM DIMM 64MB SDRAM DIMM 128MB SDRAM DIMM 2MB Flash DIMM 4MB Flash DIMM 8MB Flash DIMM Card Assembly 16MB Flash DIMM Card Assembly Bar Code Card Assembly Prescribe 5/4/2 Flash Card Assembly IPDS and SCS/Tne Hard Disk, with Control Board 5.0GB Adapter Card, SES for SCS Cable, Twinax Cable, Coax Adapter, Serial Cable, Serial Board, USB/Parallel Port Card Assembly Image Quick Optra Forms Hard Disk, with Control Board

7-76 Service Manual

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Assembly 28: Options (continued)

AsmIndex 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 Part Number 99A1890 99A1647 99A1654 56P1100 99A0799 99A1605 99A1830 12G1696 12G1697 99A0560 99A1889 56P0161 56P0162 90A2485 99A1683 99A1684 99A1685 99A1686 56P1101 56P0161 56P0162 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Tray Assembly, 250 Special Media Rib Assembly, 250 Special Media Tray Tray, Universal Adjustable 250 Sheet Cartridge, Empty Shipping - T62X/T52X Drive, Forms HD 2.1GB or larger Kit, Cap/Stack Bails 500 MarkNet N2001e 10/100 Ethernet MarkNet N2002e 10Base2/10Baset MarkNet N2000t 4/16 Adapter, Omnibus INA Card Paper Presentator, Front INA, Serial & Parallel C Adapter, Parallel 1284 C-B Tray Assembly, UAT 400 Sheet Card Assembly, FORMS Flash DIMM 2mb Card Assembly, FORMS Flash DIMM 4mb Card Assembly, FORMS Flash DIMM 8mb Card Assembly, FORMS Flash DIMM 16mb Cable Assembly, 6 Parallel, A-C Card Assembly, SER+PAR 1284C INA Cable, Parallel 1284 C-B Adapter

Parts Catalog 7-77

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Assembly 29: Miscellaneous

AsmIndex 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 29 Part Number 99A1633 99A0585 99A0267 99A0268 99A0269 99A0299 99A0271 99A0404 99A0413 99A0572 99A0577 99A0675 99A0676 99A0677 99A0083 99A0512 99A0513 99A0702 99A0703 99A0704 99A0705 99A0706 99A0707 99A0710 99A0711 99A0712 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1 Description Parts Packet, Screw Parts Packet, Contact Kit Parts Packet, Retainers Parts Packet, Springs Paper Feed Parts Packet, Duplex Option Fan Mounting Parts Packet, Duplex Option Cam Follower Assembly Parts Packet, Envelope Option Gears Parts Packet, Retainers Envelope Option Parts Packet, Screw Duplex Parts Packet, 500-Sheet Feeder Option Shaft Bearings Parts Packet, Cable Ties (10 each) Parts Packet, Screw High Capacity Feeder Parts Packet, Nuts High Capacity Feeder Parts Packet, Washers High Capacity Feeder Parts Kit, Multipurpose Tray Parts Kit, Charge Roll Link Asm, Left Side Parts Kit, Charge Roll Link Asm, Right Side Printer Stand Caster, Non Locking Printer Stand Caster, Locking Printer Stand Grommet, Wire Printer Stand Lock, Cam Printer Stand Storage Shelf Printer Stand Door Assembly, Cabinet Printer Stand Filler, Rear Top Piece Printer Stand Table Assembly, Large Printer Stand Table Assembly, Small

7-78 Service Manual

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Assembly 29:Miscellaneous (continued)

AsmIndex 29 29 29 29 29 29 Part Number 99A0208 99A0234 99A0394 99A0462 99A1852 99A1853 Units 1 1 1 1 1 1 Description Parts Packet, Pulley - Kiosk Parts Packet, Screw - Kiosk Grease Packet, Nyogel 744 Grease Packet, IBM 23 Packaging, 4069 250/250 printer Packaging, 4069 500/250 printer

Parts Catalog 7-79